Porous interlayer for a lithium-sulfur battery

1. A method for making a porous interlayer for a lithium-sulfur battery, the method comprising;

dispersing an electronic component selected from a carbon material, a conductive polymeric material, and combinations thereof in a first liquid to form a first dispersion;

exposing a porous support structure to the first dispersion, whereby the electronic component remains on a surface of the porous support structure and the first liquid filters through the porous support structure;

dispersing a negatively charged or chargeable lithium ion conducting component in a second liquid to form a second dispersion; and

exposing the porous support structure to the second dispersion, whereby the negatively charged or chargeable lithium ion conducting component remains on the surface of the porous support structure and the second liquid filters through the porous support structure.

2. The method as defined in claim 1 wherein the method further comprises: mixing the first and second dispersions to form a single dispersion; and

wherein the exposing steps are accomplished simultaneously by exposing the porous support structure to the single dispersion.

3. The method as defined in claim 1 wherein the porous support structure is a polytetrafluoroethylene film, a polyethylene (PE) membrane, a polypropylene (PP) membrane, a membrane including a blend of PE and PP, or multi-layered structured porous films of PE and PP.

4. The method as defined in claim 1 wherein the porous support structure is a porous polymer membrane, and the method further comprises allowing the porous polymer membrane to remain in contact with the electronic component and the negatively charged or chargeable lithium ion conducting, thereby forming a separator with the porous interlayer as a coating on the porous polymer membrane.

5. The method as defined in claim 4 wherein the porous interlayer coating consists of:

the electronic component;

the negatively charged lithium ion conducting component; and

the electrolyte filing pores of the porous polymer separator and the porous interlayer coating.

6. The method as defined in claim 4 wherein a percentage of the negatively charged lithium ion conducting component in the porous interlayer coating is 5 wt. % or less of a total wt. % of the porous interlayer coating.

7. The method as defined in claim 1 wherein the carbon material is selected from carbon nanotubes, graphene, microporous carbon, mesoporous carbon, hollow carbon spheres, and combinations thereof; or

the conductive polymeric material includes nanofibers, nanotubes, hollow spheres, or combinations thereof, the conductive polymeric material being made of polypyrrole, polythiophene, or polyaniline.

8. The method as defined in claim 1 wherein the negatively charged lithium ion conducting component is selected from negatively charged sulfonated tetrafluoroethylene based fluoropolymer-copolymer, negatively charged polyacrylic acid, negatively charged sodium alginate, or a single lithium ion conductive polymer.

9. A method for making a porous interlayer for a lithium-sulfur battery, the method comprising;

dispersing an electronic component for conducting electrons in the lithium-sulfur battery selected from a carbon material, a conductive polymeric material, and combinations thereof in a first liquid to form a first dispersion;

exposing a porous support structure to the first dispersion, whereby the electronic component remains on a surface of the porous support structure and the first liquid filters through the porous support structure;

dispersing a negatively charged or chargeable lithium ion conducting component for conducting lithium ions while repelling polysulfides in the lithium-sulfur battery in a second liquid to form a second dispersion; and

exposing the porous support structure to the second dispersion, whereby the negatively charged or chargeable lithium ion conducting component remains on the surface of the porous support structure and the second liquid filters through the porous support structure to form the porous interlayer for the lithium-sulfur battery that conducts electrons and lithium ions and repels polysulfides.

10. The method as defined in claim 9 wherein the porous support structure is a polytetrafluoroethylene film, a polyethylene (PE) membrane, a polypropylene (PP) membrane, a membrane including a blend of PE and PP, or multi-layered structured porous films of PE and PP.

11. The method as defined in claim 9 wherein the porous support structure is a porous polymer membrane, and the method further comprises allowing the porous polymer membrane to remain in contact with the electronic component and the negatively charged or chargeable lithium ion conducting, thereby forming a separator with the porous interlayer as a coating on the porous polymer membrane.

12. The method as defined in claim 11 wherein a percentage of the negatively charged lithium ion conducting component in the porous interlayer coating is 5 wt. % or less of a total wt. % of the porous interlayer coating.

13. The method as defined in claim 9 wherein the carbon material is selected from carbon nanotubes, graphene, microporous carbon, mesoporous carbon, hollow carbon spheres, and combinations thereof; or

the conductive polymeric material includes nanofibers, nanotubes, hollow spheres, or combinations thereof, the conductive polymeric material being made of polypyrrole, polythiophene, or polyaniline.

14. The method as defined in claim 9 wherein the negatively charged lithium ion conducting component is selected from negatively charged sulfonated tetrafluoroethylene based fluoropolymer-copolymer, negatively charged polyacrylic acid, negatively charged sodium alginate, or a single lithium ion conductive polymer.