Disclosed is method of preparing a selenium carbon composite material and a use of the selenium carbon composite material in a cathode of a lithium selenium secondary battery. A battery formed with a cathode of the disclosed selenium carbon composite material has high energy density and stable electrochemical performance. The disclosed selenium carbon composite material can effectively shorten the migration distance of lithium ions during charging and discharging of the battery and improve conductivity and utilization of selenium after compounding carbon and selenium. Multiple batteries formed with cathodes of the disclosed selenium carbon composite material can be assembled into a lithium selenium pouch-cell battery having stable electrochemical performance and high energy density.

A process for producing a lithium battery, comprising: (A) Assembling a porous cell framework composed of a foamed anode current collector, a foamed cathode current collector, and a porous separator disposed between the two collectors; wherein the current collector(s) has a thickness no less than 100 m and at least 80% by volume of pores; (B) Preparing a first suspension of an anode active material dispersed in a first liquid electrolyte and a second suspension of a cathode active material dispersed in a second liquid electrolyte; and (C) Injecting the first suspension into pores of the anode current collector to form an anode and injecting the second suspension into pores of the cathode current collector to form a cathode to an extent that the anode active material and the cathode active material combined constitutes an electrode active material mass loading no less than 40% of the total battery cell weight.

A nanosheet comprises a single crystal mixed metal oxide M1.sub.xM2.sub.yO.sub.2 material composition that may comprise a single crystal Na.sub.xCoO.sub.2 material composition. The nanosheet may be prepared using a sequential process sequence that includes chelated mixed metal ion sol-gel mixture formation, autocombustion, isostatic pressing, electro kinetic demixing and calcination. This particular process sequence provides single crystal nanosheets having in-plane mutually perpendicular lateral sheet dimensions greater than about 10 microns by about 200 microns, and a thickness from about 5 to about 100 nanometers.

The present invention relates to a sulfur-carbon composite, comprising a pyrolysis microporous carbon sphere (PMCS) substrate and sulfur loaded into said pyrolysis microporous carbon sphere (PMCS) substrate; as well as a method for preparing said sulfur-carbon composite, an electrode material and a lithium-sulfur battery comprising said sulfur-carbon composite.

Electrode structures and methods for making the same are generally described. In certain embodiments, the electrode structures can include a plurality of particles, wherein the particles comprise indentations relative to their convex hulls. As the particles are moved proximate to or in contact with one another, the indentations of the particles can define pores between the particles. In addition, when particles comprising indentations relative to their convex hulls are moved relative to each other, the presence of the indentations can ensure that complete contact does not result between the particles (i.e., that there remains some space between the particles) and that void volume is maintained within the bulk of the assembly. Accordingly, electrodes comprising particles with indentations relative to their convex hulls can be configured to withstand the application of a force to the electrode while substantially maintaining electrode void volume (and, therefore, performance). Particles having indentations relative to their convex hulls also occupy a relatively small volume, compared to spheres or other particles including boundaries that fill substantially all of their convex hulls, allowing one to introduce a desired amount of void volume while reducing the percentage of volume within the electrode occupied by particulate material.

Electrodes having nanostructure and/or utilizing nanoparticles of active materials and having high mass loadings of the active materials can be made to be physically robust and free of cracks and pinholes. The electrodes include nanoparticles having electroactive material, which nanoparticles are aggregated with carbon into larger secondary particles. The secondary particles can be bound with a binder to form the electrode.

Electrodes having nanostructure and/or utilizing nanoparticles of active materials and having high mass loadings of the active materials can be made to be physically robust and free of cracks and pinholes. The electrodes include nanoparticles having electroactive material, which nanoparticles are aggregated with carbon into larger secondary particles. The secondary particles can be bound with a binder to form the electrode. The electrodes can further comprise additives that enhance electrode wetting thereby improving overall electrode performance.

The invention relates to Chevrel-phase materials and methods of preparing these materials utilizing a precursor approach. The Chevrel-phase materials are useful in assembling electrodes, e.g., cathodes, for use in electrochemical cells, such as rechargeable batteries. The Chevrel-phase materials have a general formula of Mo.sub.6Z.sub.8 (Z=sulfur) or Mo.sub.6Z.sup.1.sub.8-yZ.sup.2.sub.y (Z.sup.1=sulfur; Z.sup.2=selenium), and partially cuprated Cu.sub.1Mo.sub.6S.sub.8 as well as partially de-cuprated Cu.sub.1-xMg.sub.xMo.sub.6S.sub.8 and the precursors have a general formula of M.sub.xMo.sub.6Z.sub.8 or M.sub.xMo.sub.6Z.sup.1.sub.8-yZ.sup.2.sub.y, M=Cu. The cathode containing the Chevrel-phase material in accordance with the invention can be combined with a magnesium-containing anode and an electrolyte.

The present invention relates to an anodic material for use in lithium ion battery (LIB) comprising of FeSe.sub.2 and its carbon composite with N, S doped porous carbon spheres (PNSCS) which can be synthesised by hydrothermal route using iron ammonium sulphate, selenium powder and citric acid as precursors and used as an anode for LIB. Further, the invention provides a process for synthesizing the said FeSe.sub.2 a PNSCS micro-flower composite by simple hydrothermal route.

The invention relates to Chevrel-phase materials and methods of preparing these materials utilizing a precursor approach. The Chevrel-phase materials are useful in assembling electrodes, e.g., cathodes, for use in electrochemical cells, such as rechargeable batteries. The Chevrel-phase materials have a general formula of Mo.sub.6Z.sub.8 (Z=sulfur) or Mo.sub.6Z.sup.1.sub.8-yZ.sup.2.sub.y (Z.sup.1=sulfur; Z.sup.2=selenium), and partially cuprated Cu.sub.1Mo.sub.6Z.sub.8 as well as partially de-cuprated Cu.sub.1-xMg.sub.xMo.sub.6S.sub.8 and the precursors have a general formula of M.sub.xMo.sub.6Z.sub.8 or M.sub.xMo.sub.6Z.sup.1.sub.8-yZ.sup.2.sub.y, M=Cu. The cathode containing the Chevrel-phase material in accordance with the invention can be combined with a magnesium-containing anode and an electrolyte.