Core-Shell Porous Carbon for Lithium-Polysulfide Confinement

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Solution Overview

Problem

Existing lithium-sulfur secondary batteries face challenges in maintaining high energy density due to the leaching of lithium polysulfide, which affects the reactivity and lifetime of the battery, despite previous attempts to improve the sulfur-carbon composite structure.

Innovation Solution

A porous carbon material with a core-shell structure is developed, comprising a core formed by stacking carbon sheets and a shell surrounding the core, prepared through a method involving mixing a carbon precursor with templates like basic zinc carbonazate, heating, and removing templates to form a structure that facilitates lithium ion transport and inhibits lithium polysulfide leaching.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If sulfur is used as a positive electrode active material to achieve high energy density, then the weight-to-energy storage density is improved, but the electrical conductivity is poor and lithium polysulfide leaching occurs

Engineering Contradiction:
Improveweight-to-energy storage densityVSAvoidelectrical conductivity and lithium polysulfide leaching
Core Design Contradiction:
Use of energy by moving objectVSReliability

Solution Approach 1:

The patent uses a core-shell composite structure where sulfur is combined with conductive carbon materials. The carbon matrix provides electrical conductivity while the core-shell configuration prevents lithium polysulfide leaching, thus maintaining both high energy density and reliability

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent employs porous carbon materials with specific pore structures to accommodate sulfur and lithium polysulfide. The porous structure provides high surface area for sulfur loading while the pore configuration prevents polysulfide dissolution into the electrolyte, addressing both conductivity and stability issues

Inventive Principle:
Principle #31Porous materials

2Use of energy by moving object

If the content of electrolyte solution is decreased to achieve high energy density, then the energy density is improved, but the concentration of lithium polysulfide increases and fluidity decreases

Engineering Contradiction:
Improveenergy densityVSAvoidfluidity of active material
Core Design Contradiction:
Use of energy by moving objectVSEase of operation

Solution Approach 1:

The porous carbon structure provides internal pathways for lithium ion transport, reducing dependence on electrolyte volume. The pore network maintains ion mobility even with reduced electrolyte content, preserving fluidity while achieving high energy density

Inventive Principle:
Principle #31Porous materials

3Reliability

If conventional carbon materials are used to suppress lithium polysulfide leaching, then the capacity is improved, but the lithium ion transport is hindered

Engineering Contradiction:
Improvelithium polysulfide leaching suppressionVSAvoidlithium ion transport
Core Design Contradiction:
ReliabilityVSSpeed

Solution Approach 1:

The patent creates different functional zones within the carbon structure: the core region provides polysulfide confinement while the shell or surface regions provide conductive pathways for lithium ion transport. This local differentiation allows simultaneous achievement of leaching suppression and fast ion transport

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The core-shell structure creates distinct functional zones: the inner core confines lithium polysulfide to prevent leaching, while the outer shell provides conductive pathways for rapid lithium ion transport, thus resolving the contradiction between suppression and transport speed

Inventive Principle:
Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The core-shell structure enhances lithium ion mobility and effectively suppresses lithium polysulfide leaching, resulting in improved capacity, charging/discharging, and lifetime characteristics of lithium-ion batteries.

Implementation Method 1

penetrating the carbon precursor into the template by heating the mixture to 120 to 350° C.

Methodology Applied
Scientific EffectThermal diffusion: Diffusion

Implementation Method 2

forming a core-shell shape while removing the template by heating the structure formed by penetration of the carbon precursor into the template to 600 to 900° C.

Methodology Applied
Scientific EffectThermal decomposition: Pyrolysis

Implementation Method 3

a core having a structure formed by stacking carbon sheets and thus facilitates the exit and entry of lithium ions

Methodology Applied
Scientific EffectIon diffusion: Diffusion

Implementation Method 4

a shell comprising carbon surrounding the core... shell part that suppresses the leaching of lithium polysulfide

Methodology Applied
Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS12418020B2Porous carbon material having core-shell structure, preparation method thereof, sulfur-carbon composite comprising same, and lithium secondary battery
Publication Date: 2025.09.16 LG ENERGY SOLUTION LTD
  • US12418020B2 patent drawing
  • US12418020B2 patent drawing
  • US12418020B2 patent drawing

AI summary

The present disclosure provides a porous carbon material having a core-shell structure, which comprises a core comprising a structure formed by stacking carbon sheets, and a shell comprising carbon surrounding the core, and a preparation method thereof, a sulfur-carbon composite comprising the same, and a lithium secondary battery comprising the same.