# US 2020/0403271 A1 · Sulfur-based composite cathode-separator laminations and battery cells comprising the same

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- Number: US 2020/0403271 A1
- Document ID: US20200403271A1
- Status: Published application
- Kind: A1
- Application number: 16/446,569
- Filed: 2019-06-19
- Published: 2020-12-24
- Earliest claimed: 2019-06-19
- Assignees: GM Global Technology Operations LLC
- Applicants: GM Global Technology Operations LLC
- Inventors: Mei Cai; Fang Dai; Shuru Chen; Biqiong Wang
- Web page: https://patentgrep.com/patent/US20200403271A1

## CPC

- H01M 10/0565: Polymeric materials, e.g. gel-type or solid-type
- H01M 4/0421: {involving vapour deposition}
- H01M 4/366: {as layered products}
- H01M 4/668: {Composites of electroconductive material and synthetic resins}
- H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
- H01M 10/36: Accumulators not provided for in groups H01M10/05-H01M10/34
- H01M 50/446: Composite material consisting of a mixture of organic and inorganic materials
- H01M 2004/028: {Positive electrodes}
- Y02E 60/10: Energy storage using batteries
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

Composite cathode-separator laminations (CSL) include a current collector with sulfur-based host material applied thereto, a coated separator comprising an electrolyte membrane separator with a carbonaceous coating, and a porous, polymer-based interfacial layer (PBIL) forming a binding interface between the carbonaceous coating and the host material. The host material includes less than about 6% polymeric binder, and less than about 40% electrically conductive carbon, with the balance comprising one or more sulfur compounds. The PBIL can have a thickness of less than about 5 μm and a porosity of about 5% to about 40%. The host material can comprise less than about 40% conductive carbon (e.g., graphene) and have a porosity of less than about 40%. The carbonaceous coating (e.g., graphene) can have a thickness of about 1 μm to about 5 μm. The CSL can be disposed with an anode within an electrolyte to form a lithium-sulfur battery cell.

## Claims

### Claim 1

A composite cathode-separator lamination (CSL) comprising:
a current collector with sulfur-based host material applied thereto, wherein the sulfur-based host material comprises less than about 6% polymeric binder, and less than about 40% electrically conductive carbon, with the balance comprising one or more sulfur compounds;
a coated separator comprising an electrolyte membrane separator with a carbonaceous coating; and
a porous, polymer-based interfacial layer forming a binding interface between the carbonaceous coating and the host material.

### Claim 2 (depends on 1)

The CSL of claim 1, wherein the polymer-based interfacial layer comprises a polymeric molecular layer deposition (MLD) coating layer.

### Claim 3 (depends on 1)

The CSL of claim 1, wherein the polymer-based interfacial layer comprises an organic-metal hybrid molecular layer deposition (MLD) coating layer.

### Claim 4 (depends on 1)

The CSL of claim 1, wherein the polymer-based interfacial layer is a polymerized gel-forming precursor, wherein the gel forming precursor comprises a branched acrylate.

### Claim 5 (depends on 4)

The CSL of claim 4, wherein the gel forming precursor is polymerized by a UV initiator in the presence of UV light.

### Claim 6 (depends on 4)

The CSL of claim 4, wherein the gel forming precursor is polymerized by an electron-beam initiator in the presence of an electron-beam.

### Claim 7 (depends on 4)

The CSL of claim 4, wherein the gel forming precursor is polymerized by thermal initiator in the presence of heat.

### Claim 8 (depends on 1)

The CSL of claim 1, wherein the polymer-based interfacial layer comprises a thickness of less than about 5 μm.

### Claim 9 (depends on 1)

The CSL of claim 1, wherein the host material comprises less than about 40% conductive carbon.

### Claim 10 (depends on 1)

The CSL of claim 1, wherein the host material comprises less than about 25% conductive carbon.

### Claim 11 (depends on 1)

The CSL of claim 1, wherein the host material has a porosity of less than about 40%.

### Claim 12 (depends on 1)

The CSL of claim 1, wherein the electrically conductive carbon of the host material consists of graphene.

### Claim 13 (depends on 1)

The CSL of claim 1, wherein the carbonaceous coating consists of graphene.

### Claim 14 (depends on 13)

The CSL of claim 13, wherein the carbonaceous coating comprises a thickness of about 1 μm to about 5 μm.

### Claim 15

A lithium-sulfur battery cell comprising:
an electrolyte;
an anode disposed within the electrolyte; and
a composite cathode-separator lamination (CSL) disposed within the electrolyte and comprising:
a current collector with sulfur-based host material applied thereto, wherein the sulfur-based host material comprises less than about 6% polymeric binder, and less than about 40% electrically conductive carbon, with the balance comprising one or more sulfur compounds;
a coated separator comprising an electrolyte membrane separator with a carbonaceous coating comprising graphene; and
a porous, polymer-based interfacial layer forming a binding interface between the carbonaceous coating and the host material.

### Claim 16 (depends on 15)

The lithium-sulfur battery cell of claim 15, wherein the polymer-based interfacial layer comprises a polymeric molecular layer deposition (MLD) coating layer.

### Claim 17 (depends on 15)

The lithium-sulfur battery cell of claim 15, wherein the polymer-based interfacial layer comprises an organic-metal hybrid molecular layer deposition (MLD) coating layer.

### Claim 18 (depends on 15)

The lithium-sulfur battery cell of claim 15, wherein the polymer-based interfacial layer is a polymerized gel-forming precursor, wherein the gel forming precursor comprises a branched acrylate and is polymerized by a UV initiator in the presence of UV light, polymerized by an electron-beam initiator in the presence of an electron-beam, or polymerized by thermal initiator in the presence of heat.

### Claim 19 (depends on 15)

The lithium-sulfur battery cell of claim 15, wherein the polymer-based interfacial layer comprises a thickness of less than about 5 μm.

### Claim 20 (depends on 15)

The lithium-sulfur battery cell of claim 15, wherein the polymer-based interfacial layer comprises porosity of about 5% to about 40%