Hybrid sulfur particles and cathode active materials containing the hybrid particles

1. A hybrid particle, comprising:

a core of a hybrid composite consisting of at least two elements selected from the group consisting of sulfur, selenium and tellurium; and

a coating encapsulating the core;

wherein the coating comprises a first layer of a polymer having hydrophobic domains and hydrophilic domains with a hydrophobic domain closest to the hybrid material core, and

at least a second conductive polymer layer having an electrical charge opposite to the first laver, adjacent to and ionically bonded with the first layer.

2. The hybrid particle of claim 1 , wherein

the core comprises elemental sulfur and elemental selenium,

a content of the sulfur is from greater than 50% to less than 100% by weight of the core, and

a content of the selenium is from greater than 0% to less than 50% by weight of the core.

3. The hybrid particle of claim 2 , wherein

the content of the sulfur is from 90% to less than 100% by weight of the core, and

the content of the selenium is from greater than 0% to less than 10% by weight of the core.

4. The hybrid particle of claim 1 , wherein

the core comprises elemental sulfur and elemental tellurium,

a content of the sulfur is from greater than 50% to less than 100% by weight of the core, and

a content of the tellurium is from greater than 0% to less than 50% by weight of the core.

5. The hybrid particle of claim 1 wherein a particle size of the core is from 0.01 micron to 1 micron.

6. The hybrid particle of claim 2 wherein the selenium is homogenously distributed with the elemental sulfur in the core.

7. The hybrid particle of claim 4 wherein the tellurium is homogenously distributed with the elemental sulfur in the core.

8. The particle of claim 1 , wherein the coating comprises a layer of at least one polymer selected from the group consisting of poly(3,4-ethylenedioxythiophene) polystyrene sulfonate, polyvinylpyrrolidone, polyaniline, poly(ethylene oxide), carboxymethyl cellulose, sodium carboxymethylcellulose, polymethacrylic acid, [poly(2-acrylamido-2-methyl-1-propanesulfonic acid)], branched polyethylenimine, and poly(diallyldimethylammoniumchloride).

9. A method for preparing the particle of claim 1 , comprising:

mixing an aqueous solution of a polymer having hydrophobic domains and hydrophilic domains with an aqueous solution of a soluble precursor of at least two elements selected from the group consisting of sulfur, selenium and tellurium to form a mixture;

adding an acid to the mixture to precipitate the hybrid material core close to a hydrophobic domain of the polymer as a first polymer layer; and

applying at least a second conductive polymer layer having an electrical charge opposite to the first layer adjacent to and ionically bonded with the first polymer layer.

10. The method of claim 9 , wherein a soluble precursor of sulfur is present and the soluble precursor of sulfur is sodium thiosulfate.

11. The method of claim 9 , wherein a soluble precursor of selenium is present and the soluble precursor of selenium is of formula (I):

Na 2 SeSO 3   (I).

12. The method of claim 9 , wherein a soluble precursor of tellurium is present and the soluble precursor of tellurium is of formula (II):

Na 2 TeSO 3   (II).

13. The method of claim 9 , wherein the acid is at least one selected from the group consisting of hydrochloric acid, oxalic acid, ascorbic acid, concentrated sulfuric acid, nitric acid, methanesulfonic acid and a mixture thereof.

14. A cathode comprising:

a conductive substrate, and

an active material comprising the hybrid particle of claim 1 .

15. A battery, comprising:

an anode comprising a metal as an active source of metal ions;

the cathode of claim 14 ; and

an electrolyte interposed between the anode and cathode.

16. A vehicle, comprising the battery of claim 15 .