PFI:AIR-TT: One-step and Continuous Manufacturing of Sponge-like Nanostructured Bulks for High Energy Density and Low Cost Batteries

这个PFI: AIR技术翻译项目的重点是翻译低成本和高能量密度的锂硫（Li-S）电池，以满足开发一种关键材料的大规模生产方法的需要，这种材料是海绵状碳纳米管（CNT）体，在本研究中被称为碳纳米管海绵。与目前在电脑、平板电脑、手机、无人机和电动汽车等各种应用中占有90%以上市场份额的商用锂离子电池相比，发明的Li-S电池的能量密度可以提高5倍，这一点很重要。此外，本发明的Li-S电池可充放电800次，容量保持率高（80~90%），原材料（硫）价格比锂离子电池中使用的含钴活性材料至少低300倍。由于现代生活包括各种电子/电气设备，使得电能存储不可或缺，高能量密度和低成本可充电电池的潜在影响是重要的。发明的Li-S电池最重要的独特之处在于海绵阴极中的高硫（活性物质）负载，这允许在实际电池组中存储大量能量。该项目将为商业批量生产提供海绵的连续批量生产方法，以及控制海绵孔径和形态的最佳合成条件。该项目解决了与大规模生产相关的技术差距，因为它从研究发现转向商业应用。海绵状多孔体是一种优异的电子传输通道和多硫化物储层，使高硫负载成为可能。共价连接的碳纳米管不仅提供了优良的电子传递通道，而且完全消除了典型锂离子电池中用于容纳粉状原料的绝缘粘结剂（非活性材料）。为了批量生产碳纳米管海绵，研究人员将研究一种连续将催化剂输送到反应区域的方法，以及连续批量生产的最佳反应条件。然后，碳纳米管的孔径和表面条件将被优化，以最大限度地适应硫负载，以获得更高的性能。最后，电池原型将被制造出来进行测试，并与目前的商用锂离子电池进行比较。这项计划将为研究生提供独特的机会，让他们在技术转移的过程中，除了技术发展，还包括让学生参与从实验室到市场的过程，以及教他们如何向商业和非技术消费者提供技术信息。该项目与德克萨斯农工大学技术商业化、德克萨斯农工大学工程实验站（TEES）商业化和创业以及TEES工业关系小组合作，寻求许可方和投资者，以从研究成果中生产商业产品。

This PFI: AIR Technology Translation project focuses on translating low-cost and high energy density lithium-sulfur (Li-S) batteries to fill the need for developing a mass-production method of a key material, a sponge-like carbon nanotube (CNT) bulk, which is called a CNT sponge in this research. The invented Li-S batteries are important because they can deliver up to five times higher energy density compared to current commercial Li-ion batteries that have over 90% market share in various applications including computers, tablets, phones, drones, and electric vehicles.  Furthermore, the invented Li-S batteries can be charged and discharged 800 times with high (80~90%) capacity retention, and the price of the raw material (sulfur) is at least 300 times lower than that of cobalt-containing active materials used in Li-ion batteries. Since modern life includes various electronic/electrical devices that have made electrical energy storage indispensable, potential impacts from high energy density and low-cost rechargeable batteries are important. The most important unique feature of the invented Li-S batteries is a high sulfur (active material) loading in the sponge cathode, which allows for storing a large amount of energy in actual battery packs.  The project will result in a continuous bulk-manufacturing method of the sponge for commercial mass-production as well as optimum synthesis conditions to control the pore size and morphology of the sponge. This project addresses the technology gaps related to mass-production as it translates from research discovery toward commercial application. The high sulfur loading is enabled by the sponge-like porous bulk, serving as an excellent electron transport channel and polysulfide reservoir. The covalently connected CNTs not only provide excellent electron transport channels, but also completely eliminate insulating binders (inactive materials) that are used in typical Li-ion batteries to hold powdery raw materials. To mass-produce the CNT sponge, the researchers will investigate a method of continuously delivering the catalyst to the reaction zone as well as optimum reaction conditions for continuous bulk manufacturing. Then the pore size and surface condition of the CNT will be optimized to maximally accommodate sulfur loadings for higher performances. Finally battery prototypes will be fabricated for testing and comparison with the current commercial Li-ion batteries. This project will provide graduate students with unique opportunities in the process of technology transfer in addition to technology development such as engaging the students in lab-to-market processes as well as educating how to deliver technical information to business and non-technical consumers. The project engages the Texas A&M Technology Commercialization as well as the Texas A&M Engineering Experiment Station (TEES) Commercialization and Entrepreneurship and TEES Industrial Relations groups to seek licensees and investors for manufacturing commercial products out of the research outcomes.