US009203O84B2

(12) United States Patent (10) Patent No.: US 9.203,084 B2 Wang et al. (45) Date of Patent: Dec. 1, 2015

(54) CATHODE ACTIVE MATERIAL-COATED USPC ...... 429/217, 212, 231.8, 231.7, 219, 405 DISCRETE GRAPHENE SHEETS FOR See application file for complete search history. LITHIUM BATTERIES AND PROCESS FOR PRODUCING SAME (56) References Cited (71) Applicants:Yanbo Wang, Huber Heights, OH (US); U.S. PATENT DOCUMENTS Bor Z, Jang, Centerville, OH (US); Hui 7,824,651 B2 11/2010 Zhamu et al. He, Beavercreek, OH (US); Aruna 8,236,446 B2* 8/2012 Lu ...... 429,209 Zhamu, Centerville, OH (US) 8,765,302 B2* 7/2014 Chen et al...... 429,219 2011/O165466 A1* 7, 2011 Zhamu et al. .. 429,231.8 (72) Inventors: Yanbo Wang, Huber Heights, OH (US); 2013/0323,603 A1* 12/2013 Ryu et al...... 429/320 Bor Z, Jang, Centerville, OH (US); Hui 2014/0013588 A1* 1/2014 Wang et al. . ... 29.623.2 He, Beavercreek, OH (US); Aruna 2014/0141328 A1* 5, 2014 Dai et al...... 429,217 Zhamu, Centerville, OH (US) OTHER PUBLICATIONS (73) Assignee: Nanotek Instrurments, Inc., Dayton, Y. Ding, et al. "Preparation of nano-structured LiFePO4, graphene OH (US) composites by co-precipitation method.” Electrochemistry Commu nications 12 (2010) 10-13. (*) Notice: Subject to any disclaimer, the term of this patent is extended or adjusted under 35 * cited by examiner U.S.C. 154(b) by 179 days. Primary Examiner — Nina Bhat (21) Appl. No.: 13/987,567 (57) ABSTRACT (22) Filed: Aug. 8, 2013 Provided is a cathode (positive electrode) of a lithium battery and a process for producing this cathode. The electrode com (65) Prior Publication Data prises a cathode active material-coated graphene sheet and the graphene sheet has two opposed parallel Surfaces, US 2015/OO44556A1 Feb. 12, 2015 wherein at least 50% area (preferably greater than 80%) of one of the two Surfaces is coated with a cathode active mate (51) Int. Cl. rial coating. The graphene material is in an amount of from HOLM 4/36 (2006.01) 0.1% to 99.5% by weight and the cathode active material is in HOLM 4/04 (2006.01) an amount of at least 0.5% by weight (preferably greater than HOIM 4/O2 (2006.01) 80% and more preferably greater than 90%), all based on the HOIM IO/O56 (2010.01) total weight of the graphene material and the cathode active (52) U.S. Cl. material combined. The cathode active material is preferably CPC ...... H01 M 4/366 (2013.01); H01 M 4/04 an inorganic material, an organic or polymeric material, a (2013.01); H0 IM 4/0421 (2013.01): HOIM metal oxide/phosphate/sulfide, or a combination thereof. 10/056 (2013.01); HOIM 2004/028 (2013.01) Also provided is a lithium battery, including a lithium-ion, (58) Field of Classification Search lithium-metal, or lithium-sulfur battery. CPC ...... H01M6/00; H01M 10/00; H01M 10/04; HO1 M 4/625 35 Claims, 10 Drawing Sheets

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Anode active Cathode active material layer .. material layer (e.g. (e.g. Si coating) LiCoO2 coating) Pofous separator

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3. 883 & 83 8: 888 :88: 388: 88: 88: 8: 88. : ::: US 9,203,084 B2 1. 2 CATHODE ACTIVE MATERAL-COATED a conductive additive for the cathode of a lithium battery. DISCRETE GRAPHENE SHEETS FOR These include carbon nano-tubes (CNTs), vapor-grown car LITHIUM BATTERIES AND PROCESS FOR bon nano-fibers (VG-CNFs), and simple carbon coating on PRODUCING SAME the surface of cathode active material particles. The result has not been satisfactory and hence, as of today, carbon black and FIELD OF THE INVENTION artificial graphite particles are practically the only two types of cathode conductive additives widely used in lithium ion The present invention relates generally to the field of battery industry. Thereasons are beyondjust the obvious high lithium metal or lithium ion batteries and, in particular, to a costs of both CNTs and VG-CNFs. The difficulty in disentan graphene-enhanced cathode of a lithium metal battery, 10 gling CNTs and VG-CNFs and uniformly dispersing them in lithium-sulfur battery, or lithium-ion battery. a liquid or Solid medium has been an impediment to the more widespread utilization of these expensive materials as a con BACKGROUND ductive additive. Additionally, the production of both CNTs Due to extremely poor electrical conductivity of all cath- 15 and VG-CNFs normally require the use of a significant ode (positive electrode) active materials in a lithium-ion, amount of transition metal nano particles as a catalyst. It is lithium metal, or lithium-sulfur cell, a conductive additive difficult to remove and impossible to totally remove these (e.g. carbon black, fine graphite particles, expanded graphite transition metal particles, which can have adverse effect on particles, or their combinations), typically in the amount of the cycling stability of a lithium metal. 5%-20%, must be added into the electrode. In the case of a As for the less expensive carbon coating, being considered lithium-sulfur cell, a carbon amount as high as 50% by weight for use in lithium iron phosphate, the conductivity of the is used as a conductive Support for Sulfur in the cathode. carbon coating (typically obtained by converting a precursor However, the conductive additive is not an electrode active Such as Sugar or resin via pyrolyzation) is relatively low. It material (i.e. it is not capable of reversibly storing lithium would take a graphitization treatment to render the carbon ions). The use of a non-active material means that the relative 25 coating more conductive, but this treatment requires a tem proportion of an electrode active material, such as LiFePO, perature higher than 2,000° C., which would degrade the is reduced or diluted. For instance, the incorporation of 5% by underlying cathode active material (e.g., LiFePO). weight of PVDF as a binder and 5% of carbon black as a As an alternative approach, Ding, et al investigated the conductive additive in a cathode would mean that the maxi electrochemical behavior of LiFePO/graphene composites mum amount of the cathode active material (e.g., lithium 30 cobalt oxide) is only 90%, effectively reducing the total Y. Ding, et al. “Preparation of nano-structured LiFePO/ lithium ion storage capacity. Since the specific capacities of graphene composites by co-precipitation method.” Electro the more commonly used cathode active materials are already chemistry Communications 12 (2010) 10-13. The co-pre very low (140-170 mAh/g), this problem is further aggravated cipitation method leads to the formation of LiFePO nano ifa significant amount of non-active materials is used to dilute 35 particles coated on both primary Surfaces of graphene nano the concentration of the active material. sheets. The cathode is then prepared by stacking these State-of-the-art carbon black (CB) materials, as a conduc LiFePO-coated graphene sheets together. This approach has tive additive, have several drawbacks: several major drawbacks: (1) CBS are typically available in the form of aggregates of (1) With the two primary surfaces of a graphene sheet multiple primary particles that are typically spherical in 40 attached with LiFePO nano-particles, the resulting shape. Due to this geometric feature (largest dimension-to electrode entails many insulator-to-insulator contacts Smallest dimension ratio or aspect ratio ~1) and the notion between two adjoining coated sheets in a stack. that CBS are a minority phase dispersed as discrete par (2) Only less than 30% of the graphene surface area is ticles in an electrically insulating matrix (e.g. lithium covered by LiFePO particles on either side. This is a cobalt oxide and lithium iron phosphate), a large amount of 45 relatively low proportion of the cathode active material. CBs is required to reach a percolation threshold where the (3) The LiFePO particles are easily detached from CB particles are combined to form a 3-D network of elec graphene sheets during handling and electrode produc tron-conducting paths. tion. (2) CBs themselves have a relatively low electrical conduc (4) We have found that the nano particle-attached graphene tivity and, hence, the resulting electrode remains to be of 50 sheets as prepared by the co-precipitation method are relatively low conductivity even when the percolation not amenable to fabrication of cathodes with current threshold is reached. A relatively high proportion of CBS electrode coating equipment. In particular, these par (far beyond the percolation threshold) must be incorpo ticle-attached graphene sheets could not be compacted rated in the cathode to make the resulting composite elec into a dense state with a high mass per unit electrode trode reasonably conducting. 55 volume. In other words, the cathode tap density is rela Clearly, an urgent need exists for a more effective electri tively low. This is a very serious issue since all of the cally conductive additive material. Preferably, this electri commonly used cathode active materials, including cally conductive additive is also of high thermal conductivity. LiFePO, already have a very low specific capacity Such a thermally conductive additive would be capable of (mAh/g), and not being able to pack a large mass of a dissipating the heat generated from the electrochemical 60 cathode active material into a given electrode Volume operation of the Li-ion battery, thereby increasing the reli would mean an excessively low overall capacity at the ability of the battery and decreasing the likelihood that the cathode side. (It may be noted that the typical specific battery will suffer from thermal runaway and rupture. With a capacity (140-170 mAh/g) of a cathode active material is high electrical conductivity, there would be no need to add a already much lower than that (330-360 mAh/g) of an high proportion of conductive additives. 65 anode active material. Such an imbalance has been a There have been several attempts to use other carbon nano major issue in the design and fabrication of lithium ion materials than carbon black (CB) or acetylene black (AB) as batteries). US 9,203,084 B2 3 4 Thus, it is an object of the present invention to provide a a. In particular, the lithium Vanadium oxide may be thermally and electrically conductive cathode active material selected from the group consisting of VO, LiVO, that can be easily incorporated in a cathode electrode of a V2Os, Li V2O5, VOs, LiVOs, LiVO7. VOo. lithium battery. LiVO, VO, LiVO, their doped versions, A specific object of the present invention is to provide a their derivatives, and combinations thereof, wherein cathode active material-coated discrete graphene sheets (as 0.1bismuth 15 selenide orbismuth telluride, (b) transition metal dichal tional conductivity to the cathode and enabling the cathode to cogenide or trichalcogenide, (c) sulfide, selenide, or tel become high-rate capable. luride of niobium, Zirconium, molybdenum, hafnium, The cathode active material-coated graphene sheets dis tantalum, tungsten, titanium, cobalt, manganese, iron, closed herein, typically 0.3 um-10 um long or wide, have a nickel, or a transition metal; (d) boron nitride, or (e) graphene sheet thickness in the range of 0.5 nm to 10 nm and Sulfur, Sulfur compound, lithium polysulfide (f) a com cathode active material coating thickness in the range of 2 mm bination thereof. In particular, TiS, TaS, MoS,NbSes, to 100 nm (more typically 5-50 nm). The cathode active non-lithiated MnO, CoO, iron oxide, Vanadium oxide, material loading (percentage) is typically >80%, more typi or a combination thereofmay be used as a cathode active cally >90%, and most typically 95-99%. This active material material in a lithium metal cell. proportion is readily adjustable. 25 c) The organic material or polymeric material may be Another object of the present invention is to provide a selected from Poly(anthraquinonyl sulfide) (PAQS), a process to produce cathode active material-coated graphene lithium oxocarbon, 3.4.9,10-perylenetetracarboxylic sheets. dianhydride (PTCDA), poly(anthraquinonyl sulfide), A further object of the present invention is to provide a pyrene-4.5,9,10-tetraone (PYT), polymer-bound PYT, cathode electrode that has a high cathode active material 30 Quino(triaZene), redox-active organic material, Tetracy proportion and a rechargeable battery that contains such a anoquinodimethane (TCNQ), tetracyanoethylene cathode electrode. (TCNE), 2,3,6,7,10,11-hexamethoxytriphenylene (HMTP), poly(5-amino-1,4-dyhydroxy anthraquinone) SUMMARY OF THE INVENTION (PADAQ), phosphazene disulfide polymer (I(NPS) 35 n), lithiated 1,4,5,8-naphthalenetetraol formaldehyde The present invention provides a cathode (positive elec polymer, Hexaazatrinaphtylene (HATN), Hexaazatriph trode) of a lithium battery, which is a lithium-ion battery, enylene hexacarbonitrile (HAT(CN)), 5-Benzylidene lithium metal battery (using lithium metal as a primary anode hydantoin, Isatine lithium salt, Pyromellitic diimide active material), or lithium-sulfur battery. The cathode elec lithium salt, tetrahydroxy-p-benzoquinone derivatives trode comprises one or multiple cathode active material 40 (THQLi.), N,N'-diphenyl-2,3,5,6-tetraketopiperazine coated graphene sheets, wherein the graphene sheet has two (PHP), N,N'-diallyl-2,3,5,6-tetraketopiperazine (AP), opposed parallel surfaces and at least 50% area of one of the N,N'-dipropyl-2,3,5,6-tetraketopiperazine (PRP), a two Surfaces is coated with a cathode active material coating thioether polymer, a quinone compound, 1,4-benzo (the other surface typically free of cathode active material). In quinone, 5.7.12, 14-pentacenetetrone (PT), 5-amino-2, the coated sheet, the graphene material is in an amount of 45 3-dihydro-1,4-dyhydroxy anthraquinone (ADDAQ), from 0.1% to 99.5% by weight and the cathode active mate 5-amino-1,4-dyhydroxy anthraquinone (ADAQ), calix rial is in an amount of at least 0.5% by weight, all based on the quinone, LiCO, Li2CO. LiCO, or a combination total weight of said graphene material and the cathode active thereof. material combined. The thioether polymer is selected from Polymethane Preferably, at least 80% area of one of the surfaces is coated 50 tetryl-tetra(thiomethylene) (PMTTM), Poly(2,4- with a cathode active material. In a preferred embodiment, the dithiopentanylene) (PDTP), a polymer containing coated graphene sheet contains at least 60% (preferably at Poly(ethene-1,1,2,2-tetrathiol) (PETT) as a main least 80% and further preferably at least 90%) by weight or by chain thioether polymers, a side-chain thioether poly Volume of the cathode active material based on the total mer having a main-chain consisting of conjugating weight of said coated graphene sheet. 55 aromatic moieties, and having a thioether side chain In the cathode electrode, the cathode active material may as a pendant, Poly(2-phenyl-1,3-dithiolane) (PPDT), be selected from a metal oxide/phosphate/sulfide, an inor Poly(1,4-di(1,3-dithiolan-2-yl)benzene) (PDDTB), ganic material, an organic or polymeric material, or a com poly(tetrahydrobenzodithiophene) (PTHBDT), poly bination thereof: 1,2,4,5-tetrakis(propylthio)benzene (PTKPTB, or a) the group of metal oxide, metal phosphate, and metal 60 poly(3,4(ethylenedithio)thiophene (PEDTT). sulfides consisting of lithium cobalt oxide, lithium The organic material may include a phthalocyanine nickel oxide, lithium manganese oxide, lithium vana compound selected from copperphthalocyanine, Zinc dium oxide, lithium transition metal oxide, lithium phthalocyanine, tin phthalocyanine, iron phthalocya mixed metal oxide, lithium iron phosphate, lithium man nine, lead phthalocyanine, nickel phthalocyanine, ganese phosphate, lithium Vanadium phosphate, lithium 65 Vanadyl phthalocyanine, fluorochromium phthalo mixed metal phosphates, transition metal sulfides, and cyanine, magnesium phthalocyanine, manganous combinations thereof. phthalocyanine, dilithium phthalocyanine, aluminum US 9,203,084 B2 5 6 phthalocyanine chloride, cadmium phthalocyanine, In a preferred version of the process, the continuous film of chlorogallium phthalocyanine, cobalt phthalocya a graphene material may be produced by (a) spraying a nine, silver phthalocyanine, a metal-free phthalocya graphene Suspension onto a solid Substrate, wherein the nine, a chemical derivative thereof, or a combination graphene Suspension contains a graphene material dispersed thereof. 5 in a liquid medium, and (b) by removing said liquid medium. The graphene material is selected from pristine graphene, Alternatively, the continuous sheet of a graphene material graphene oxide, reduced graphene oxide, graphene fluoride, may be produced by chemical vapor deposition of a graphene graphene bromide, graphene iodide, boron-doped graphene, material onto a solid Substrate. nitrogen-doped graphene, chemically functionalized The coated film (the sheet of a cathode active material graphene, or a combination thereof, and the graphene mate 10 rial comprises single-layer or less than 10 graphene planes. coated graphene material film) preferably has a cathode Preferably, the cathode active material coating has a thickness active material coating thickness less than 500 nm, more less than 100 nm, more preferably less than 50 nm, and most preferably less than 100 nm, further preferably less than 50 preferably less than 20 nm. nm, most preferably less than 20 nm. The coated film may be Multiple sheets of cathode active material-coated graphene 15 produced through chemical vapor deposition, physical vapor may be combined, with additional graphene sheets (optional) deposition, Sputtering, or laser-assisted thin-film deposition or other conductive additives (optional), to form a secondary of an anode active material onto a sheet of a graphene mate particle having a size preferably less than 20 um, further rial. preferably less than 10 Lim, and most preferably less than 5 In the process, step (c) of mechanical breaking can be um. The additional conductive additive incorporated into the conducted using air jet milling, impact milling, grinding. secondary particles may be a carbon or graphite material mechanical shearing, ultrasonication, or a combination selected from polymeric carbon, amorphous carbon, chemi thereof. cal vapor deposition carbon, coal tar pitch, petroleum pitch, The process can further comprise a step of shaping those meso-phase pitch, carbon black, coke, acetylene black, acti multiple pieces of cathode active material-coated graphene vated carbon, fine expanded graphite particle with a dimen 25 material into a secondary particle having a size less than 20 sion Smaller than 100 nm, artificial graphite particle, natural um, preferably less than 10 um, and more preferably less than graphite particle, or a combination thereof. 5um. Preferably, this secondary particle is spherical in shape. The invention also provides a lithium battery containing an The step of shaping multiple pieces of cathode active mate anode electrode, a cathode electrode as described above, a rial-coated graphene material into a secondary particle may porous separator and/or electrolyte in contact with the anode 30 comprise dispersing the multiple pieces of cathode active electrode and the cathode electrode. The lithium battery may material-coated graphene in a liquid medium to form a multi further comprise an anode current collector and/or a cathode component suspension and drying the multi-component sus current collector. The lithium battery may be a lithium metal pension to form the secondary particle using a spray-drying, secondary battery, wherein the anode electrode contains a spray-pyrolysis, fluidized-bed drying, atomization, or aero lithium metal, lithium metal alloy, or lithium compound as an 35 Solizing technique. anode active material. The lithium battery may be a lithium In a preferred process, Step (b) further comprises deposit sulfur cell wherein the anode electrode contains a lithium ing a layer of carbon or graphite material onto a surface of the metal, lithium metal alloy, or lithium compound as an anode sheet of cathode active material-coated graphene. This car active material and the cathode electrode contains Sulfur, bon or graphite material can act as a Supplementary conduc Sulfur compound, or lithium polysulfide as a cathode active 40 tive additive that works with graphene to form a robust 3-D material. network of electron-conducting path that remains in contact The present invention also provides a cathode active mate with the cathode active material during the battery charge and rial-coated graphene sheets and a process for producing Such discharge. This carbon or graphite material is selected from a graphene-enhanced cathode active material. The process polymeric carbon, amorphous carbon, chemical vapor depo comprises (a) providing a continuous film of a graphene 45 sition carbon, coal tar pitch, petroleum pitch, meso-phase material into a deposition Zone; (b) introducing vapor or pitch, carbon black, coke, acetylene black, activated carbon, atoms of a precursor cathode active material into the deposi fine expanded graphite particle with a dimension Smaller than tion Zone, allowing the vapor or atoms to deposit onto a 100 nm, artificial graphite particle, natural graphite particle, surface of the graphene material film to form a coated film of or a combination thereof. The polymeric carbon or amor a cathode active material-coated graphene; and (c) mechani 50 phous carbon may be obtained from pyrolyzation of a poly cally breaking this coated film into multiple pieces of cathode mer selected from the group consisting of phenol-formalde active material-coated graphene sheets; wherein the graphene hyde, polyacrylonitrile, Styrene-based polymers, cellulosic material is in an amount of from 0.1% to 99.5% by weight and polymers, epoxy resins, and combinations thereof. the cathode active material is in an amount of at least 0.5% by The process may further comprise a step of separating or weight, all based on the total weight of the graphene material 55 removing the Supporting graphene sheet from the cathode and the cathode active material combined. active materials and a step of collecting the separated cathode Steps (a) and (b) can be conducted in a roll-to-roll manner active material. This is a Surprisingly simple and cost-effec that includes feeding a continuous film of a graphene material tive way of mass-producing free-standing, nanometer-thin from a feeder roller into a deposition Zone and collecting the cathode active materials (e.g. as thin as 2-20 nm with a length/ coated film onto a winding roller. 60 width from 30 nm to several microns). No prior art method The graphene material may be selected from pristine offers such a versatile capability. graphene, graphene oxide, reduced graphene oxide, graphene Alternatively, the process can further comprise a step of fluoride, graphene bromide, graphene iodide, boron-doped mixing multiple pieces of cathode active material-coated graphene, nitrogen-doped graphene, chemically functional graphene sheets, additional un-coated graphene sheet(s), and ized graphene, or a combination thereof, and the graphene 65 a conductive filler to form a secondary particle. Such a sec material is preferably of single-layer or few-layer sheets (less ondary particle may be composed of Small active material than 10 graphene planes). coated graphene sheets (e.g. <3 um in length) and conductive US 9,203,084 B2 7 8 additive (such as carbon black) which are embraced by lithium secondary battery can be cylindrical, square, button graphene sheets to form a more or less spherical particle. like, etc. The present invention is not limited to any battery Further alternatively, the process can further comprise a shape or configuration. step of mixing multiple pieces of cathode active material For convenience, we will use lithium iron phosphate coated graphene material sheets and a resin binder and/or a (LFP), vanadium oxide (V.O.), sulfur (S), and copper phtha conductive filler to form a cathode layer on a cathode current locyanine (CuPe) as illustrative examples of the cathode collector. active material. This should not be construed as limiting the Scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS As illustrated in FIGS. 5(A) and5(B), a lithium-ion battery 10 cell is typically composed of an anode current collector (e.g. FIG. 1 Schematic of a process for producing cathode active Cu foil), an anode electrode (anode active material layer), a material-coated graphene sheets. porous separator and/or an electrolyte component, a cathode FIG. 2 SEM image of a graphene-enhanced cathode par electrode (cathode active material layer), and a cathode cur ticulate (secondary particle) according to a preferred embodi rent collector (e.g. Al foil). In a more commonly used cell 15 configuration (FIG. 5(B)), the anode layer is composed of ment of the present invention particles of an anode active material (e.g. graphite or Si), a FIG. 3 SEM image of a graphene-enhanced anode particu conductive additive (e.g. carbon black particles), and a resin late (secondary particle) for comparison purpose. binder (e.g. SBR or PVDF). The cathode layer is composed of FIG. 4 The cathode active material coating volume fraction particles of a cathode active material (e.g. LFP particles), a of coated graphene sheets plotted as a function of the active conductive additive (e.g. carbon black particles), and a resin material coating thickness for various graphene platelet binder (e.g. PVDF). Both the anode and the cathode layers are thickness values. typically 100-300 um thick to give rise to a sufficient amount FIG. 5 (A) schematic of a prior art lithium-ion battery cell of current per unit electrode area. This thickness range is an composed of an anode current collector, an anode electrode industry-accepted constraint under which a battery designer (e.g. thin Si coating layer), a porous separator, a cathode 25 must work. This constraint is due to several reasons: (a) the electrode (e.g. Sulfur layer), and a cathode current collector, existing battery electrode coating machines are not equipped (B) the electrode layer is composed of discrete particles of an to coat excessively thin or excessively thick electrode layers: active material (e.g. graphite or tin oxide particles in the (b) a thinner layer is preferred based on the consideration of anode layer or LiCoO in the cathode layer). reduced lithium ion diffusion path lengths; but, too thin a FIG. 6 (A) a prior art cathode containing a thin film S 30 layer (e.g. <100 um) does not contain a Sufficient amount of coated on a sheet of Alfoil current collector; (B) schematic of an active lithium storage material (hence, insufficient current an example of a S-coated graphene sheet of the present inven output); and (c) all non-active material layers in a battery cell tion. (e.g. current collectors and separator) must be kept to a mini FIG. 7 Cycling behaviors of three lithium batteries having mum in order to obtain a minimum overhead weight and a a graphene-Supported V2O5 coating, a graphene/V2O5 nano 35 maximum lithium storage capability and, hence, a maximized particle mixture (co-precipitated V2O5 with GO), and a car energy density (Wk/kg or Wh/L of cell). bon nano fiber (CNF)-supported VOs coating, respectively, In a less commonly used cell configuration, as illustrated in as a cathode active material. FIG. 5(A), either the anode active material (e.g. Si) or the FIG. 8 Cycling behaviors of a lithium-ion battery having a cathode active material (e.g. S) is deposited in a thin film form graphene-Supported LFP coating cathode of the present 40 directly onto a current collector. Such as a sheet of copper foil invention, those of a battery containing a LFP-graphene sheet or Al foil. However, such a thin film structure with an mixture cathode, and those of a battery containing a carbon extremely small thickness-direction dimension (typically coated LFP composite-based cathode. much smaller than 500 nm, often necessarily thinner than 100 FIG.9 Ragone plots of three Li S cells having a S-coated um) implies that only a small amount of active material can be graphene based cathode with a Scoating thickness of 20 nm, 45 incorporated in an electrode (given the same electrode or 65 nm, and 125 nm, respectively. current collector Surface area), providing a low total lithium FIG. 10 Cycling behaviors of a lithium metal battery hav storage capacity and low lithium storage capacity per unit ing a graphene-supported CuPeorganic coating (25 nm) cath electrode surface area. Such a thin film must have a thickness ode of the present invention, those of a battery containing a less than 100 nm to be more resistant to cycling-induced graphene-Supported CuPe coating (120 nm) based cathode, 50 cracking (for the anode) or to facilitate a full utilization of the and those of a battery containing a CuPe-carbon black com cathode active material. Such a constraint further diminishes posite-based cathode. the total lithium storage capacity and the lithium storage capacity per unit electrode surface area. Such a thin-film DETAILED DESCRIPTION OF PREFERRED battery has very limited scope of application. (On the other EMBODIMENTS 55 hand, a Silayer thicker than 100 nm has been found to exhibit poor cracking resistance during battery charge/discharge This invention is directed at graphene-enabled cathode cycles. It takes but a few cycles to get fragmented). A Sulfur active materials, a process for producing such a cathode layer thicker than 100 nm does not allow lithium ions to fully active material, a cathode (positive electrode) containing Such penetrate and reach full body of the Slayer, resulting in a poor a cathode active material, and a lithium battery containing 60 sulfur utilization rate. A desirable electrode thickness is at such a cathode. This lithium battery can be a primary battery, least 100 um, with individual active material coating or par but is preferably a secondary battery selected from a lithium ticle having a dimension desirably less than 100 nm. These ion battery, a lithium metal secondary battery (e.g. using thin-film electrodes (with a thickness <100 nm) directly lithium metal as an anode active material), or a lithium-sulfur deposited on a current collector fall short of the required battery. The battery is based on a non-aqueous electrolyte, a 65 thickness by three (3) orders of magnitude. As a further prob polymer gel electrolyte, an ionic liquid electrolyte, a quasi lem, all of the cathode active materials are not conductive to solid electrolyte, or a solid-state electrolyte. The shape of a both electrons and lithium ions. A large layer thickness US 9,203,084 B2 10 implies an excessively high internal resistance and a poor battery cell leading to a high rate capability. These features active material utilization rate. have not been possible with any prior art cathode active In other words, there are several conflicting factors that materials and electrodes. must be considered concurrently when it comes to the design FIG. 4 shows the volume fraction of the S coating in and selection of a cathode oranode active material interms of 5 S-coated graphene sheets plotted as a function of the S coat material type, shape, size, porosity, and electrode layer thick ing thickness for various graphene platelet thickness values. ness. Thus far, there has been no effective solution offered by This chart indicates that, with a single-layer graphene sheet any prior art teaching to these often conflicting problems. We (<0.5 nm thick), a Scoating thickness as thin as 1 nm implies have solved these challenging issues that have troubled bat a S volume fraction >66%. One can imagine that such an 10 ultra-thin S coating would enable extremely easy transport of tery designers and electrochemists alike for more than 30 both the electrons and lithium ions with ultra-low resistance, years by developing the cathode active material-coated enabling ultra-fast battery charge and discharge. A Sulfur graphene sheets as herein disclosed. coating thickness of 20 nm would meana S Volume or weight An embodiment of the present invention is a graphene fraction >96%, leaving behind very low percentage of non enhanced cathode active material, which is a cathode active 15 active material. With a multi-layer graphene platelet as a material-coated graphene sheet. In such a coated sheet, the Supporting Substrate (e.g. 5 nm), a Scoating thickness of 8 nm graphene material is in an amount from 0.1% to 99.5% by is sufficient to achieve an active material percentage >60%. weight and the cathode active material is in an amount of at One might argue that one could easily achieve a Sulfurloading least 0.5% by weight (typically and preferably >60%, more higher than 70%, 80%, or even 90% by simply mixing sulfur typically and preferably >80%, and most typically and pref with a carbon material less than 30%, 20%, or 10%. However, erably >90%), all based on the total weight of the graphene in Such a mixture, a significant proportion of the Sulfur is material and the cathode active material combined. These present in large Zones or domains significantly larger than 100 pieces of coated sheets have a typical length/width from 100 nm in size. As such, a high percentage of sulfur would not be nm to 10 um, more typically 500 nm to 5 um (but most readily accessible to lithium ions and the sulfur utilization preferably <3 um). Typically, at least 60% of the surface area 25 rate is low. In a conventional Li-S cell, a carbon loading as of a primary Surface of the Supporting graphene sheet is high as 50% is very common. Even with such a high percent covered by a thin layer of the desired active material (e.g. S or age of inactive material, the Sulfur utilization rate remains MoS). This surface coverage is preferably >80%, more pref very low. This is why one often observes a sulfur cathode erably >90%, and most preferably >99%. The thickness of the specific capacity of <600 mAh/g even though the theoretical 30 capacity of sulfur is 1,675 mAh/g. (With 50% carbon and cathode active material coating layer is preferably from 2 nm 50% sulfur, the composite sulfur is expected to give rise to a to 100 nm, and more preferably from 5 nm to 20 nm. There are cathode specific capacity of 1,675x0.5–837.5 mAh/g, based significant and non-trivial reasons for specifying these pre on the composite weight, provided that 100% of the sulfur is ferred dimensions, further explained below: fully utilized. But, the actual capacity is normally signifi As illustrated in FIG. 6(A), a prior art cathode is a thin film 35 cantly lower than this. An actual capacity of 600 mAh/g sulfur or lithium polysulfide coated on a sheet of Al foil would mean a Sulfur utilization rate of 600/837.5=71.6%. current collector. The thinnest available Al foil is 10-20 um This low sulfur utilization rate has been a most serious prob thick and the maximum S coating film thickness is 100 nm, lem associated with Li S batteries). beyond which the Slayer would not allow for a high sulfur We have further observed that the presently invented cath utilization rate. This problem is not just limited to S; rather, it 40 ode active material-coated graphene sheets can be combined, is observed for all active materials in a thin film form. With with or without additional neat graphene sheets and/or other Such a configuration (e.g. 10 um thick Al foil and 100 nm conductive additive, into secondary particles, typically 1-20 thick S film), the volume fraction of S (the active material um in diameter. With the length/width of the supporting responsible for storing or discharging lithium) is only 100/ graphene sheets being in the range of 300 nm to 5 um, the 100+10,000=1/101<1%. With an Al physical density of 2.7 45 secondary particle typically has a diameter less than 10 um. g/cm and S density of 2.0 g/cm, this implies a S weight With a Supporting graphene sheet length <3 um, the resulting fraction less than 1%. In other words, more than 99% by secondary particle has a typical diameter <5 um, which is weight or by Volume of this configuration is aluminum, which ideal for use as a cathode active material in terms of electrode is not a cathode active material incapable of reversibly storing production ease, electrode tap density, rate capability, and lithium ions in a battery cell. This is an extremely undesirable 50 cycling stability of resulting lithium batteries. These obser and non-efficient battery design. Vations mean that the presently invented cathode active mate By contrast, referring to FIG. 6(B) as an illustrative rial-coated graphene sheets are ideal cathode structures. example, the Sulfur coating layer is 20 nm thick and the In an embodiment of the present invention, the process for Supporting graphene sheet is 1 nm thick, implying a cathode producing Such a cathode-coated sheet comprises (a) provid active material percentage of 20/21=95% by volume. With a 55 ing a continuous film of a graphene material into a deposition graphene physical density of 2.2 g/cm and S density of 2.0 Zone; (b) introducing vapor or atoms of a precursor cathode g/cm, this implies a sulfur weight fraction of approximately active material into the deposition Zone, allowing the vapor or 94.7%, having a very minimal non-active material. The Sup atoms to deposit onto a Surface of the graphene material film porting graphene sheet plays the role of a conducting filler, to form a coated film of a cathode active material-coated and every piece of sulfur is guaranteed to be in direct physical 60 graphene material; and (c) mechanically breaking this film contact with an underlying, highly conducting graphene into multiple pieces of cathode active material-coated sheet. Graphene has an electrical conductivity higher than the graphene sheets. This process may further include a step (d) conductivity of carbon black by at least 3 orders of magni of combining multiple pieces of cathode active material tude. During battery operations, both electrons and lithium coated graphene sheets, along with an optional binder and/or ions only have to travel to a maximum path length of 20 nm, 65 an optional carbon/graphite material, to form multiple sec resulting in very low internal resistance, and Such a short ondary particles that are then combined to form a cathode transport path also enables fast charge and recharge of a electrode. Step (d) may entail combining multiple pieces of US 9,203,084 B2 11 12 cathode active material-coated graphene sheets, along with nm). This Supporting film preferably has a thickness between an optional binder and/or an optional carbon/graphite mate 0.4 nm and 20 nm, more preferably between 0.4 nm and 5 nm. rial, to directly form a cathode electrode without going A nanographene platelet (NGP) or graphene sheet is com through the intermediate step of forming secondary particles. posed of one basal plane (graphene plane) or multiple basal In step (a), the continuous sheet of a graphene material (the planes stacked together in the thickness direction. In a continuous film) may be produced by chemical vapor depo graphene plane, carbonatoms occupy a 2-D hexagonal lattice sition (CVD) of graphene onto a solid substrate. However, the in which carbon atoms are bonded together through strong CVD is an expensive process. Alternatively and preferably, as in-plane covalent bonds. In the c-axis or thickness direction, illustrated in FIG. 1, this continuous film may be produced by these graphene planes may be weakly bonded together preparing a Suspension of graphene material sheets (e.g. 10 through van der Waals forces. An NGP can have a platelet graphene oxide sheets) in a liquid medium (e.g. water) and thickness from less than 0.34 nm (single-layer graphene) to spraying the Suspension onto a Solid Substrate surface to form 100 nm (multi-layer). For the present electrode use, the pre a graphene film. Preferably, an ultrasonic spraying or electro ferred thickness is <10 nm and most preferably <3 nm or 10 static spraying device is used to propel and deposit graphene layers). The presently invented anode active material-coated material sheets onto the substrate surface so that multiple 15 sheets and the resulting graphene-enhanced secondary par graphene material sheets are overlapped to form a cohered ticle or particulate preferably contains mostly single-layer film or sheet, from approximately 0.5 nm to several micron graphene, but could make use of some few-layer graphene thick (preferably from 1 nm to 20 nm). (less than 10 layers). The graphene sheet may contain a small This graphene film, with or without the Supporting Sub amount (typically <25% by weight) of non-carbon elements, strate, is then introduced into a deposition Zone (e.g. a vacuum Such as hydrogen, boron, fluorine (or other halogen), nitro chamber or a CVD chamber) wherein streams of vapor or gen, and oxygen, which are attached to an edge or Surface of atoms of a cathode active material are deposited onto one the graphene plane. Graphene was recently discovered to Surface of the graphene film to form a coated film (e.g. exhibit the highest thermal conductivity of all existing mate S-coated graphene film). This deposition may be accom rials. In addition to the electrical conductivity, this high ther plished through physical vapor deposition (PVD), Sputtering, 25 mal conductivity is clearly an advantageous property that laser-assisted deposition, chemical vapor deposition, includ could not be achieved by any other type of conductive addi ing plasma-enhanced CVD and hot-wire CVD. atomic layer tives. Graphene also exhibits the highest intrinsic strength deposition, and deposition from solution. The thickness of the among all materials ever reported. anode active material coating is preferably less than 500 nm Graphene sheets may be oxidized to various extents during thick, more preferably less than 100 nm, further preferably 30 their preparation, resulting in graphite oxide (GO) or less than 50 nm, and most preferably less than 20 nm. graphene oxide. Hence, in the present context, graphene pref Again referring to FIG. 1, the cathode material-coated erably or primarily refers to those graphene sheets containing graphene film is then Subjected to mechanical breakage to no or low oxygen content; but, they can include GO of various produce pieces of cathode active material-coated graphene oxygen contents. Further, graphene may be fluorinated to a sheets with a lateral dimension preferably in the range of 0.3 35 controlled extent to obtain graphene fluoride. um to 10 uM, but further preferably from 0.5um to 3 um. The NGPs may be obtained from exfoliation and platelet These size ranges are particularly Suitable for combining separation of a natural graphite, synthetic graphite, highly these primary particles (cathode active material-coated oriented pyrolytic graphite, graphite fiber, carbon fiber, car graphene sheets) into secondary particles or particulates with bon nano-fiber, graphitic nano-fiber, spherical graphite or a diameter in the range of 1 um to 10um, preferably less than 40 graphite globule, meso-phase micro-bead, meso-phase pitch, 5um. These secondary particles with proper sizes are ame graphitic coke, or graphitized polymeric carbon. nable to the fabrication of cathode material layers on a cath In a preferred version of the process, the continuous film of ode current collector using conventional slurry coating pro a graphene material may be produced by (a) spraying a cesses. The slurries containing these secondary particles are graphene Suspension onto a solid Substrate, wherein the found to have very desirable viscosity and other flow charac 45 graphene Suspension contains discrete sheets or platelets of a teristics. They flow very well on the surface of a cathode graphene material dispersed in a liquid medium, and (b) current collector (e.g. Al foil). The resulting electrode thick removing the liquid medium. Alternatively, the continuous ness can be from 50 um to 500 um or thicker, but most sheet of a graphene material may be produced by chemical preferably from 100 um to 250 um. vapor deposition of agraphene material onto a solid Substrate. As illustrated in the top portion of FIG. 1, the use of a 50 The sheet of a cathode active material-coated graphene graphene film prepared by deposition from a graphene Sus film preferably has a cathode active material coating thick pension is preferred overa CVD graphene film because of the ness less than 500 nm, more preferably less than 100 nm, need to break the film, after being coated with a cathode active further preferably less than 50 nm, most preferably less than material, into Small pieces of coated graphene sheets. The 20 nm. The coated sheet may be produced through chemical continuous graphene film made from overlapped graphene 55 vapor deposition, physical vapor deposition, Sputtering, or sheets can be readily broken along the original graphene sheet laser-assisted thin-film deposition of an anode active material boundaries. The resulting coated graphene sheets are compa onto a sheet of a graphene material. rable in sizes to the original graphene material sheets. The In the process, step (c) of mechanical breaking can be Suspension-derived graphene film is much weaker than the conducted using air jet milling, impact milling, grinding. CVD graphene film. However, we have turned this weakness 60 mechanical shearing, ultrasonication, or a combination into an advantageous feature for the production of coated thereof. graphene sheets of desired sizes. FIG. 2 shows an example of graphene-enhanced particu The present invention provides a nanographene-enhanced lates comprising graphene sheets in and around the particu particulate (secondary particle) for use as a lithium-ion bat late. Graphene sheets embrace and protect the primary par tery electrode material. The Supporting graphene film is pref 65 ticles (S-coated graphene sheets) to form secondary particles erably made from single-layer graphene or few-layer (particulates) that are easier to handle in a real anode produc graphene (up to 10 graphene planes, or approximately <4-5 tion environment. The embracing graphene sheets also pre US 9,203,084 B2 13 14 vent Sulfur from getting dissolved in electrolyte (a major cycloaliphatic carboxylic acid, straight chain or branched cause for rapid capacity decay in a Li-S cell). The notion chain carboxylic acid, saturated and unsaturated monocar that the exterior surface is embraced with highly conductive boxylic acids, dicarboxylic acids and polycarboxylic acids graphene sheets implies that these sheets can naturally form a that have 1-10 carbon atoms, alkyl esters thereof, and com 3-D network of electron-conducting paths when multiple par binations thereof. Preferably, the carboxylic acid is selected ticulates are packed together in an anode. FIG. 3 shows a from the group consisting of Saturated aliphatic carboxylic corresponding particulate from Si-coated graphene sheets for acids of the formula H(CH),COOH, wherein n is a number use in an anode of a lithium-ion battery. of from 0 to 5, including formic, acetic, propionic, butyric, These more or less spherical secondary particles can be pentanoic, and hexanoic acids, any drides thereof, reactive easily handled and made into electrodes using existing bat 10 carboxylic acid derivatives thereof, and combinations tery electrode coating machines. These particulates were thereof. The most preferred carboxylic acids are formic acid found to lead to electrodes that have a higher tap density and acetic acid. (weight per volume of the electrode), which is a very impor In step (e), optionally, particles of a carbon or graphite tant parameter for an electrode. material may be added along with the cathode active material As a preferred embodiment, the process of producing 15 coated graphene sheets. graphene-enhanced particulates from active material-coated The step of drying the multi-component Suspension to graphene sheets comprises (i) preparing a precursor mixture form the precursor mixture may be conducted using a spray of graphene or graphene precursor with a cathode active drying, spray-pyrolysis, fluidized-bed drying procedure, or material-coated graphene sheets; and (ii) thermally and/or any step that involves atomizing or aerosolizing the Suspen chemically converting the precursor mixture to the graphene Sion. The step of converting may comprise a sintering, heat enhanced anode particulate. Described in more detail, the treatment, spray-pyrolysis, or fluidized bed drying or heating process entails: procedure. The step of converting may comprise a procedure (a) dispersing or immersing a laminar graphite material (e.g., of chemically or thermally reducing the graphene precursor graphite powder) in a mixture of an intercalant and an to reduce or eliminate oxygen or fluorine content and other oxidant (e.g., concentrated Sulfuric acid and nitric acid, 25 non-carbon elements of the graphene precursor, which respectively) to obtain a graphite intercalation compound graphene precursor may contain graphene oxide or graphene (GIC) or graphite oxide (GO); fluoride. Upon conversion, the graphene in the particulate has (b) exposing the resulting GIC or GO to a thermal shock, an oxygen content typically less than 5% by weight. preferably in a temperature range of 600-1,100° C. for a As another preferred embodiment, the process may begin short period of time (typically 15 to 60 seconds), to obtain 30 with the production of a precursor Solution or Suspension of exfoliated graphite or graphite worms; and pristine graphene (non-oxidized graphene) directly from (c) dispersing exfoliated graphite in a liquid (e.g. water) and graphite particles, which is followed by the addition of a mechanically separating individual nano graphene plate cathode active material-coated graphene sheets to this solu lets or sheets from graphite worms using, for instance, a tion or Suspension to obtain a precursor mixture. The produc high-shear mixer or an ultrasonicator to obtain a graphene 35 tion of a precursor Solution or Suspension may include the or graphene precursor Suspension; or, alternatively, following steps: (d) re-dispersing the exfoliated graphite to a liquid medium (a) Preparing a suspension containing pristine nano containing an acid (e.g., Sulfuric acid), an oxidizing agent graphene platelets (NGPs) dispersed in a liquid medium (e.g. nitric acid), or an organic solvent (e.g., NMP) at a using, for instance, direct ultrasonication (e.g., a process desired temperature for a duration of time until the exfoli 40 disclosed by us in U.S. patent application Ser. No. ated graphite is converted into graphene oxide or graphene 1 1/800,728 (May 8, 2007)); dissolved in the liquid medium. The acid is preferably a (b) Optionally removing some of the liquid from the sus weak acid (such as diluted Sulfuric acid) or a more envi pension; ronmentally benign acid, such as formic acid, acetic acid, (c) Adding a desired amount of cathode active material citric acid, carboxylic acid, and combinations thereof. The 45 coated graphene sheets to obtain a precursor mixture exfoliated graphite, when dispersed in these acids, was Suspension or Solution; gradually dispersed and essentially dissolved to form a (d) Removing the liquid from the Suspension to obtain a graphene or graphene oxide solution or Suspension. precursor mixture solid; and Although not a required operation, stirring, mechanical (e) Thermally and/or chemically converting the precursor shearing, or ultrasonication can be used to accelerate the 50 mixture solid to the graphene-enhanced cathode particu dispersion and dissolution step; late. (e) dispersing cathode active material-coated graphene sheets For the preparation of a cathode, multiple graphene-en to the graphene or graphene precursor Solution or Suspen hanced particulates are mixed with a binder Solution (e.g., sion prepared in step (c) or step (d) to obtain a precursor PVDF in NMP) to obtain a slurry or paste. A desired amount mixture Suspension; and 55 of the slurry or paste is then coated onto a current collector, (f) thermally and/or chemically converting the precursor mix allowing the liquid to evaporate and leaving behind an elec ture to the graphene-enhanced anode particulate. trode bonded to a surface of a current electrode. For An optional, but desirable intermediate step between (e) examples, particulates containing S-coated graphene sheets and (f) involves drying the Suspension to form the precursor and graphite particles embraced by separate graphene sheets mixture in a solid state. If the precursor mixture contains a 60 may be added to a solution containing a solvent (NMP). The precursor to graphene (e.g. graphene oxide), then the precur resulting paste may be coated onto an aluminum foil as a Sor may be subjected to a chemical or thermal reduction current collector to form a coating layer of 50-500 Lum thick treatment. A heat treatment at a temperature of preferably (preferably 100-250 um). By allowing the solvent to vaporize 500-1,000°C. for 1-2 hours would serve to eliminate a major one obtains a positive electrode (cathode) for a lithium bat ity of the oxygen content from the graphene sheets. 65 tery. The carboxylic acid used in step (d) may be selected from In the aforementioned examples, the starting material for the group consisting of aromatic carboxylic acid, aliphatic or the preparation of NGPs is a graphitic material that may be US 9,203,084 B2 15 16 selected from the group consisting of natural graphite, artifi between 5% and 20% by weight. The oxygen content can be cial graphite, graphite oxide, graphite fluoride, graphite fiber, determined using chemical elemental analysis and/or X-ray carbon fiber, carbon nano-fiber, carbon nano-tube, photoelectron spectroscopy (XPS). mesophase carbon micro-bead (MCMB) or carbonaceous Multiple graphene sheets Suspended in a liquid (e.g. water) micro-sphere (CMS), soft carbon, hard carbon, and combi may be spray-deposited to form a continuous film of nations thereof. graphene materials, which is deposited with a coating of a Graphite oxide may be prepared by dispersing or immers cathode active material. The coated film is then broken into ing a laminar graphite material (e.g., powder of natural flake pieces of active material-coated graphene sheets. These graphite or synthetic graphite) in an oxidizing agent, typically coated graphene sheets are re-dispersed into a liquid to form a mixture of an intercalant (e.g., concentrated Sulfuric acid) 10 a Suspension. and an oxidant (e.g., nitric acid, hydrogen peroxide, sodium perchlorate, potassium permanganate) at a desired tempera The resulting Suspension can be converted into micron ture (typically 0-70° C.) for a sufficient length of time (typi scaled droplets (particulates) using several approaches. For cally 30 minutes to 5 days). In order to reduce the time instance, the Suspension may be aerosolized or atomized to required to produce a precursor Solution or Suspension, one 15 form fine aerosol particles. Concurrently or Subsequently, the may choose to oxidize the graphite to some extent for a liquid or solvent is removed to form solid particles that are shorter period of time (e.g., 30 minutes) to obtain graphite typically spherical or ellipsoidal in shape with a diameter or intercalation compound (GIC). The GIC particles are then major axis typically less than 10. This procedure may be exposed to athermal shock, preferably in a temperature range executed by using an aerosol generation, atomization, spray of 600-1,100° C. for typically 15 to 60 seconds to obtain drying, or inkjet printing apparatus. As an optional but pre exfoliated graphite or graphite worms, which are optionally ferred procedure, the solid particles are simultaneously or (but preferably) Subjected to mechanical shearing (e.g. using Subsequently Subjected to a pyrolysis or carbonization treat a mechanical shearing machine or an ultrasonicator) to break ment to convert the organic or polymeric material, if existing, up the graphite flakes that constitute a graphite worm. The into a carbon material. The heat treatment of petroleum or un-broken graphite worms or individual graphite flakes are 25 coal-based heavy oil or pitch will serve to convert at least part then re-dispersed in water, acid, or organic solvent and ultra of the oil or pitch into a meso-phase, an optically anisotropic Sonicated to obtain a graphene polymer Solution or Suspen or liquid crystalline phase of a fused aromatic ring structure. S1O. The converted pitch is called a meso-phase pitch. Since NGPs The pristine graphene material is preferably produced by are essentially pure graphite-based or graphene materials, one of the following three processes: (A) Intercalating the 30 this low temperature heat treatment (350-1200° C.) has no graphitic material with a non-oxidizing agent, followed by a adverse effect on the NGP structure. Essentially, one can use thermal or chemical exfoliation treatment in a non-oxidizing a spray pyrolysis technique, such as ultrasonic spray pyroly environment; (B) Subjecting the graphitic material to a Super sis or electro-spray pyrolysis, to accomplish both the aerosol critical fluid environment for inter-graphene layer penetration generation and pyrolysis procedures and exfoliation; or (C) Dispersing the graphitic material in a 35 Another embodiment of the present invention is a lithium powderform to an aqueous Solution containing a surfactant or battery cathode comprising multiple nano graphene-en dispersing agent to obtain a Suspension and Subjecting the hanced cathode particulates as described above. A further Suspension to direct ultrasonication. embodiment is a lithium battery comprising Such a cathode, In Procedure (A), a particularly preferred step comprises an anode, a separator disposed between the anode and the (i) intercalating the graphitic material with a non-oxidizing 40 cathode, and electrolyte in physical contact with both the agent, selected from an alkali metal (e.g., potassium, Sodium, anode and the cathode. lithium, or cesium), alkaline earth metal, oran alloy, mixture, There is no particular restriction on the type and nature of or eutectic of an alkali or alkaline metal; and (ii) a chemical the cathode active material, which can be selected for prac exfoliation treatment (e.g., by immersing potassium-interca ticing the present invention. The cathode active material may lated graphite in ethanol solution). 45 be preferably selected from a metal oxide/phosphate/sulfide, In Procedure (B), a preferred step comprises immersing the an inorganic material, an organic or polymeric material, or a graphitic material to a Supercritical fluid. Such as carbon combination thereof: dioxide (e.g., at temperature T-31° C. and pressure P-7.4 a) The group of metal oxide, metal phosphate, and metal MPa) and water (e.g., at T>374° C. and Pd22.1 MPa), for a sulfides consisting of lithium cobalt oxide, lithium nickel period of time Sufficient for inter-graphene layer penetration 50 oxide, lithium manganese oxide, lithium Vanadium oxide, (tentative intercalation). This step is then followed by a Sud lithium transition metal oxide, lithium-mixed metal oxide, den de-pressurization to exfoliate individual graphene layers. lithium iron phosphate, lithium manganese phosphate, Other suitable supercritical fluids include methane, ethane, lithium Vanadium phosphate, lithium mixed metal phos ethylene, hydrogen peroxide, oZone, water oxidation (water phates, transition metal Sulfides, and combinations thereof. containing a high concentration of dissolved oxygen), or a 55 a. In particular, the lithium Vanadium oxide may be mixture thereof. selected from the group consisting of VO, LiVO, In Procedure (C), a preferred step comprises (a) dispersing V2Os, LiV2Os. VOs, LiVOs, LiVO7. VO9. particles of a graphitic material in a liquid medium containing LiVO, VO, LiVO, their doped versions, their therein a surfactant or dispersing agent to obtain a suspension derivatives, and combinations thereof, wherein or slurry; and (b) exposing the Suspension or slurry to ultra 60 0.1oxides provide a high cell volt trichalcogenide, (c) sulfide, selenide, or telluride of nio age. Lithium iron phosphate is also preferred due to its safety bium, Zirconium, molybdenum, hafnium, tantalum, tung feature and low cost. sten, titanium, cobalt, manganese, iron, nickel, or a transi For the preparation of a cathode, the binder may be chosen tion metal; (d) boron nitride, or (e) sulfur, sulfur from polytetrafluoroethylene (PTFE), polyvinylidene fluo compound, lithium polysulfide (f) a combination thereof. ride (PVDF), ethylene-propylene-diene copolymer (EPDM), In particular, TiS, TaS, MoS NbSe non-lithiated or styrene-butadiene rubber (SBR), for example. Conductive MnO, CoO, iron oxide, Vanadium oxide, or a combina materials such as electronically conductive polymers, meso tion thereof may be used as a cathode active material in a 10 phase pitch, coal tar pitch, and petroleum pitch may also be lithium metal cell. used. Preferable mixing ratio of these ingredients may be 90 c) An organic material or polymeric material selected from to 98% by weight for the particulates, and 2 to 10% by weight Poly(anthraquinonyl sulfide) (PAQS), a lithium oxocar for the binder. The current collector may be selected from bon, 3.4.9,10-perylenetetracarboxylic dianhydride aluminum foil, stainless steel foil, and nickel foil. There is no (PTCDA), poly(anthraquinonyl sulfide), pyrene-4.5,9,10 15 particularly significant restriction on the type of current col tetraone (PYT), polymer-bound PYT, Quino(triazene), lector, provided the material is a good electrical conductor redox-active organic material, Tetracyanoquinodimethane and relatively corrosion resistant. The separator may be (TCNQ), tetracyanoethylene (TCNE), 2,3,6,7,10,11-hex selected from a synthetic resin nonwoven fabric, porous poly amethoxytriphenylene (HMTP), poly(5-amino-1,4-dyhy ethylene film, porous polypropylene film, or porous PTFE droxy anthraquinone) (PADAQ), phosphazene disulfide film. polymer ((NPS),n), lithiated 1.4.5.8-naphthalenetetraol A wide range of electrolytes can be used for practicing the formaldehyde polymer, Hexaazatrinaphtylene (HATN), instant invention. Most preferred are non-aqueous and poly Hexaazatriphenylene hexacarbonitrile (HAT(CN)), mergel electrolytes although other types can be used. The 5-Benzylidene hydantoin, Isatine lithium salt, Pyromellitic non-aqueous electrolyte to be employed herein may be pro diimide lithium salt, tetrahydroxy-p-benzoquinone deriva 25 duced by dissolving an electrolytic salt in a non-aqueous tives (THQLi.), N,N'-diphenyl-2,3,5,6-tetraketopipera Solvent. Any known non-aqueous solvent which has been zine (PHP), N,N'-diallyl-2,3,5,6-tetraketopiperazine (AP), employed as a solvent for a lithium secondary battery can be N,N'-dipropyl-2,3,5,6-tetraketopiperazine (PRP), a thioet employed. A non-aqueous solvent mainly consisting of a her polymer, a quinone compound, 1,4-benzoquinone, 5.7. mixed solvent comprising ethylene carbonate (EC) and at 12, 14-pentacenetetrone (PT), 5-amino-2,3-dihydro-1,4- 30 least one kind of non-aqueous solvent whose melting point is dyhydroxy anthraquinone (ADDAQ), 5-amino-1,4- lower than that of aforementioned ethylene carbonate and dyhydroxy anthraquinone (ADAQ), calixquinone, whose donor number is 18 or less (hereinafter referred to as a LiCO, Li2CO. LiCO, or a combination thereof. second solvent) may be preferably employed. This non-aque The thioether polymer is selected from Polymethane ous solvent is advantageous in that it is (a) stable against a tetryl-tetra(thiomethylene) (PMTTM), Poly(2,4- 35 negative electrode containing a carbonaceous material well dithiopentanylene) (PDTP), a polymer containing Poly developed in graphite structure; (b) effective in Suppressing (ethene-1,1,2,2-tetrathiol) (PETT) as a main-chain the reductive or oxidative decomposition of electrolyte; and thioether polymers, a side-chain thioether polymer hav (c) high in conductivity. A non-aqueous electrolyte solely ing a main-chain consisting of conjugating aromatic composed of ethylene carbonate (EC) is advantageous in that moieties, and having a thioether side chain as a pendant, 40 it is relatively stable against decomposition through a reduc Poly(2-phenyl-1,3-dithiolane) (PPDT), Poly(1,4-di(1, tion by a graphitized carbonaceous material. However, the 3-dithiolan-2-yl)benzene) (PDDTB), poly(tetrahy melting point of EC is relatively high, 39 to 40°C., and the drobenzodithiophene) (PTHBDT), poly 1,2,4,5-tet viscosity thereof is relatively high, so that the conductivity rakis(propylthio)benzene (PTKPTB, or poly(3,4 thereof is low, thus making EC alone unsuited for use as a (ethylenedithio)thiophene (PEDTT). 45 secondary battery electrolyte to be operated at room tempera The organic material may include a phthalocyanine com ture or lower. The second solvent to be used in a mixture with pound selected from copper phthalocyanine, Zinc phtha EC functions to make the viscosity of the solvent mixture locyanine, tin phthalocyanine, iron phthalocyanine, lead lower than that of EC alone, thereby promoting the ion con phthalocyanine, nickel phthalocyanine, Vanadyl phtha ductivity of the mixed solvent. Furthermore, when the second locyanine, fluorochromium phthalocyanine, magne 50 solvent having a donor number of 18 or less (the donor num sium phthalocyanine, manganous phthalocyanine, dil ber of ethylene carbonate is 16.4) is employed, the aforemen ithium phthalocyanine, aluminum phthalocyanine tioned ethylene carbonate can be easily and selectively sol chloride, cadmium phthalocyanine, chlorogallium vated with lithium ion, so that the reduction reaction of the phthalocyanine, cobalt phthalocyanine, silver phthalo second solvent with the carbonaceous material well devel cyanine, a metal-free phthalocyanine, a chemical deriva 55 oped in graphitization is assumed to be Suppressed. Further, tive thereof, or a combination thereof. when the donor number of the second solvent is controlled to Most preferably, the cathode active material is selected not more than 18, the oxidative decomposition potential to the from the group consisting of lithium cobalt oxide, lithium lithium electrode can be easily increased to 4V or more, so nickel oxide, lithium manganese oxide, lithium Vanadium that it is possible to manufacture a lithium secondary battery oxide, lithium-mixed metal oxide, lithium iron phosphate, 60 of high Voltage. lithium manganese phosphate, lithium Vanadium phosphate, Preferable second solvents are dimethyl carbonate (DMC), lithium mixed metal phosphates, metal sulfides, and combi methylethyl carbonate (MEC), diethyl carbonate (DEC), nations thereof. ethyl propionate, methyl propionate, propylene carbonate The positive electrode active material may also be selected (PC), gamma.-butyrolactone (gamma.-BL), acetonitrile from chalcogen compounds, Such as titanium disulfate or 65 (AN), ethyl acetate (EA), propyl formate (PF), methyl for molybdenum disulfate. More preferred are lithium cobalt mate (MF), toluene, xylene and methyl acetate (MA). These oxide (e.g., Li CoO where 0.8sXs 1), lithium nickel oxide second solvents may be employed singly or in a combination US 9,203,084 B2 19 20 of two or more. More desirably, this second solvent should be NGPs were between 1 and 10 layers. The graphene-water selected from those having a donor number of 16.5 or less. Suspension was used for Subsequent preparation of a precur The viscosity of this second solvent should preferably be 28 Sor mixture containing primary particles of either an anode cps or less at 25°C. active material or a cathode active material. The mixing ratio of the aforementioned ethylene carbonate in the mixed solvent should preferably be 10 to 80% by EXAMPLE 2 volume. If the mixing ratio of the ethylene carbonate falls outside this range, the conductivity of the solvent may be Oxidation and Exfoliation of Natural Graphite lowered or the solvent tends to be more easily decomposed, thereby deteriorating the charge/discharge efficiency. More 10 Graphite oxide was prepared by oxidation of graphite preferable mixing ratio of the ethylene carbonate is 20 to 75% flakes with Sulfuric acid, Sodium nitrate, and potassium per by volume. When the mixing ratio of ethylene carbonate in a manganate at a ratio of 4:1:0.05 at 30° C. for 48 hours, non-aqueous solvent is increased to 20% by Volume or more, according to the method of Hummers U.S. Pat. No. 2,798, the solvating effect of ethylene carbonate to lithium ions will 878, Jul. 9, 1957. Upon completion of the reaction, the be facilitated and the solvent decomposition-inhibiting effect 15 mixture was poured into deionized water and filtered. The thereof can be improved. sample was then washed with 5% HCl solution to remove Examples of preferred mixed solvent are a composition most of the sulfate ions and residual salt and then repeatedly comprising EC and MEC; comprising EC, PC and MEC: rinsed with deionized water until the pH of the filtrate was comprising EC, MEC and DEC; comprising EC, MEC and approximately 7. The intent was to remove all sulfuric and DMC; and comprising EC, MEC, PC and DEC; with the nitric acid residue out of graphite interstices. The slurry was volume ratio of MEC being controlled within the range of 30 dried and stored in a vacuum oven at 60° C. for 24 hours. to 80%. By selecting the volume ratio of MEC from the range The dried, intercalated (oxidized) compound was exfoli of 30 to 80%, more preferably 40 to 70%, the conductivity of ated by placing the sample in a quartz tube that was inserted the solvent can be improved. With the purpose of suppressing into a horizontal tube furnace pre-set at 1,050° C. to obtain the decomposition reaction of the solvent, an electrolyte hav 25 highly exfoliated graphite. The exfoliated graphite was dis ing carbon dioxide dissolved therein may be employed, persed in water along with a 1% surfactant at 45° C. in a thereby effectively improving both the capacity and cycle life flat-bottomed flask and the resulting graphene oxide (GO) of the battery. The electrolytic salts to be incorporated into a Suspension was subjected to ultrasonication for a period of 15 non-aqueous electrolyte may be selected from a lithium salt minutes. Portions of the resulting GO-water suspension were such as lithium perchlorate (LiCIO), lithium hexafluoro 30 then spin-coated onto a polyimide film to form thin films of phosphate (LiPF), lithium borofluoride (LiBF), lithium GO sheets with various different film thicknesses, from hexafluoroarsenide (LiAsF), lithium trifluoro-metasul approximately 1 nm to 30 nm. fonate (LiCFSO) and bis-trifluoromethyl sulfonylimide lithium LiN(CFSO). Among them, LiPF LiBF and EXAMPLE 3 LiN(CFSO) are preferred. The content of aforementioned 35 electrolytic salts in the non-aqueous solvent is preferably 0.5 Preparation of Cathode Active Material-Coated to 2.0 mol/l. Graphene Sheets and Secondary Particles The following examples serve to illustrate the best mode practice of the present invention and should not be construed Continuous graphene films coated with a cathode active as limiting the scope of the invention, which is defined in the 40 material were prepared from Sputtering (e.g. lithium metal claims. oxide), physical vapor deposition (e.g. S), and Solution depo sition. The coated film was broken, cut into pieces, and then EXAMPLE1 air jet milled to obtain Small pieces of active material-coated graphene sheets. Graphene Oxide from Sulfuric Acid Intercalation 45 For the preparation of graphene-enhanced particulates, an and Exfoliation of MCMBS amount of a selected electrode active material powder (con trol sample, no supporting graphene sheet) or active material MCMB 2528 meso-carbon microbeads were supplied by coated graphene sheets was added to a desired amount of GO Alumina Trading, which was the U.S. distributor for the Sup Suspension to form a precursor mixture Suspension with a plier, Osaka Gas Chemical Company of Japan. This material 50 solid content of approximately 10% by weight. After thor has a density of about 2.24 g/cm with a median particle size ough mixing in an ultrasonication reactor, the Suspension was of about 22.5. MCMB 2528 (10 grams) were intercalated then spray-dried to form the graphene-enhanced secondary with an acid solution (sulfuric acid, nitric acid, and potassium particles (particulates). The cathode active materials studied permanganate at a ratio of 4:1:0.05) for 48 hours. Upon in this example include lithium cobalt oxide, lithium manga completion of the reaction, the mixture was poured into 55 nese oxide, lithium iron phosphate, Vanadium oxide, and deionized water and filtered. The intercalated MCMBs were sulfur. repeatedly washed in a 5% solution of HCl to remove most of the Sulphate ions. The sample was then washed repeatedly EXAMPLE 4 with deionized water until the pH of the filtrate was neutral. The slurry was dried and stored in a vacuum oven at 60°C. for 60 Lithium Iron Phosphate-Coated Graphene Sheets 24 hours. The dried powder sample was placed in a quartz and Cathode Electrodes tube and inserted into a horizontal tube furnace pre-set at a desired temperature, 800° C. for 30 seconds to obtain Sample A LFP target for Sputtering was prepared by compacting 1. A Small quantity of each sample was mixed with water and and sintering LFT powders together. Sputtering of LFP was ultrasonicated at 60-W power for 10 minutes to obtain a 65 conducted on a graphene film and, separately, carbon nano Suspension. A small amount was sampled out, dried, and fiber (CNF) mat. The LFP-coated graphene film was then investigated with TEM, which indicated that most of the broken and pulverized to form LFP-coated graphene sheets. US 9,203,084 B2 21 22 As a control sample, the LFP particle-bonded graphene sheets pared from spin coating of RGO-water Suspension. The were also produced by following the procedure proposed by resulting coated film was cut and milled to produce CuPc Ding, et al. Electrochemistry Communications, 12 (2010) coated graphene sheets. Two CuPe coating thicknesses were pages 10-13. produced in two separate samples. Experimental data show that NGPs, when incorporated to form graphene-enhanced particulates of the present inven The specific capacity of this CuPe-coated graphene sheet tion, provide exceptional electrical conductivity characteris electrode was measured by using a coin cell configuration tics to the electrodes in terms of a much lower percolation with Li metal as the anode active material and 1 M LiClO in threshold and higher electrical conductivity at a given weight propylene carbonate (PC) solution as the electrolyte. A base % of additive as compared to the corresponding CNT-en line sample of CuPe with 30% by weight of AB (acetylene hanced or carbon black-enhanced electrodes. 10 derived carbon black) as the conductive additive was also Representative electrochemical testing results are Summa prepared in a similar manner. The charge/discharge behaviors rized in FIG. 8, which show the cycling behaviors of a of this cell were also monitored. FIG. 10 shows the cycling lithium-ion battery having a LFP-coated graphene sheet cath behaviors of a lithium metal battery having a graphene-Sup ode of the present invention, those of a battery containing a ported CuPe organic coating (25 nm) cathode of the present graphene-bonded LFP nano particle cathode, and those of a 15 invention, those of a battery containing a graphene-supported battery containing a carbon-coated LFP composite-based CuPC coating (120 nm) based cathode, and those of a battery cathode. After 140 charge/discharge cycles, the battery con containing a CuPe-carbon black composite-based cathode. taining a carbon-coated LFP composite-based cathode has There are several significant observations that can be made lost 26.3% of the original capacity and the battery containing from these data. First, given the same volume fraction of a simple mixture of LFP and graphene sheets for the cathode CuPC, the CuPe-AB composite based cell is capable of deliv lost 16.8% of the capacity. In contrast, the battery having a ering an initial specific capacity of only 345 mAh/g, but the LFP-coated graphene cathode of the present invention has graphene-Supported CuPe coating (120 nm) based cell has an exhibited a 4% capacity loss. This is a highly significant initial specific capacity of 532 mAh/g, based on measure improvement over the prior art. ments conducted at 1 C rate (1 C rate completing charge or EXAMPLE 5 25 discharge in 1 hour, 2C rate completing in /2 hours, and in C rate completing in 1/n hours, etc). This implies that the use of Graphene-Enabled VOs carbon black as a conductive filler does not enable a high cathode active material utilization rate. The thinner CuPc Powder of V2O5 particles was compacted to form a disc coating (25 nm) enables a much higher active material utili shape target for use in a sputtering chamber. A graphene film 30 Zation rate. Second, the data have also clearly demonstrated prepared from spin-casting of graphene-water Suspension that the CuPc-AB composite cathode has a fast capacity was dried and placed under the sputtering target for a con decay rate with the specific capacity dropping to an unaccept trolled duration of time to obtain a VOs-coated film. The coated film was then cut into Small pieces (approximately 1 ably low value in less than 100 cycles. In contrast, the cathode cm) and then subjected to ball-milling for further size reduc active material-coated graphene based batteries (coating tion to obtain VO-graphene sheets. 35 thickness of 25 nm and 120 nm) exhibit minimal capacity For the preparation of a control sample, in a typical experi decay (2-5%) even after 200 cycles. ment, Vanadium pentoxide gels were obtained by mixing V2O5 in a LiClaqueous solution. The Li'-exchanged gels EXAMPLE 7 obtained by interaction with LiCl solution (the Li:V molar ratio was kept as 1:1) was mixed with a GO Suspension and 40 Li S Cells Containing S-Coated Graphene Sheets then placed in a Teflon-lined stainless steel 35 ml autoclave, sealed, and heated up to 180° C. for 12 h. After such a S-coated graphene sheets can be easily made by sealing a hydrothermal treatment, the green solids were collected, thor Sufficient amount of Sulfur powder and a graphene film (pre oughly washed, ultrasonicated for 2 minutes, and dried at 70° pared from ultrasonic spraying) in a vacuum chamber (high C. for 12 h followed by mixing with another 0.1% GO in 45 degree of vacuum is not required). Sulfur can be readily water, ultrasonicating to breakdown nano-belt sizes, and then sublimed into vapor by heating the sulfur powder from spray-drying at 200° C. to obtain graphene-embraced com approximately 145° C. to 210° C. Various S coating thick posite particulates. nesses from a few nanometers to a few um can be obtained FIG. 7 shows the cycling behaviors of three lithium batter simply by varying the physical vapor deposition times. ies having a VO-coated graphene sheet cathode, a 50 S-coated graphene sheets are then produced through film graphene/VO nano particle mixture cathode (co-precipi cutting and milling. tated VOs with GO), and a carbon nano fiber (CNF)-sup As a typical procedure for preparing electrochemical test ported VOs coating cathode, respectively. After 105 cycles, ing cells, the working electrodes were prepared by mixing 85 the battery cell having a carbon nano fiber (CNF)-supported VOs coating cathode has suffered a capacity decay of 44% wt % active material (e.g., S-coated graphene sheets), 7 wt % and the battery having a graphene/V2O5 nano particle com 55 acetylene black (Super-P), and 8 wt % polyvinylidene fluo posite cathode suffered a capacity decay of 21.5%. In con ride (PVDF, 5 wt % solid content) binder dissolved in N-me trast, the battery having a VO-coated graphene sheet cath thyl-2-pyrrolidinoe (NMP). After coating the slurries on Al ode has lost less than 4% of its original capacity after 105 foil, the electrodes were dried at 120° C. in vacuum for 2 h to cycles, representing a major improvement. remove the solvent before pressing. Then, the electrodes were 60 cut into a disk (diameter=12 mm) and dried at 100° C. for 24 EXAMPLE 6 hin vacuum. Electrochemical measurements were carried out using CR2032 (3V) coin-type cells with lithium metal as the Metal Naphthalocyanine-Reduced Graphene Oxide anode electrode, Celgard 2400 membrane as separator, and 1 (RGO) Hybrid Cathode M LiPF electrolyte solution dissolved in a mixture of ethyl 65 ene carbonate (EC) and diethyl carbonate (DEC) (EC-DEC, CuPe-coated graphene sheets were obtained by vaporizing 1:1 V/v). The cell assemblies were made in an argon-filled CuPe in a chamber along with a graphene film (5 nm) pre glove-box. The CV measurements were carried out using an US 9,203,084 B2 23 24 Arbin electrochemical workstation at a scanning rate of 1 all existing materials. High strength imparts good struc mV/s. In addition, the electrochemical performances of vari tural integrity to the resulting electrode. ous cells were also evaluated by galvanostatic charge/dis (4) A high thermal conductivity implies a high heat dissipa charge cycling at a current density of 50 mA/g. For long-term tion rate. This is an important feature since the charge and cycling tests, multi-channel battery testers manufactured by 5 discharge operations of a battery produce a great amount of LAND were used. heat. Without a fast heat dissipation rate, the battery cannot Some representative data are presented in FIG. 9, which be charged or discharged at a high rate. shows the Ragone plots (cell power density vs. energy den (5) The most commonly used conductive additives are carbon sity) of three Li-S cells having a S-coated graphene based black (CB) or acetylene black (AB), which are not very 10 electrically conductive. Graphene sheets have an electrical cathode with a Scoating thickness of 20 nm, 65 nm, and 125 conductivity (up to 20,000 S/cm) that is several orders of nm, respectively. Clearly, thinnest coating provides the high magnitude higher than that of CB or AB (typically 0.01-10 est energy density among the three cells. The highest achiev S/cm). able cell energy density of the cell containing the thinnest S (6) Graphene sheets in the interior and the exterior surface of coating Supported on graphene sheets is as high as 802 15 a particulate provide not only a robust 3-D network of Wh/kg, which is 4 times better than the energy density (150 electron-conducting paths and high conductivity, but also 200 Wh/kg) of the best lithium-ion battery cells currently enable the electrode materials to be readily made into elec available on the market. trodes with a high tap density and long-term cycling sta These data have clearly demonstrated the superior advan bility. tages of the presently invented cathode active material-coated (7) The embracing graphene sheets effectively isolate the graphene sheets. The presently invented Li S battery fea anode active materials (e.g., Si and SnO particles) from turing a S-coated graphene sheet cathode can be charged/ the electrolyte, which otherwise could react with these discharged for 1,000 cycles without suffering a 20% capacity active materials, thereby reducing the reversible capacity. decay. The high energy density implies that a current electric (8) Quite Surprisingly, spray-drying readily produces vehicle with a rating of 300 miles on one battery charge (e.g. 25 graphene-enhanced particulates of a spherical shape that is Tesla Model-S all battery EV) can be improved to a rating of conducive to the formation of interconnected pores in an 1,200 miles on one charge, given the same battery weight. actual electrode to enable easy penetration of electrolyte. This would reduce the need to build so many charging stations The embraced primary particles (coated sheets) having a and would also reduce drivers “range anxiety', the two fac small thickness (typically smaller than 100 nm) provide a tors that have thus far prevented all EVs from been widely 30 short lithium diffusion path for lithium to enter and leave. accepted by consumers. With 1,200 miles per cycle and a life This is particularly desirable for power tool and electric expectancy of approximately 1,000 cycles, the presently vehicle applications where the battery must be capable of invented Li S battery would enable an EV to run for 1,200, being charged and discharged at a high rate. 000 miles before needing a battery replacement. This inven In Summary, the presently invented graphene-enhanced tion represents a very significant accomplishment that can 35 particulates Surprisingly impart the following highly desir have a dramatic impact on the emergence of a vibrant EV able attributes to a lithium battery electrode: high reversible industry. capacity, low irreversible capacity, high tap density, electrode In conclusion, we have successfully developed a new and fabrication ease (shape of secondary particles typically being novel class of high-capacity cathode active materials (cath spherical or near spherical), Small primary particle sizes (for ode active material-coated graphene sheets) and the relating 40 high-rate capacity), compatibility with commonly used elec cathode electrode for lithium batteries. Such a graphene trolytes (embracing graphene sheets help to isolate active enhanced particulate platform technology has the following material particles from electrolyte), and long charge-dis highly desirable features and advantages: charge cycle life. (1) The cathode active material-coated graphene sheets have a very high loading (percentage) of the active material, 45 The invention claimed is: typically from 60% to 99% (more typically from 90 to 1. A cathode electrode of a lithium battery, wherein said 95%) by weight of the cathode active material. The cathode cathode electrode comprises a cathode active material-coated active material coating typically covers 60%-100% of one graphene sheet, wherein said graphene sheet has two opposed of the primary Surface of a graphene sheet. The length/ parallel surfaces and at least 50% area of one of said two width of these coated graphene sheets, typically in the 50 Surfaces is coated with a cathode active material and wherein range of 0.5-10 um, are amenable to the fabrication of said graphene material is in an amount of from 0.1% to 99.5% porous secondary particles having a diameter of 1-10 um, by weight and said cathode active material is in an amount of the most ideal particle sizes for electrode fabrication ease, at least 0.5% by weight, all based on the total weight of said lithium ion transport, and long-term cycling stability. graphene material and said cathode active material combined. (2) The cathode active material coating can be very thin (1 55 2. The cathode electrode of claim 1, wherein at least 80% nm -100 nm), enabling fast electron and lithium ion trans area of one of said Surfaces is coated with a cathode active port, yet still providing a high active material content and material. being conducive to the formation of electrodes with a 3. The cathode electrode of claim 1, wherein said coated desired thickness (100-250 um). Further, each and every graphene sheet contains at least 60% by weight or by volume thin active material coating (e.g. non-conducting S) has a 60 of said cathode active material based on the total weight of conductive backing (graphene Substrate). These combined said coated graphene sheet. features have never been possible with any prior art cath 4. The cathode electrode of claim 1, wherein said coated ode active material. graphene sheet contains at least 90% by weight or by volume (3) Graphene sheets are of high strength, high electrical con of said cathode active material based on the total weight of ductivity, and high thermal conductivity. Single layer 65 said coated graphene sheet. graphene was recently found to exhibit the highest intrinsic 5. The cathode electrode of claim 1, wherein said cathode strength and highest intrinsic thermal conductivity among active material is selected from an inorganic material, an US 9,203,084 B2 25 26 organic or polymeric material, a metal oxide/phosphate/sul conjugating aromatic moieties, and having a thioether side fide, or a combination thereof. chain as a pendant, Poly(2-phenyl-1,3-dithiolane) (PPDT), 6. The cathode electrode of claim 5, wherein said cathode Poly(1,4-di(1,3-dithiolan-2-yl)benzene) (PDDTB), poly(tet active material contains a metal oxide/phosphate/sulfide rahydrobenzodithiophene) (PTHBDT), poly 1,2,4,5-tetrakis selected from a lithium cobalt oxide, lithium nickel oxide, (propylthio)benzene (PTKPTB, or poly(3,4(ethylenedithio) lithium manganese oxide, lithium Vanadium oxide, lithium thiophene (PEDTT). mixed metal oxide, lithium iron phosphate, lithium manga 14. The cathode electrode of claim 5, wherein said organic nese phosphate, lithium Vanadium phosphate, lithium mixed material contains a phthalocyanine compound selected from metal phosphate, transition metal Sulfide, or a combination copper phthalocyanine, Zinc phthalocyanine, tin phthalocya thereof. 10 nine, iron phthalocyanine, lead phthalocyanine, nickel phtha 7. The cathode electrode of claim 5, wherein said inorganic material is selected from sulfur, sulfur compound, lithium locyanine, Vanadyl phthalocyanine, fluorochromium phtha polysulfide, transition metal dichalcogenide, a transition locyanine, magnesium phthalocyanine, manganous metal trichalcogenide, or a combination thereof. phthalocyanine, dilithium phthalocyanine, aluminum phtha 8. The cathode electrode of claim 5, wherein said inorganic 15 locyanine chloride, cadmium phthalocyanine, chlorogallium material is selected from TiS, TaS, MoS NbSes, MnO, phthalocyanine, cobalt phthalocyanine, silver phthalocya CoO, an iron oxide, a vanadium oxide, or a combination nine, a metal-free phthalocyanine, a chemical derivative thereof. thereof, or a combination thereof. 9. The cathode electrode of claim 5, wherein said metal 15. The cathode electrode of claim 1, wherein said oxide/phosphate/sulfide contains a vanadium oxide selected graphene material is selected from pristine graphene, from the group consisting of VO, LiVO, VOs, LiVOs, graphene oxide, reduced graphene oxide, graphene fluoride, VOs, LiVOs, LiVO7. VOo, LiNO9.V.O., LiVO. graphene bromide, graphene iodide, boron-doped graphene, their doped versions, their derivatives, and combinations nitrogen-doped graphene, chemically functionalized thereof, wherein 0.1