Multi-Layer Anode Stabilization Layer For Preventing Dendrites and Li Corrosion In Lithium-Sulfur Batteies

72969S03-I In a conventional Li-S battery, liquid from the electrolyte, along with polysulfide species migrating from the cathode, attack and corrode the metallic Li anode during each charge/discharge cycle. These cumulative processes tie up more and more of the Li in electrochemically inactive compounds, until the battery can no longer be recharged, thereby limiting battery lifetimes to typically less than 100 rechargeable cycles. A high-rate vacuum deposition process for the fabrication of more electrochemically robust metallic Li, followed by the vacuum deposition of Multi-Layer Polymer-Ceramic Anode Stabilization Layers, has already produced an improved cell that yields more than 300 rechargeable cycles. This project will perfect the stabilization laminates ¿ in a process that deposits all layers on a thin, flexible, plastic substrate to be wound into a Li-S cell ¿ to yield between 500 and 1000 rechargeable cycles. In Phase I, the efficacy of Multi-Layer Polymer-Ceramic Anode Stabilization Layers will be demonstrated by building a series of 800 milliamp-hour Li-S cells, both with and without stabilization layers, and cycling the cells to determine cycle life improvement. An atmospheric roll-coating process will deposit the Polymer layers, while all other layers will be deposited in a roll-to-roll vacuum process. Rolls of substrate will be transferred between the vacuum and atmospheric coaters. In Phase II, all layers will be vacuum deposited. Commercial Applications and Other Benefits as described awardee: The high energy density and low weight of these Li-S batteries should be ideal for powering consumer electronic products along with numerous industrial, military, aeronautical, and vehicular applications. Applications include electric vehicles, hybrid electric vehicles, portable communications equipment, space borne applications in Low Earth Orbit and Geo-Synchronous Earth Orbit satellites, and high-rate pulsed power applications.