US5582623A
Expired / Lapsed
US
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Methods of fabricating rechargeable positive electrodes
Assignee: Polyplus Battery Co Inc
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Filing: 1995-06-07
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Granted: 1996-12-10
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Expires: 2015-06-07
Abstract
Abstract Disclosed are methods of making solid-phase active-sulfur-based composite electrodes. The method begins with a step of combining the electrode components (including an electrochemically active material, an electronic conductor, and an ionic conductor) in a slurry. Next, the slurry is homogenized such that the electrode components are well mixed and free of agglomerates. Very soon thereafter, before the electrode components have settled or separated to any significant degree, the slurry is coated on a substrate to form a thin film. Finally, the coated film is dried to form the electrode in such a manner that the electrode components do not significantly redistribute.
Inventors
- 👤 May-Ying Chu
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 13:52
CPC Classifications
H; H01; H01M; H01M10/00; H01M10/05; H01M10/052; H01M10/056; H01M10/0564; H01M10/0565; H01M10/36; H01M4/00; H01M4/02; H01M4/04; H01M4/0402; H01M4/0404; H01M4/0409; H01M4/0411; H01M4/0414; H01M4/0416; H01M4/0421; H01M4/0423; H01M4/0426; H01M4/043; H01M4/0435; H01M4/13; H01M4/36; H01M4/38; H01M4/381; H01M4/382; H01M4/58; H01M4/581; H01M4/5815; H01M4/583; H01M4/62; H01M4/624; H01M4/626; H01M10/39; H01M10/3909; H01M10/42; H01M10/44; H01M2004/026; H01M2004/028; H01M2300/00; H01M2300/0017; H01M2300/0065; H01M2300/0085; H01M4/60; H01M4/621; H01M4/625; H01M50/00; H01M50/40; H01M50/46; H01M6/00; H01M6/14; H01M6/16; H01M6/162; H01M6/168; H01M6/18; H01M6/181; H01M6/188; H01M6/40; Y; Y02; Y02E; Y02E60/00; Y02E60/10; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49108; Y10T29/49115
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
62 words
A method of forming an active-sulfur-containing electrode, the method comprising the following steps: combining active-sulfur, an electronic conductor, and an ionic conductor to form a mixture; homogenizing the mixture to form a homogeneous mixture; and forming the active-sulfur-containing electrode from said homogeneous mixture, wherein said active-sulfur-containing electrode has at least about 10% of its active-sulfur accessible to electrons and ionic charge carriers.
Claim 2
Independent Claim
62 words
A method of forming an active-sulfur-containing electrode, the method comprising the following steps: combining active-sulfur, an electronic conductor, and an ionic conductor to form a mixture; homogenizing the mixture to form a homogeneous mixture; and forming the active-sulfur-containing electrode from said homogeneous mixture, wherein said active-sulfur-containing electrode has at least about 10% of its active-sulfur accessible to electrons and ionic charge carriers.
Claim 3
Dependent Claim
29 words
The method of claim 1 wherein the method includes a step of forming a slurry by combining the active-sulfur, the electronic conductor, and the ionic conductor with a liquid.
Claim 4
Dependent Claim
19 words
The method of claim 2 wherein said step of homogenizing involves agitating the slurry to form said homogeneous mixture.
Claim 5
Dependent Claim
28 words
The method of claim 2 wherein, in the step of forming a slurry, soluble and insoluble components of the mixture are combined with said liquid at different times.
Claim 6
Dependent Claim
27 words
The method of claim 2 wherein the slurry is formed from a dispersant in addition to the active-sulfur, the electronic conductor, the ionic conductor, and the liquid.
Claim 7
Dependent Claim
26 words
The method of claim 1 wherein said step of homogenizing comprises homogenizing a solid phase mixture containing the active-sulfur, the electronic conductor, and the ionic conductor.
Claim 8
Dependent Claim
27 words
The method of claim 1 wherein the step of forming the active-sulfur-containing electrode includes the step of applying a layer of said homogeneous mixture to a substrate.
Claim 9
Dependent Claim
26 words
The method of claim 1 wherein the mixture is formed from a polydisulfide material in addition to the active-sulfur, the electronic conductor, and the ionic conductor.
Claim 10
Dependent Claim
26 words
The method of claim 1 wherein the electronic conductor employed in the step of combining is selected from the group consisting of carbon and conductive polymers.
Claim 11
Dependent Claim
13 words
The method of claim 1 wherein the ionic conductor is a polyalkylene oxide.
Claim 12
Dependent Claim
18 words
The method of claim 1 further comprising a step of preparing an electrochemical cell containing said active-sulfur-containing electrode.
Claim 13
Independent Claim
81 words
A method of forming an active-sulfur-containing electrode, the method comprising the following steps: combining active-sulfur, an electronic conductor, and an ionic conductor to form a mixture; homogenizing the mixture to form a homogeneous mixture; and depositing a layer of said homogeneous mixture on a substrate by a technique that does not rely on capillary action to form said active-sulfur containing electrode, wherein said active-sulfur-containing electrode has at least about 10% of its active-sulfur is accessible to electrons and ionic charge carriers.
Claim 14
Independent Claim
81 words
A method of forming an active-sulfur-containing electrode, the method comprising the following steps: combining active-sulfur, an electronic conductor, and an ionic conductor to form a mixture; homogenizing the mixture to form a homogeneous mixture; and depositing a layer of said homogeneous mixture on a substrate by a technique that does not rely on capillary action to form said active-sulfur containing electrode, wherein said active-sulfur-containing electrode has at least about 10% of its active-sulfur is accessible to electrons and ionic charge carriers.
Claim 15
Dependent Claim
29 words
The method of claim 12 wherein the method includes a step of forming a slurry by combining the active-sulfur, the electronic conductor, and the ionic conductor with a liquid.
Claim 16
Dependent Claim
21 words
The method of claim 13 wherein the step of depositing includes a step of forming a slurry layer on the substrate.
Claim 17
Dependent Claim
19 words
The method of claim 14 further comprising a step of drying said slurry layer to form said active-sulfur-containing electrode.
Claim 18
Dependent Claim
42 words
The method of claim 15 wherein said step of drying includes the following steps: drying the slurry layer under ambient conditions to form a partially dried layer; and further drying the partially dried layer under a vacuum to form said active-sulfur-containing electrode.
Claim 19
Dependent Claim
15 words
The method of claim 14 wherein said slurry layer is formed on a current collector.
Claim 20
Dependent Claim
15 words
The method of claim 14 wherein said slurry layer is formed on a non-adhesive substrate.
Claim 21
Dependent Claim
49 words
The method of claim 18 further comprising the following steps: drying said slurry layer to form the active-sulfur-containing electrode; removing the active-sulfur-containing electrode from the non-adhesive substrate; and affixing the active-sulfur-containing electrode to a current collector such that the active-sulfur-containing electrode is in electrical contact with the current collector.
Claim 22
Dependent Claim
24 words
The method of claim 14 wherein the slurry layer is continuously formed on the substrate which is continuously contacted with a source of slurry.
Claim 23
Dependent Claim
25 words
The method of claim 12 wherein the step of homogenizing comprises homogenizing a solid-phase mixture containing the active-sulfur, the electronic conductor, and the ionic conductor.
Claim 24
Dependent Claim
18 words
The method of claim 12 further comprising a step of preparing an electrochemical cell containing said active-sulfur-containing electrode.
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