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

该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，以满足开发关键材料，海绵状碳纳米管（CNT）块的大规模生产方法的需要，在本研究中称为CNT海绵。 发明的Li-S电池很重要，因为它们可以提供比目前商业锂离子电池高五倍的能量密度，目前商业锂离子电池在包括计算机，平板电脑，手机，无人机和电动汽车在内的各种应用中拥有超过90%的市场份额。 此外，本发明的Li-S电池可以充放电800次，具有高（80~90%）容量保持率，并且原材料（硫）的价格比锂离子电池中使用的含钴活性材料低至少300倍。 由于现代生活包括各种电子/电气设备，这些设备使得电能存储不可或缺，因此来自高能量密度和低成本可充电电池的潜在影响很重要。 本发明的Li-S电池的最重要的独特特征是海绵阴极中的高硫（活性材料）负载，这允许在实际电池组中存储大量能量。 该项目将产生用于商业大规模生产的海绵的连续批量制造方法以及控制海绵的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化为商业应用。 高硫负载是由海绵状多孔体实现的，其用作优异的电子传输通道和多硫化物储库。 共价连接的CNT不仅提供了优异的电子传输通道，而且完全消除了典型锂离子电池中用于容纳粉末状原材料的绝缘粘合剂（非活性材料）。 为了大规模生产CNT海绵，研究人员将研究一种将催化剂连续输送到反应区的方法，以及连续批量生产的最佳反应条件。 然后，CNT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，将制造电池原型进行测试，并与当前商业锂离子电池进行比较。 该项目将为研究生提供技术转让过程中的独特机会，除了技术开发，如让学生参与实验室到市场的过程，以及教育如何向企业和非技术消费者提供技术信息。 该项目涉及德克萨斯州A M技术商业化以及德克萨斯州A M工程实验站（TEES）商业化和创业以及TEES工业关系组，以寻求许可证持有人和投资者，用于制造研究成果的商业产品。

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.