A method of: forming an aerosol of a powder comprising one or more of lithium, germanium, phosphorus, sulfur, boron, fluorine, chlorine, bromine, aluminum, nitrogen, arsenic, niobium, titanium, vanadium, molybdenum, manganese, zinc, hafnium, and nickel and directing the aerosol at a substrate at a velocity that forms a film of the powder on the substrate. The method makes an article having an ionic conductor in the form of a film at most 0.5 mm thick.

A negative electrode for an electrochemical cell of a secondary lithium metal battery is manufactured by a method in which a precursor solution is applied to a major surface of a lithium metal substrate to form a precursor coating thereon. The precursor solution includes an organophosphate, a nonpolar organic solvent, and a lithium-containing inorganic ionic compound dissolved therein. At least a portion of the nonpolar organic solvent is removed from the precursor coating to form a protective interfacial layer on the major surface of the lithium metal substrate. The protective interfacial layer exhibits a composite structure including a carbon-based matrix component and a lithium-containing dispersed component. The lithium-containing dispersed component is embedded in the carbon-based matrix component and includes a plurality of lithium-containing inorganic ionic compounds, e.g., lithium phosphate (Li.sub.3PO.sub.4) and lithium nitrate (LiNO.sub.3).

Provided are a positive electrode for a metal-sulfur battery, a method of manufacturing the same, and a metal-sulfur battery including the same. The positive electrode comprises a positive electrode active material layer including carbon material and sulfur-containing material. In the positive electrode active material layer, a region in which the sulfur-containing material is densified and a region in which the carbon material is densified are arranged separately. By providing a positive electrode capable of exhibiting a high utilization rate of sulfur, it is possible to provide a metal-sulfur battery having high capacity and stable life characteristics.

An object of the present disclosure is to provide a new sulfur-based positive-electrode active material which can improve cyclability of a lithium-ion secondary battery while maintaining a charging and discharging capacity, a positive-electrode comprising the positive-electrode active material, and a lithium-ion secondary battery comprising the positive-electrode. The sulfur-based positive-electrode active material is one comprising doped nitrogen atoms obtainable by heat-treating a starting material comprising a chain organic compound and sulfur under an atmosphere of a nitrogen atom-doping gas.

An lithium-sulfur battery including an anode, a cathode, and a solid-state electrolyte is provided. The anode may be formed as a single layer of lithium and/or as a cavity. In some aspects, the cavity may receive lithium deposits based on lithium output from the cathode. The cathode may be formed from a composition of matter including pores. A solid-state electrolyte may be dispersed throughout the cathode and in contact with the anode. The solid-state electrolyte may be formed as a membrane and may provide ionic conduction capabilities associated with a separator. The solid-state electrolyte includes a polymer matrix formed of glass fibers interconnected with each other. The polymer matrix has an ionic conductivity and includes polyethylene oxide (PEO), polyvinylidene difluoride (PVDF), polyetheramine having repeated oxypropylene units in its backbone, and one or more lithium-containing salts including one or more of lithium bis(trifluoromethanesulfonyl)imide (LiTFSI) or lithium iodide (LiI).

Provided is a magnesium-sulfur secondary battery including a positive electrode that includes a carbon material layer and a laminated structure of a positive electrode active material layer including sulfur or a sulfur compound; an electrolyte layer; and a negative electrode. In the magnesium-sulfur secondary battery, the positive electrode active material layer, the carbon material layer, and the electrolyte layer are provided in this order, and the positive electrode active material layer and the carbon material layer are in contact with each other.

A process for binding sulfur to carbon to form carbon polysulfide is described that better secures sulfur to the cathode in a lithium-sulfur battery during lithium oxidation and reduction. The process includes selecting a suitable carbon precursor, blending it with sulfur and an organic solvent and mill the combination to make a fine particle size mix and then driving off the solvent along with species that have been dissolved in the solvent. The remaining carbon precursor and sulfur are heated in an inert environment at a temperature between about 300° C. and about 550° C. to chemically bind the sulfur and the carbon to form carbon polysulfide suitable for use as a cathode powder in a lithium-sulfur battery.

A process for binding sulfur to carbon to form carbon polysulfide is described that better secures sulfur to the cathode in a lithium-sulfur battery during lithium oxidation and reduction. The process includes selecting a suitable carbon precursor, blending it with sulfur and an organic solvent and mill the combination to make a fine particle size mix and then driving off the solvent along with species that have been dissolved in the solvent. The remaining carbon precursor and sulfur are heated in an inert environment at a temperature between about 300° C. and about 550° C. to chemically bind the sulfur and the carbon to form carbon polysulfide suitable for use as a cathode powder in a lithium-sulfur battery.

This application relates to nanostructures, such as nanoparticles, having covalently cross-linked, conductive polymer shells, such as those that may be used as electrode materials for secondary batteries or other energy storage devices, and methods of making same.

A method of manufacturing an electrode for an electrochemical cell includes providing an admixture including an electroactive material, a binder, and a solvent. The method further includes rolling the admixture to form a sheet and forming a multi-layer stack from the sheet. The method further includes forming an electrode film precursor by performing a plurality of sequential rollings, each including rolling the stack through a first gap. The plurality of sequential rollings includes first and second rollings. In the first rolling, the stack is in a first orientation. In the second rolling, the stack is in a second orientation different from the first orientation. The method further includes forming an electrode film by rolling the electrode film precursor through a second gap less than or equal to the first gap. The method further includes drying the electrode film to remove at least a portion of the solvent.