POSITIVE ELECTRODE MATERIAL FOR FREE-STANDING FILM-TYPE LITHIUM SECONDARY BATTERY, PREPARATION METHOD THEREOF, AND LITHIUM SECONDARY BATTERY COMPRISING SAME

Abstract

A positive electrode material for a free-standing film-type lithium secondary battery, a preparation method thereof, and a lithium secondary battery including the same. More specifically, the positive electrode material is manufactured in the form of a free-standing film. The positive electrode material contains carbon-containing sulfur melt, which is obtained through a dry process using the properties of pressurization, and sulfur exhibits strong self-cohesion and the porous carbon material exhibits flexibility. The positive electrode material may be applied with a high loading amount as a positive electrode, and since it is prepared by a simplified process, process efficiency may be improved in terms of cost and time.

Claims

1. A positive electrode material for a lithium secondary battery, wherein the positive electrode material is in a form of a free-standing film, and wherein the positive electrode material comprises a carbon-containing sulfur melt.

2. The positive electrode material for the lithium secondary battery according to claim 1, wherein the carbon-containing sulfur comprises a porous carbon material dispersed in the sulfur melt.

3. The positive electrode material for the lithium secondary battery according to claim 2, wherein the carbon-containing sulfur melt comprises 50 wt. % to 80 wt. % of sulfur and 20 wt. % to 50 wt. % of the porous carbon material.

4. The positive electrode material for the lithium secondary battery according to claim 1, wherein an adhesive strength inside the positive electrode material is 10 gf/cm or more.

5. The positive electrode material for the lithium secondary battery according to claim 2, wherein the porous carbon material is at least one selected from the group consisting of graphite, graphene, Denka black, acetylene black, Ketjen black, channel black, furnace black, lamp black, and thermal black, single wall carbon nanotube (SWCNT), multiwall carbon nanotube (MWCNT), graphite nanofiber (GNF), carbon nanofiber (CNF), activated carbon fiber (ACF), and activated carbon.

6. The positive electrode material for the lithium secondary battery according to claim 1, wherein a porosity of the positive electrode material is 68% or less.

7. A method for preparing a positive electrode material for a lithium secondary battery comprising: (S1) mixing sulfur and a porous carbon material to form a mixture; (S2) heat-treating the mixture formed in step (S1); and (S3) forming a carbon-containing sulfur melt by filling the sulfur-carbon composite formed in step (S2) in a container and then pressurizing the sulfur-carbon composite in the container.

8. The method for preparing the positive electrode material for the lithium secondary battery according to claim 7, wherein the heat treatment is performed in a range of from 130° C. to 170° C.

9. The method for preparing the positive electrode material for the lithium secondary battery according to claim 7, wherein the pressurization is performed under a pressure of from 0.8 MPa to 15 MPa.

10. A lithium secondary battery comprising: a positive electrode comprising the positive electrode material according to claim 1; a negative electrode comprising lithium metal or a lithium alloy; a separator positioned between the positive electrode and the negative electrode; and an electrolyte solution impregnating the positive electrode, negative electrode, and separator.

11. The lithium secondary battery according to claim 10, wherein the lithium secondary battery is a lithium-sulfur secondary battery.

12. The lithium secondary battery according to claim 10, wherein the loading amount of the positive electrode is from 3.0 mAh/cm.sup.2 to 5.0 mAh/cm.sup.2.

Description

DESCRIPTION OF DRAWINGS

[0025] FIG. 1 is a schematic diagram showing changes in physical properties and moldability when pressing sulfur, carbon and sulfur-carbon composite which can be used as a positive electrode material for a lithium secondary battery.

[0026] FIG. 2 is a photograph of the free-standing film-type positive electrode material prepared in Example 1.

[0027] FIG. 3 is a photograph of the positive electrode material prepared in Comparative Example 3.

[0028] FIGS. 4a and 4b are graphs showing measurement results of initial discharge capacity for coin cells to which positive electrode materials prepared in Examples and Comparative Examples are applied.

[0029] FIG. 5 is a graph showing the measurement results of lifetime characteristics for coin cells to which the positive electrode materials prepared in Example 2 and Comparative Example 2 are applied.

[0030] FIG. 5 is a SEM photograph of carbon nanotubes (CNTs) and sulfur-carbon composites (S-CNTs) of Preparation Example 1.

BEST MODE

[0031] Hereinafter, the present invention will be described in more detail in order to help the understanding of the present invention.

[0032] The terms and words used in the present specification and claims should not be construed as limited to ordinary or dictionary terms, and should be construed in a sense and concept consistent with the technical idea of the present invention, based on the principle that the inventor can properly define the concept of a term to describe his invention in the best way possible.

[0033] As used herein, the term “free-standing film” refers to a film capable of maintaining the shape of a film by itself without a separate support at room temperature and atmospheric pressure.

[0034] As used herein, the term “carbon-containing sulfur melt” refers to a material in which the porous carbon material is dispersed inside the sulfur melt, which may be prepared through heat treatment and pressurization using sulfur and carbon as raw materials.

[0035] Positive Electrode Material for Lithium Secondary Battery

[0036] One aspect of the present disclosure provides a positive electrode material for a lithium secondary battery in the form of a free-standing film, wherein the positive electrode material contains carbon-containing sulfur melt. The positive electrode material may be in a form in which a porous carbon material is dispersed in a sulfur melt. In addition, as will be described later, since the positive electrode material is prepared by a dry process using only sulfur and a porous carbon material as raw materials, it may be composed of only sulfur and the porous carbon material.

[0037] In general, the sulfur-carbon composite used as a positive electrode material of a lithium secondary battery means a composite in which sulfur is supported on a porous carbon material. For example, sulfur may be uniformly attached or coated on the surface of the porous carbon material. In addition, the sulfur may be attached, filled, or coated in the internal pores of the porous carbon material.

[0038] However, in one aspect of the present disclosure, the positive electrode material may comprise a carbon-containing sulfur melt in which a porous carbon material is dispersed inside the sulfur melt, and may be easily molded due to the properties of sulfur that melts and aggregates under pressurization condition, and may be prepared in the form of a free-standing film due to the flexibility of the porous carbon material.

[0039] The positive electrode material in the form of a free-standing film may not be coated on the current collector, and also the positive electrode material itself in the form of a free-standing film may be utilized as a positive electrode.

[0040] Since the positive electrode material is prepared by a dry process using sulfur and a porous carbon material as raw materials, as it contains only sulfur and the porous carbon material, so it has the advantage of high loading when used as a positive electrode. In addition, the dry process can omit a series of processes such as mixing, defoaming, coating, drying and rolling required in the conventional slurry process, thereby reducing process costs. In addition, since the dry process does not use a slurry, the carbon-containing sulfur melt prepared by the dry process does not contain any binder, so that the deterioration of battery performance due to resistance by the binder can be fundamentally eliminated. In addition, since the carbon-containing sulfur melt prepared by the dry process does not contain an electrically conductive material at all, the problem of the deterioration of moldability by the electrically conductive material lacking cohesive force can be minimized.

[0041] In addition, the positive electrode material is connected by the sulfur melt formed on the surface of the porous carbon material porous or surrounding the porous carbon material in a state where the carbon material forms the skeleton of the positive electrode material, thereby exhibiting the form of a free-standing film.

[0042] In addition, the positive electrode material may be a positive electrode material having an adhesive strength of 10 gf/cm or more in the positive electrode material after press-molding of the electrode. The adhesive strength is due to the property of sulfur that melts and aggregates with surrounding sulfur during the pressing process. If the adhesive strength of the positive electrode material is less than 10 gf/cm, it may be difficult to form the electrode due to the lack of adhesive strength between the positive electrodes. Specifically, the adhesive strength may be 10 gf/cm or more, 15 gf/cm or more, 20 gf/cm or more, 25 gf/cm or more, 30 gf/cm or more, or 35 gf/cm or more. In addition, the upper limit of the adhesive strength may be, but is not limited to, 50 gf/cm or less, 60 gf/cm or less, 70 gf/cm or less, 80 gf/cm or less, 90 gf/cm or less, or 100 gf/cm or less. As the adhesive strength in the positive electrode material is increased, it can be good in terms of moldability, durability and battery performance.

[0043] In addition, the porosity of the positive electrode material may be 68% or less, 65% or less, 60% or less, or 55% or less, and 45% or more or 50% or more. If the porosity of the positive electrode material is more than 68%, the durability of the positive electrode may be reduced. If the porosity of the positive electrode material is less than 45%, since the space in the pores where the electrochemical reaction occurs is narrowed, it may be difficult to normally operate the cell.

[0044] In one aspect of the present disclosure, sulfur may be at least one selected from the group consisting of inorganic sulfur (S.sub.8), Li.sub.2S.sub.n (n≥1, wherein n is an integer), organic sulfur compounds and carbon-sulfur polymers[(C.sub.2S.sub.x).sub.n, 2.5≤x≤50, n≥2, wherein x and n are an integer].

[0045] In addition, the content of sulfur may be 50 wt. % or more, 55 wt. % or more, or 60 wt. % or more, 70 wt. % or less, 75 wt. % or less, 80 wt. % or less, based on the total weight of the carbon-containing sulfur melt. If the content of sulfur is less than 50% by weight, as the ratio of sulfur, which is an electrochemically active material, is decreased, the thickness of the sulfur melt formed on the surface of the porous carbon material becomes thinner, so that it may be difficult to form the carbon-containing sulfur melt properly, or the amount of sulfur may be reduced and thus the capacity of the battery may be reduced. In addition, if the content of sulfur is more than 80 wt. %, since the non-conductive sulfur blocks the conductive structure of the porous carbon material, the electrochemical activity is blocked, so that the operation of the battery may be limited.

[0046] When sulfur is contained in the carbon-containing sulfur melt in an amount of 50 wt. % to 80 wt. %, the positive electrode material can exhibit strong self-cohesion, and the porous carbon material can be well dispersed in the sulfur melt, so that a positive electrode in free-standing form can be formed well.

[0047] In one aspect of the present disclosure, the porous carbon material may have a structure in which pores or hollows are formed therein, or may be a porous carbon material having a high specific surface area, and any material commonly used in the art may be used.

[0048] The porous carbon material may be, but is not limited to, at least one selected from the group consisting of graphite; graphene; carbon blacks such as Denka black, acetylene black, Ketjen black, channel black, furnace black, lamp black, and thermal black; carbon nanotubes (CNTs) such as single wall carbon nanotube (SWCNT) and multiwall carbon nanotubes (MWCNT); carbon fibers such as graphite nanofiber (GNF), carbon nanofiber (CNF), and activated carbon fiber (ACF); and activated carbon. Preferably, the porous carbon material may be carbon nanotubes.

[0049] The carbon nanotubes may have more connection points due to structural characteristics, and thus may be more advantageous when forming a free-standing film. Specifically, since the carbon nanotubes have a shape having an aspect ratio of greater than 1, they may be advantageously connected to each other to form a free-standing film.

[0050] In addition, the graphene refers to the form of a single layer in which carbon atoms are arranged in a two-dimensional honeycomb shape, which is a material that has a thin, wide cross-sectional area and excellent conduction properties, and exhibits excellent physical properties such as bending properties and high sensitivity to light. In the present invention, graphene comprises at least one selected from reduced graphene formed by reducing graphene oxide and physically exfoliated graphene. The graphene thin film may be comprised in a form surrounding the outer surface of the carbon nanotube, and can suppress the leaching of sulfur into the electrolyte solution during operation of the battery while reinforcing the electrical conduction path.

[0051] In addition, the content of the porous carbon material may be 20 wt. % or more, 25 wt. % or more, 30 wt. % or more, or 35 wt. % or more, and may be 40 wt. % or less, 45 wt. % or less, or 50 wt. % or less, based on the total weight of the carbon-containing sulfur melt. If the content of the porous carbon material is less than 20 wt. %, the surface area and space on which molten sulfur can be filled, attached or coated are not sufficiently provided, so that electrochemical availability (reactivity) of sulfur may be reduced. If the carbon material is more than 50 wt. %, the content of sulfur is relatively lowered, so that when applied to a lithium secondary battery, the energy density of the battery may be excessively reduced.

[0052] Preparation Method of Positive Electrode Material for Lithium Secondary Battery

[0053] FIG. 1 is a schematic diagram showing changes in physical properties and moldability when pressing sulfur, carbon and sulfur-carbon composite which can be used as a positive electrode material for a lithium secondary battery.

[0054] The sulfur can be molded because its surface is melted under pressurization condition and exhibits a property of gathering with surrounding sulfur, but since sulfur is inflexible, it is impossible to prepare a positive electrode material (positive electrode) in the form of a free-standing film by sulfur alone.

[0055] Since the carbon is flexible but lacks cohesive strength, when pressed, it cannot be molded by itself, and thus cannot produce a positive electrode material (positive electrode) in the form of a free-standing film.

[0056] The sulfur-carbon composite is a composite of sulfur and a porous carbon material. In the case of the sulfur-carbon composite, since sulfur is also present on the outer surface of the porous carbon material, and when pressed, the sulfur present on the outer surface of the porous carbon material is melted, and thus the porous carbon material exists in a dispersed form in the sulfur melt and the sulfur-carbon composite can be molded, and since the porous carbon material is flexible, it is also possible to form a positive electrode material (positive electrode) in the form of a free-standing film by punching.

[0057] Therefore, another aspect of the present disclosure provides a method of preparing a positive electrode material for a lithium secondary battery by applying the sulfur-carbon composite to a dry process using the characteristics of the sulfur-carbon composite as described above during pressurization to form a carbon-containing sulfur melt.

[0058] The preparation method of the positive electrode material for the lithium secondary battery comprises the following steps (S1) to (S3):

[0059] (S1) mixing sulfur and a porous carbon material;

[0060] (S2) heat-treating the mixture formed in step (S1); and

[0061] (S3) forming a carbon-containing sulfur melt by filling the sulfur-carbon composite formed in step (S2) in a container and then pressurizing it.

[0062] Hereinafter, the preparation method of the positive electrode material for a lithium secondary battery of the present invention will be described in more detail for each step.

[0063] In step (S1), a mixture of sulfur, which is a raw material for manufacturing the positive electrode material made of the carbon-containing sulfur melt, and a porous carbon material may be formed. In this case, the type and appropriate weight range of sulfur and the porous carbon material are the same as described above.

[0064] In step (S2), the mixture formed in step (S1) may be heat-treated.

[0065] If the mixture of sulfur and the porous carbon material is heated, the sulfur is changed to a liquid state and then sulfur in the liquid state enters the interior of the porous carbon material or is coated or adhered to the surface, so that the porous carbon material is dispersed in sulfur in the liquid state. For example, if the porous carbon material is a carbon nanotube, sulfur in the liquid state is sucked into the carbon nanotubes through capillary action, sulfur is supported on the carbon nanotubes, and the carbon nanotubes are dispersed in sulfur in the liquid state.

[0066] The heat treatment may be performed above the melting point of sulfur. For example, the heat treatment temperature may be 130° C. or more, 140° C. or more, or 150° C. or more, and 160° C. or less, 165° C. or less, or 170° C. or less. If the heat treatment temperature is less than 130° C., sulfur does not melt and thus it is difficult to form a form supported or coated on the carbon material and also it is difficult to form a form in which the carbon material is dispersed in sulfur. If the heat treatment temperature is higher than 170° C., the volatilization of sulfur may occur and thus the loss of sulfur and the deterioration of manufacturing equipment may be induced.

[0067] In addition, the heat treatment time is possible as long as the sulfur is melted and supported on the porous carbon material by heat treatment or the porous carbon material can be dispersed into sulfur, and it may be 25 minutes or more or 30 minutes or more, and 40 minutes or less, 45 minutes or less, or 50 minutes or less.

[0068] In step (S3), the carbon-containing sulfur melt formed in step (S2) is filled in a container and pressurized to prepare a positive electrode material in the form of a free-standing film.

[0069] The composite of sulfur and carbon has a characteristic that shows strong self-cohesion in the pressurized state. Specifically, in a pressurized state, the sulfur on the surface of the sulfur-carbon composite is partially melted to give connectivity, thereby exhibiting strong self-cohesion. Accordingly, if pressure is applied to the sulfur-carbon composite, a sulfur melt in which carbon is dispersed is formed, and cohesive force is generated between the carbon particles, and also since the carbon material functions as a skeleton and has flexibility by itself, a free-standing film is formed.

[0070] The pressure at the time of pressurization can be a pressure to an extent that cohesion between the sulfur-carbon composites is sufficiently generated to form a free-standing film. For example, the pressure at the time of pressurization may be 0.8 Mpa or more, 0.9 Mpa or more, or 1 Mpa or more, and 5 Mpa or less, 8 Mpa or less, 10 Mpa or less, 13 Mpa or less, or 15 Mpa or less. If the pressure at the time of pressurization is less than 0.8 Mpa, the cohesive force between the sulfur-carbon composites is weak, and a free-standing film may not be formed. If the pressure at the time of pressurization exceeds 15 Mpa, the porosity of the positive electrode material is too low, and the structure of the electrode may be collapsed.

[0071] Lithium Secondary Battery

[0072] The other aspect of the present disclosure also relates to a lithium secondary battery comprising, as a positive electrode, the free-standing film-type positive electrode material which contains the carbon-containing sulfur melt, as described above.

[0073] If the free-standing film-type positive electrode material is used as a positive electrode, the loading amount of the positive electrode active material in the positive electrode may be 3.0 mAh/cd to 5.0 mAh/W, which may be due to the positive electrode material being prepared by a dry process that does not require a binder or an electrically conductive material.

[0074] The lithium secondary battery according to the present invention comprises a positive electrode, a negative electrode, and an electrolyte interposed therebetween, wherein the positive electrode material itself in the form of a free-standing film as described above as the positive electrode may be used as the positive electrode.

[0075] In addition, in the lithium secondary battery according to the present invention, the negative electrode is manufactured by forming a negative electrode active material layer having a negative electrode active material on the negative electrode current collector, or may be a negative electrode active material layer (for example, lithium foil) alone.

[0076] At this time, the types of the negative electrode current collector and the negative electrode active material layer are not particularly limited in the present invention, and known materials can be used.

[0077] In addition, the negative electrode current collector is not particularly limited as long as it has electrical conductivity without causing a chemical change in the battery. For example, copper, stainless steel, aluminum, nickel, titanium, sintered carbon, copper, or stainless steel surface-treated with carbon, nickel, titanium, silver or the like; aluminum-cadmium alloy or the like may be used as the negative electrode current collector. Also, as with the positive electrode current collector, the shape of the negative electrode current collector can be various forms such as a film having fine irregularities on its surface, a sheet, a foil, a net, a porous body, foam, a nonwoven fabric and the like.

[0078] In addition, the negative electrode active material may comprises, but is not limited to, at least one carbon-based material selected from the group consisting of crystalline artificial graphite, crystalline natural graphite, amorphous hard carbon, low crystalline soft carbon, carbon black, acetylene black, Ketjen black, Super-P, graphene, and fibrous carbon, Si-based material, metal composite oxides such as LixFe.sub.2O.sub.3(0≤x≤1), Li.sub.xWO.sub.2(0≤x≤1), Sn.sub.xMe.sub.1−xMe′.sub.yO.sub.z (Me: Mn, Fe, Pb, Ge; Me′: Al, B, P, Si, elements of groups 1, 2, and of the periodic table, halogen; 0<x≤1; 1≤y≤3; 1≤z≤8); lithium metal; lithium alloy; silicon-based alloy; tin-based alloy; metal oxide such as SnO, SnO.sub.2, PbO, PbO.sub.2, Pb.sub.2O.sub.3, Pb.sub.3O.sub.4, Sb.sub.2O.sub.3, Sb.sub.2O.sub.4, Sb.sub.2O.sub.5, GeO, GeO.sub.2, Bi.sub.2O.sub.3, Bi.sub.2O.sub.4, Bi.sub.2O.sub.5; an electrically conductive polymer such as polyacetylene; Li—Co—Ni based material; titanium oxide; lithium titanium oxide.

[0079] In addition, the negative electrode active material may be metal composite oxides such as SnxMe.sub.1−xMe′.sub.yO.sub.z (Me: Mn, Fe, Pb, Ge; Me′: Al, B, P, Si, elements of groups 1, 2, and 3 of the periodic table, halogen; 0<x≤1; 1≤y≤3; 1≤z≤8); oxides such as SnO, SnO.sub.2, PbO, PbO.sub.2, Pb.sub.2O.sub.3, Pb.sub.3O.sub.4, Sb.sub.2O.sub.3, Sb.sub.2O.sub.4, Sb.sub.2O.sub.5, GeO, GeO2.sub.2, Bi.sub.2O.sub.3, Bi.sub.2O.sub.4 and Bi.sub.2O.sub.5, and may be carbon-based negative electrode active materials such as crystalline carbon, amorphous carbon, or carbon composite alone or in combination of two or more.

[0080] In addition, in the lithium secondary battery according to the present invention, any of those conventionally used in the manufacture of a lithium secondary battery can be used as an electrolyte solution.

[0081] For example, lithium salts that may be included as electrolytes in the electrolyte solution may be used without limitation as long as they are commonly used in electrolyte solutions for a lithium secondary battery. For example, the anion of the lithium salt may be any one selected from the group consisting of F.sup.−, Cl.sup.−, Br.sup.−, I.sup.−, NO.sub.3.sup.−, N(CN).sub.2.sup.−, BF.sub.4.sup.−, ClO.sub.4.sup.−, PF.sub.6.sup.−, (CF.sub.3).sub.2PF.sub.4.sup.−, (CF.sub.3).sub.3PF.sub.3.sup.−, (CF.sub.3).sub.4PF.sub.2.sup.−, (CF.sub.3).sub.5PF.sup.−, (CF.sub.3) .sub.6P.sup.−, CF.sub.3SO.sub.3.sup.−, CF.sub.3CF.sub.2SO.sub.3.sup.−, (CF.sub.3SO.sub.2).sub.2N.sup.−, (FSO.sub.2).sub.2N.sup.−, CF.sub.3CF.sub.2(CF.sub.3).sub.2CO.sup.−, (CF.sub.3SO.sub.2).sub.2CH.sup.−, (SF.sub.5).sub.3C.sup.−, (CF.sub.3SO.sub.2).sub.3C.sup.−, CF.sub.3(CF.sub.2).sub.7SO.sub.3.sup.−, CF.sub.3CO.sub.2.sup.−, CH.sub.3CO.sub.2.sup.−, SCN.sup.− and (CF.sub.3CF.sub.2SO.sub.2).sub.2N.sup.−. Specifically, the lithium salt may be LiPF.sub.6, LiClO.sub.4, LiAsF.sub.6, LiBF.sub.4, LiSbF.sub.6, LiAlO.sub.4, LiAlCl.sub.4, LiCF.sub.3SO.sub.3, LiC.sub.4F.sub.9SO.sub.3, LiN (C.sub.2F.sub.5SO.sub.3).sub.2, LiN(C.sub.2F.sub.5SO.sub.2).sub.2 (Lithium bis(perfluoroethylsulfonyl)imide, BETI), LiN(CF.sub.3SO.sub.2).sub.2(Lithium bis(Trifluoromethanesulfonyl)imide, LiTFSI), LiN(C.sub.aF.sub.2a+1SO.sub.2) (C.sub.bF.sub.2b+1SO.sub.2) (wherein, a and b are natural number, preferably 1≤a≤20, 1≤b≤20), lithium poly[4,4′-(hexafluoroisopropylidene)diphenoxy]sulfonylimide (LiPHFIPSI), LiCl, LiI, LiB(C.sub.2O.sub.4).sub.2, LiNO.sub.3 or the like. Among them, a sulfonyl group-containing imide lithium compound such as LiTFSI, BETI or LiPHFIPSI may be more preferable.

[0082] In the electrolyte solution used in the present invention, the organic solvent contained in the electrolyte solution may be used without limitation so long as they are conventionally used in the electrolyte solution for a lithium secondary battery. Typically, at least one selected from the group consisting of propylene carbonate (PC), ethylene carbonate (EC), diethyl carbonate (DEC), dimethyl carbonate (DMC), ethylmethyl carbonate (EMC), methylpropyl carbonate, dipropyl carbonate, tetraethylene glycol dimethyl ether (TEGDME), dioxolane (DOL), dimethylsulfuroxide, acetonitrile, dimethoxyethane, diethoxyethane, vinylene carbonate, sulfolane, gamma-butyrolactone, propylene sulfite, and tetrahydrofuran, and a mixture of two or more of them, and the like can be used representatively. In particular, ethylene carbonate and propylene carbonate which are cyclic carbonates among the carbonate-based organic solvents are highly viscous organic solvents, which can be preferably used because they have a high dielectric constant and dissociate lithium salts in the electrolyte well. If such cyclic carbonates are mixed with a linear carbonate having a low viscosity and a low dielectric constant, such as dimethyl carbonate and diethyl carbonate in an appropriate ratio, an electrolyte solution having a high electrical conductivity can be made, and thus it can be used more preferably.

[0083] In addition, in the lithium secondary battery according to the present invention, the separator may be a conventional porous polymer film conventionally used as a separator. For example, as the separator, a porous polymer film made of a polyolefin-based polymer such as ethylene homopolymer, propylene homopolymer, ethylene/butene copolymer, ethylene/hexene copolymer, and ethylene/methacrylate copolymer may be used alone or they may be laminated and used, or a conventional porous nonwoven fabric, for example, a non-woven fabric made of high melting glass fibers, polyethylene terephthalate fibers, or the like may be used, but is not limited thereto.

[0084] The type of lithium secondary battery as described above is not particularly limited, and may be, for example, a jelly-roll type, a stack type, a stack-folding type (including a stack-Z-folding type), or a lamination-stack type, preferably a stack-folding type.

[0085] The negative electrode, the separator, and the positive electrode as described above are sequentially stacked, and the electrolyte solution is injecting to prepare an electrode assembly, and then the electrode assembly is placed in a battery case and sealed with a cap plate and a gasket to manufacture a lithium secondary battery.

[0086] In this case, the lithium secondary battery can be classified into various types of batteries such as lithium-sulfur secondary battery, lithium-air battery, lithium-oxide battery, and lithium all-solid-state battery depending on the materials of positive electrode/negative electrode used, can be classified into cylindrical, rectangular, coin-shaped, pouch type depending on the type, and can be divided into bulk type and thin film type depending on the size. The structure and preparation method of these batteries are well known in the art, and thus detailed description thereof is omitted.

[0087] In the present invention, since the lithium secondary battery uses a positive electrode material in the form of a free-standing film which contains the carbon-containing sulfur melt as a positive electrode, it may be a lithium-sulfur secondary battery. The lithium-sulfur secondary battery may use lithium metal as a negative electrode active material. During discharging of the lithium-sulfur secondary battery, an oxidation reaction of lithium occurs at the negative electrode and a reduction reaction of sulfur occurs at the positive electrode. At this time, the reduced sulfur is combined with lithium ions moved from the negative electrode to be converted into lithium polysulfide and finally accompanied by a reaction to form lithium sulfide.

[0088] Also, the present invention relates to a battery module comprising the lithium secondary battery, which can be used as a power source for devices requiring high capacity and high-rate characteristics, etc. Specific examples of the device may comprise, but are not limited to, a power tool that is powered by a battery powered motor; electric cars including an electric vehicle (EV), a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHEV), and the like; an electric motorcycle including an electric bike (E-bike) and an electric scooter (Escooter); an electric golf cart; and a power storage system.

[0089] Hereinafter, preferred examples are presented to facilitate understanding of the present invention. However, it is apparent to those skilled in the art that the following examples are merely illustrative of the present invention and that various changes and modifications can be made within the scope and spirit of the present invention, and also that such changes and modifications fall within the scope of the appended claims.

PREPARATION EXAMPLE 1

Preparation of Sulfur-Carbon Composite

[0090] Sulfur (S) and carbon nanotubes (CNT) were uniformly mixed in a solid state in a weight ratio of 65:35, and then ball-milled at 100 rpm for 1 hour to prepare a mixture.

[0091] The mixture was heat-treated at 155° C. for 35 minutes, allowing sulfur to be loaded into the pores of CNTs and to be coated on their surface to prepare a sulfur-carbon composite (S-CNT). In this case, the CNTs having a specific surface area of 350 m.sup.2/g were used.

EXAMPLE 1

[0092] (1) Preparation of Free-Standing Film-Type Positive Electrode Material

[0093] The sulfur-carbon composite (S-CNT) of Preparation Example 1 was filled in a mold, and pressurized at a pressure of 1 MPa using a hydraulic press to form a carbon-containing sulfur melt, thereby preparing a free-standing film-type positive electrode material, as shown in FIG. 2.

[0094] (2) Manufacture of Lithium-Sulfur Secondary Battery

[0095] The prepared free-standing film-type positive electrode material was prepared as a positive electrode, and lithium metal having a thickness of 150 μm was prepared as a negative electrode.

[0096] Lithium bis(trifluoromethanesulfonyl)imide (LiTFSI) at a concentration of 1 M and lithium nitrate (LiNO.sub.3) at a concentration of 0.1 M were mixed in an organic solvent formed by mixing tetraethylene glycol dimethyl ether (TEGDME)/dioxolane (DOL)/dimethoxyethane (DME) in a volume ratio of 1:1:1 to prepare a electrolyte solution.

[0097] A porous polyethylene separator having a thickness of 20 μm and a porosity of 45% was interposed between the positive electrode and the negative electrode to prepare an electrode assembly, and the electrode assembly was placed inside the case, and then the electrolyte was injected into the case to prepare a lithium-sulfur secondary battery.

EXAMPLE 2

[0098] The same method as in Example 1 was performed, except that the pressure at the time of pressurization of the sulfur-carbon composite is 1.5 Mpa.

EXAMPLE 3

[0099] The same method as in Example 1 was performed, except that the pressure at the time of pressurization of the sulfur-carbon composite is 3 Mpa.

COMPARATIVE EXAMPLE 1

[0100] A lithium-sulfur secondary battery was prepared in the same manner as in Example 1, except that the sulfur-carbon composite (S-CNT) of Preparation Example 1, an electrically conductive material, and a binder were mixed in a weight ratio of 90:5:5 to prepare a slurry, then coated on aluminum foil, dried and rolled to prepare a positive electrode.

[0101] At this time, the electrically conductive material was VGCF (Vapor grown carbon fiber), and the binder was SBR (Styrene Butadiene Rubber).

[0102] Also, by the rolling, the porosity of the positive electrode was set to be 68%.

COMPARATIVE EXAMPLE 2

[0103] A lithium-sulfur secondary battery was prepared in the same way as Comparative Example 1, except that the rolled thickness is reduced relative to Comparative Example 1, so that the porosity of the positive electrode is 65%.

COMPARATIVE EXAMPLE 3

[0104] A lithium-sulfur secondary battery was prepared in the same way as Comparative Example 1, except that the rolled thickness is reduced relative to Comparative Example 2, so that the porosity of the positive electrode is 58%.

COMPARATIVE EXAMPLE 4

[0105] The same method as in Example 1 was performed, except that the pressure at the time of pressurization of the sulfur-carbon composite is 0.5 Mpa.

COMPARATIVE EXAMPLE 5

[0106] The same method as in Example 1 was performed, except that the pressure at the time of pressurization of the sulfur-carbon composite is 20 Mpa.

COMPARATIVE EXAMPLE 6

[0107] A lithium-sulfur secondary battery was prepared in the same manner as in Example 1, except that 10 wt. % of CNT, which is the electrically conductive material, is filled in the mold together with the sulfur-carbon composite and pressed. At this time, the content of the electrically conductive material is based on the total weight of the sulfur-carbon composite and the electrically conductive material.

EXPERIMENTAL EXAMPLE 1

Comparison of Process Time

[0108] The time required for the process to prepare the positive electrode material in Examples and Comparative Examples was measured and compared. The time required for the process is as shown in Table 1 below.

TABLE-US-00001 TABLE 1 Detailed process Example Example Example Comparative Comparative Comparative (unit:hr) 1 2 3 Example 1 Example 2 Example 3 Mixing — — — 1.5 1.5 1.5 Coating — — — 0.5 0.5 0.5 Drying — — — 3   3   3   Rolling — — — 0.5 0.5 0.5 Filling 0.5 0.5 0.5 — — — Pressing 0.01 0.01 0.01 — — — Time in 0.51 0.51 0.51 5.5 5.5 5.5 total

[0109] As shown in Table 1 above, it can be seen that in Examples 1, 2, and 3, since the positive electrode materials are prepared using a dry process that includes only filling and pressing processes as detailed processes, the total process time is less than 1 hour.

[0110] On the contrary, it can be seen that in Comparative Examples 1, 2 and 3, since the positive electrode materials are prepared using a slurry process including mixing, coating, drying and rolling processes as detailed processes, the total process time all exceeds 5 hours.

[0111] From these results, it was confirmed that if a positive electrode material is manufactured using a dry process, process efficiency can be improved.

Experimental Example 2

Measurement of Porosity of Positive Electrode Material and Adhesive Strength in Positive Electrode Material

[0112] The porosity of the positive electrodes prepared in Examples and Comparative Examples was measured and compared, and the results are shown in Table 2.

[0113] The porosity was calculated by calculating the density of the positive electrode based on the weight and thickness of the positive electrode, and then inversely calculating the true density of sulfur and carbon (the true density of sulfur: 2.07 mg/cc, the true density of carbon: 2.00 mg/cc).

[0114] The adhesive strength was measured using an adhesive strength measuring device (AMETEK company, LS1).

TABLE-US-00002 TABLE 2 Pressure when Porosity Adhesive strength pressurized (Mpa) (%) (gf/cm) Example 1 1 68 18 Example 2 1.5 65 29 Example 3 3 58 38 Comparative — 68 10 Example 1 Comparative — 65 13 Example 2 Comparative — 58 18 Example 3 Comparative 0.5 73 5 Example 4 (forming of electrode: X) Comparative 20 40 50 Example 5 Comparative 1.5 68 8 Example 6

[0115] As shown in Table 2 above, it was confirmed that in the case of Examples 1, 2, and 3 in which the positive electrode material was manufactured by the dry process, as the pressure when pressurized is increased, the porosity is reduced and the adhesive strength in the positive electrode material is increased.

[0116] Also, it was confirmed that in the case of Comparative Examples 1, 2 and 3 in which the positive electrode material was prepared by a wet process, as the number of rolling is increased, the porosity is decreased and the adhesive strength in the positive electrode material is increased.

[0117] If the porosity of the positive electrode material is too high, the durability is lowered, and if the porosity is too low, the electrical conductivity or ionic conductivity is lowered. Therefore, in order to exhibit proper porosity, it is also necessary to properly control the pressure during pressurization.

[0118] FIG. 3 is a photograph of the positive electrode material obtained in Comparative Example 4. From this, it can be seen that in the case of Comparative Example 4, the positive electrode material is not prepared since the carbon-containing sulfur melt is not formed due to low pressure during pressurization and thus due to lack of cohesion between sulfur-carbon composites.

[0119] It can be seen that in the case of Comparative Example 5, the porosity is significantly reduced due to the high-pressure during pressurization, and in the case of Comparative Example 6 which is case where a separate electrically conductive material is externally added to the sulfur-carbon composite, the adhesive strength is significantly reduced.

EXPERIMENTAL EXAMPLE 3

Measurement of Capacity and Charging Efficiency

[0120] For the batteries manufactured in Examples and Comparative Examples, the capacity (mAh) was measured by discharging at 0.1 C and charging at 0.1 C at 25° C., the capacity and charging efficiency were measured by repeating charging and discharging to measure the capacities, and the results are shown in Table 3 below and FIGS. 4a to 4e. As shown in Table 2 above, in the case of Comparative Example 4, the electrode was not manufactured due to the lack of cohesion between the sulfur-carbon composites due to the low pressurized pressure. Therefore, experiments were conducted on Examples 1 to 3 and Comparative Examples 1 to 3 and 5 and 6.

TABLE-US-00003 TABLE 3 Initial discharging Discharging capacity per capacity (mAh/g.sub.s) electrode (mAh/g.sub.active) Example 1 1211 1211 Example 2 1183 1183 Example 3 1191 1191 Comparative 1129 1016 Example 1 Comparative 1112 1000 Example 2 Comparative 1145 1031 Example 3 Comparative 976 976 Example 5 Comparative 1210 1089 Example 6

[0121] Referring to Table 3 above, FIGS. 4a, 4b, and 4c, it was confirmed that Examples 1, 2, and 3, which are electrodes manufactured by the dry process, have improved overvoltage in the initial discharging curve and have higher initial discharging capacity compared to Comparative Examples 1, 2, and 3 manufactured by the wet process.

[0122] In general, the porosity is an important factor in lithium-sulfur secondary batteries. It means that the lower the porosity is, the more compact the cell is. However, as the porosity is lowered, the reaction space becomes narrower. Therefore, a situation in which normal cell operation is difficult may occur at a lower porosity.

[0123] However, it was confirmed that Examples 1, 2, and 3 manufactured by the dry process show improvement in overvoltage and higher initial discharging capacity when they have the same porosity as Comparative Examples 1, 2, and 3 manufactured by the wet process.

[0124] Also, referring to Table 3 and FIG. 4d, it was confirmed that in the case of Comparative Example 5, the pressure applied during the production of the positive electrode material is as high as 20 Mpa, and the porosity is excessively lowered, so the cell does not operate normally.

[0125] Also, referring to Table 3 and FIG. 4e, it was confirmed that in the case of Comparative Example 6, when the positive electrode material is manufactured by a dry process by adding CNTs as the electrically conductive material in addition to the sulfur-carbon composite, it is difficult to form the positive electrode material during pressurization due to the lack of cohesive force of carbon itself, and the capacity of the positive electrode material is inferior to Example 1 to which no electrically conductive material is added.

[0126] In addition, FIG. 5 is a graph showing the measurement results of lifetime characteristics for the coin cells to which the positive electrode materials prepared in Example 2 and Comparative Example 2 were applied. From this, it can be seen that the lifetime characteristics of the battery including the electrode of Example 2 manufactured by the dry process is improved.

EXPERIMENTAL EXAMPLE 4

Confirmation of Internal Shape of Positive Electrode Material

[0127] After applying the carbon nanotubes (CNTs) used as raw materials in Preparation Example 1 and sulfur-carbon composite (S-CNTs) to the pressing process, the internal shape was confirmed. The pressing process was applied as shown in (1) of Example 1.

[0128] After the carbon nanotubes (CNTs) and sulfur-carbon composites (S-CNTs) were filled in a mold, it was pressurized at a pressure of 1 Mpa using a hydraulic press, and then the internal shape was confirmed with a scanning electron microscope (SEM).

[0129] FIG. 6 is a SEM photograph of the carbon nanotubes (CNTs) and sulfur-carbon composite (S-CNTs) of Preparation Example 1.

[0130] As shown in FIG. 6, it was found that CNTs did not connect to each other due to lack of connectivity between CNTs and were not connected to each other even after the pressing process.

[0131] In addition, the sulfur-carbon composites (S-CNTs) were found to be connected as a whole by dispersing CNTs in the sulfur melt formed by melting sulfur. This is due to the fact that when the melting point of sulfur reduces during the high-pressure process and the melting of sulfur occurs on the surface of the sulfur-carbon composite instantaneously, the CNTs are connected as a whole by the sulfur melt formed. That is, it can be seen that the CNTs are dispersed in the sulfur melt.

[0132] In the above, although the present invention has been described by means of a limited embodiment and drawings, the present invention is not limited thereto. Various modifications and variations can be made by those skilled in the art within the equivalent scope of the technical concept of the present invention and the claims to be described below.