Electrochemical cells comprising porous structures comprising sulfur

Abstract

The present invention relates to the use of porous structures comprising sulfur in electrochemical cells. Such materials may be useful, for example, in forming one or more electrodes in an electrochemical cell. For example, the systems and methods described herein may comprise the use of an electrode comprising a conductive porous support structure and a plurality of particles comprising sulfur (e.g., as an active species) substantially contained within the pores of the support structure.

What is claimed is: 
     
         1 . (canceled) 
     
     
         2 . A method of forming an electrode, comprising:
 combining a plurality of templating entities with a support structure material and/or a precursor of a support structure material;   at least partially removing the templating entities from the support structure material and/or the precursor to form a porous support structure; and   providing an electrode active material comprising sulfur substantially within the pores of the porous support structure to form the electrode, wherein:   the porous support structure has a total pore volume defined by the sum of each of the individual pore volumes; and   at least about 50% of the total pore volume is occupied by pores having cross-sectional diameters of between about 0.1 microns and about 10 microns.   
     
     
         3 . The method of  claim 2 , wherein the templating entities comprise silica. 
     
     
         4 . The method of  claim 2 , wherein at least partially removing the templating entities comprises exposing the templating entities to a fluid. 
     
     
         5 . The method of  claim 2 , wherein at least partially removing the templating entities comprises exposing the templating entities to hydrofluoric acid. 
     
     
         6 . The method of  claim 2 , wherein the templating entitles are substantially spherical. 
     
     
         7 . The method of  claim 2 , wherein the templating entities comprise fluid bubbles. 
     
     
         8 . The method of  claim 2 , wherein the templating entities comprise particles. 
     
     
         9 . The method of  claim 2 , wherein the templating entities form an interconnected network within the support structure material and/or precursor. 
     
     
         10 . The method of  claim 2 , wherein the porous support structure comprises particulate material. 
     
     
         11 . The method of  claim 2 , wherein the support structure material comprises carbon. 
     
     
         12 . The method of  claim 2 , wherein the support structure material comprises a metal. 
     
     
         13 . The method of  claim 2 , wherein the support structure material comprises a polymer. 
     
     
         14 . The method of  claim 2 , wherein the support structure material comprises a ceramic. 
     
     
         15 . The method of  claim 2 , wherein the electrode active material comprises at least one of elemental sulfur, polymeric sulfur, inorganic sulfides, inorganic polysulfides, organic sulfides, organic polysulfides, and sulfur organic compounds. 
     
     
         16 . The method of  claim 15 , wherein the electrode active material comprises elemental sulfur. 
     
     
         17 . The method of  claim 2 , wherein the electrode comprises at least about 20 wt % sulfur. 
     
     
         18 . The method of  claim 2 , wherein the electrode has a porosity of at least about 40%. 
     
     
         19 . The method of  claim 2 , wherein less than about 20 wt % of the electrode is formed of binder. 
     
     
         20 . The method of  claim 2 , wherein at least about 70% of the total pore volume is occupied by pores having cross-sectional diameters of between about 0.1 microns and about 10 microns. 
     
     
         21 . The method of  claim 2 , wherein the distribution of the cross-sectional diameters of the pores within the support structure material has a standard deviation of less than about 50% of the average cross-sectional diameter of the plurality of pores.