Sulfur-Carbon Composite Network Coating for Lithium-Ion Mobility

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Solution Overview

Problem

Existing sulfur-carbon composites in lithium-sulfur batteries face challenges with reduced conductivity and lithium ion mobility due to the use of electrically conductive polymers coated as thin films, which hinder the movement of lithium ions.

Innovation Solution

A sulfur-carbon composite with an electrically conductive polymer coating layer, specifically formed as a network-type with polyaniline nanofibers, enhances lithium ion mobility and improves conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an electrically conductive polymer is coated as a thin film on sulfur-carbon composite, then the conductivity is improved, but the lithium ion mobility deteriorates

Engineering Contradiction:
ImproveconductivityVSAvoidlithium ion mobility
Core Design Contradiction:
ReliabilityVSEase of operation

Solution Approach 1:

The patent employs a porous hollow fiber structure as the substrate for the sulfur-carbon composite. This porous architecture provides interconnected void spaces that allow lithium ions to diffuse through the coating layer and access the sulfur active material, thereby maintaining ion mobility while benefiting from the conductive polymer coating.

Inventive Principle:
Principle #31Porous materials

Solution Approach 2:

The patent implements a nested structure where the sulfur-carbon composite is contained within the porous hollow fiber. This nested configuration allows the conductive polymer coating to be applied on the outer surface while the inner porous structure remains accessible to lithium ions, resolving the contradiction between conductivity enhancement and ion transport.

Inventive Principle:
Principle #7Nested doll (Nesting)

2Quantity of substance

If sulfur content in the positive electrode is increased, then the energy density is improved, but the amount of conductive material decreases

Engineering Contradiction:
Improveenergy densityVSAvoidelectromotive force
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The porous hollow fiber substrate serves multiple functions simultaneously: it provides mechanical support, acts as a conductive network, and offers porous pathways for ion transport. This multi-functionality allows high sulfur content to be incorporated without proportionally reducing conductive material, as the hollow fiber structure contributes to both structural integrity and electrical conductivity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent creates a composite structure combining sulfur, carbon, and porous hollow fiber materials. This composite approach allows optimization of each component's function: sulfur provides high capacity, carbon enhances conductivity, and the porous hollow fiber provides both structural support and conductive pathways, enabling high sulfur content while maintaining sufficient conductivity.

Inventive Principle:
Principle #40Composite materials

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 network-type coating layer improves lithium ion mobility, reduces polysulfide loss, and enhances the performance and lifetime of lithium-sulfur secondary batteries by forming a conductive structure with carbon.

Implementation Method 1

a technique of coating a material capable of adsorbing polysulfide on a positive electrode material

Methodology Applied
Scientific EffectAdsorption: Adsorption

Implementation Method 2

carbon-based materials in which intercalation and deintercalation of metal ions such as lithium ions occur

Methodology Applied
Scientific EffectIntercalation: Absorption (physical)

Implementation Method 3

Through this oxidation-reduction reaction, electrical energy is stored and generated

Methodology Applied
Scientific EffectOxidation-reduction reaction: Redox Reactions

Data Source

PatentUS12463216B2Sulfur-carbon composite and lithium secondary battery comprising same
Publication Date: 2025.11.04 LG ENERGY SOLUTION LTD
  • US12463216B2 patent drawing
  • US12463216B2 patent drawing
  • US12463216B2 patent drawing

AI summary

A positive electrode containing a sulfur-carbon composite and a lithium secondary battery including the same are discussed. More specifically, a network-shaped coating layer including a conductive polymer on a surface of the sulfur-carbon composite, and thus the conductivity of the sulfur-carbon composite is enhanced and also, lithium ions move freely, and accordingly, when applied to lithium secondary batteries, the sulfur-carbon composite can enhance the performance of batteries.