Optimization of the Form Factors of Advanced Li-S Pouch Cells

Lithium-sulfur (Li-S) batteries hold immense promise as next-generation energy storage due to their high theoretical energy density (2600 Wh kg⁻¹), low cost, and non-toxic nature. However, practical implementation faces challenges, primarily from Li polysulfide (LiPS) shuttling within the cathode and Li dendrite growth at the anode. Optimized electrodes/electrolytes design effectively confines LiPS to the cathode, boosting cycling performance in coin cells to up to hundreds of cycles. Scaling up to larger pouch cells presents new obstacles, requiring further research for long-term stability. A 1.45 Ah pouch cell, with optimized sulfur loading and electrolyte/sulfur ratio is developed, which delivers an energy density of 151 Wh kg-1 with 70% capacity retention up to 100 cycles. Targeting higher energy density (180 Wh kg-1 ), the developed 1Ah pouch cell exhibits 68% capacity retention after 50 cycles. Morphological analysis reveals that pouch cell failure is primarily from Li metal powdering and resulting polarization, rather than LiPS shuttling. This occurs for continuous Li ion stripping/plating during cycling, leading to dendrite growth and formation of non-reactive Li powder, especially under high currents. These issues increase ion diffusion resistance and reduce coulombic efficiency over time. Therefore, the study highlights the importance of a protected Li metal anode for achieving high-energy-dense batteries.

High Entropy Sulfide Nanoparticles as Lithium Polysulfide Redox Catalysts

The polysulfide shuttle contributes to capacity loss in lithium-sulfur batteries, which limits their practical utilization. Materials that catalyze the complex redox reactions responsible for the polysulfide shuttle are emerging, but foundational knowledge that enables catalyst development remains limited with only a small number of catalysts identified. Here, we employ a rigorous electrochemical approach to show quantitatively that the lithium polysulfide redox reaction is catalyzed by nanoparticles of a high entropy sulfide material, Zn0.30Co0.31Cu0.19In0.13Ga0.06S. When 2% by weight of the high entropy sulfide is added to the lithium sulfur cathode composite, the capacity and Coulombic efficiency of the resulting battery are improved at both moderate (0.2 C) and high (1 C) charge/discharge rates. Surface analysis of the high entropy sulfide nanoparticles using X-ray photoelectron spectroscopy provides important insights into how the material evolves during the cycling process. The Zn0.30Co0.31Cu0.19In0.13Ga0.06S nanoparticle catalyst outperformed the constituent metal sulfides, pointing to the role that the high-entropy "cocktail effect" can play in the development of advanced electrocatalytic materials for improved lithium sulfur battery performance.

Insights into the Pseudocapacitive Behavior of Sulfurized Polymer Electrodes for Li-S Batteries

Practical applications of sulfurized polymer (SP) materials in Li-S batteries (LSBs) are often written off due to their low S content (≈35 wt%). Unlike conventional S₈ /C composite cathodes, SP materials are shown to function as pseudocapacitors with an active carbon backbone using a comprehensive array of tools including in situ Raman and electrochemical impedance spectroscopy. Critical metric analysis of LSBs containing SP materials with an active carbon skeleton shows that SP cathodes with 35 wt% S are suitable for 350 Wh kg^-1 target at the cell level if S loading >5 mg cm^-2 , electrolyte-to-sulfur ratio <2 µL mg^-1 , and negative-to-positive ratio <5 can be achieved. Although 3D current collectors can enable such high loadings, they often add excess mass decreasing the total capacity. An "active" carbon nanotube bucky sandwich current collector developed here offsets its excess weight by contributing to the electric double layer capacity. SP cathodes (35 wt% S) with ≈5.5 mg cm^-2 of S loading (≈15.8 mg cm^-2 of SP loading) yield a sulfur-level gravimetric capacity ≈1360 mAh g_s ^-1 (≈690 mAh g_s ^-1 ), electrode level capacity 200 mAh g_electrode ^-1 (100 mAh g_electrode ^-1 ), and areal capacity ≈7.8 mAh cm^-2 (≈4.0 mAh cm^-2 ) at 0.1C (1C) rate for ≈100 cycles at E/S ratio = 7 µL mg^-1 .

Synergetic Effects of Multifunctional Composites with More Efficient Polysulfide Immobilization and Ultrahigh Sulfur Content in Lithium-Sulfur Batteries

A high sulfur loading cathode is the most crucial component for lithium-sulfur batteries (LSBs) to obtain considerable energy density for commercialization applications. The major challenges associated with high sulfur loading electrodes are poor material utilization caused via the nonconductivity of the charged product (S) and the discharged product (Li₂S), poor stability arisen from dissolution of lithium polysulfides (LiPSs) into most organic electrolytes and pulverization, and structural damage of the electrode caused by large volumetric expansion. A multifunctional synergistic composite enables ultrahigh sulfur content for advanced LSBs, which comprises the sulfur particle encapsulated with an ion-selective polymer with conductive carbon nanotubes and dispersed around Magnéli phase Ti₄O₇ (MS-3) by the bottom-up method. The ion-selective polymer provides a physical shield and electrostatic repulsion against the shuttling of polysulfides with negative charge, whereas it can permit the transmission of lithium ion (Li⁺) through the polymer membrane, and the carbon nanotubes twined around the sulfur promote electronic conductivity and sulfur utilization as well as strong chemical adsorption of LiPSs by means of Ti₄O₇. Because of this hierarchical construction, the cathode possesses a lofty final sulfur loading of 72% and large sulfur areal mass loading of 3.56 mg cm^-2, which displays the large areal specific capacity of 4.22 mA h cm^-2. In the same time, it can provide excellent cyclic performance with the corresponding capacity attenuation ratio of 0.08% per cycle at 0.5 C after 300 cycles. Especially, while sulfur areal mass loading is sharply enhanced to 5.11 mg cm^-2, the MS-3 composite exhibits a large initial areal capacity of 5.04 mA h cm^-2 and still keeps a high reversible capacity of 696 mA h g^-1 at 300th cycle even at a 1.0 C. The design of high sulfur content cathodes is a viable approach for boosting practical commercialized application of LSBs.

Characterization of Sulfur and Nanostructured Sulfur Battery Cathodes in Electron Microscopy Without Sublimation Artifacts

Lithium sulfur (Li-S) batteries have the potential to provide higher energy storage density at lower cost than conventional lithium ion batteries. A key challenge for Li-S batteries is the loss of sulfur to the electrolyte during cycling. This loss can be mitigated by sequestering the sulfur in nanostructured carbon-sulfur composites. The nanoscale characterization of the sulfur distribution within these complex nanostructured electrodes is normally performed by electron microscopy, but sulfur sublimates and redistributes in the high-vacuum conditions of conventional electron microscopes. The resulting sublimation artifacts render characterization of sulfur in conventional electron microscopes problematic and unreliable. Here, we demonstrate two techniques, cryogenic transmission electron microscopy (cryo-TEM) and scanning electron microscopy in air (airSEM), that enable the reliable characterization of sulfur across multiple length scales by suppressing sulfur sublimation. We use cryo-TEM and airSEM to examine carbon-sulfur composites synthesized for use as Li-S battery cathodes, noting several cases where the commonly employed sulfur melt infusion method is highly inefficient at infiltrating sulfur into porous carbon hosts.

A MnO2/Graphene Oxide/Multi-Walled Carbon Nanotubes-Sulfur Composite with Dual-Efficient Polysulfide Adsorption for Improving Lithium-Sulfur Batteries

Lithium-sulfur batteries can potentially be used as a chemical power source because of their high energy density. However, the sulfur cathode has several shortcomings, including fast capacity attenuation, poor electrochemical activity, and low Coulombic efficiency. Herein, multi-walled carbon nanotubes (CNTs), graphene oxide (GO), and manganese dioxide are introduced to the sulfur cathode. A MnO₂/GO/CNTs-S composite with a unique three-dimensional (3D) architecture was synthesized by a one-pot chemical method and heat treatment approach. In this structure, the innermost CNTs work as a conducting additive and backbone to form a conducting network. The MnO₂/GO nanosheets anchored on the sidewalls of CNTs have a dual-efficient absorption capability for polysulfide intermediates as well as afford adequate space for sulfur loading. The outmost nanosized sulfur particles are well-distributed on the surface of the MnO₂/GO nanosheets and provide a short transmission path for Li⁺ and the electrons. The sulfur content in the MnO₂/GO/CNTs-S composite is as high as 80 wt %, and the as-designed MnO₂/GO/CNTs-S cathode displays excellent comprehensive performance. The initial specific capacities are up to 1500, 1300, 1150, 1048, and 960 mAh g^-1 at discharging rates of 0.05, 0.1, 0.2, 0.5, and 1 C, respectively. Moreover, the composite cathode shows a good cycle performance: the specific capacity remains at 963.5 mAh g^-1 at 0.2 C after 100 cycles when the area density of sulfur is 2.8 mg cm^-2.

Ultrafine Iron Pyrite (FeS₂) Nanocrystals Improve Sodium-Sulfur and Lithium-Sulfur Conversion Reactions for Efficient Batteries

Nanocrystals with quantum-confined length scales are often considered impractical for metal-ion battery electrodes due to the dominance of solid-electrolyte interphase (SEI) layer effects on the measured storage properties. Here we demonstrate that ultrafine sizes (∼4.5 nm, average) of iron pyrite, or FeS2, nanoparticles are advantageous to sustain reversible conversion reactions in sodium ion and lithium ion batteries. This is attributed to a nanoparticle size comparable to or smaller than the diffusion length of Fe during cation exchange, yielding thermodynamically reversible nanodomains of converted Fe metal and NaxS or LixS conversion products. This is compared to bulk-like electrode materials, where kinetic and thermodynamic limitations of surface-nucleated conversion products inhibit successive conversion cycles. Reversible capacities over 500 and 600 mAh/g for sodium and lithium storage are observed for ultrafine nanoparticles, with improved cycling and rate capability. Unlike alloying or intercalation processes, where SEI effects limit the performance of ultrafine nanoparticles, our work highlights the benefit of quantum dot length-scale nanocrystal electrodes for nanoscale metal sulfide compounds that store energy through chemical conversion reactions.

Systematic Effect for an Ultralong Cycle Lithium-Sulfur Battery

Rechargeable lithium-sulfur (Li-S) batteries are attractive candidates for energy storage devices because they have five times the theoretical energy storage of state-of-the-art Li-ion batteries. The main problems plaguing Li-S batteries are poor cycle life and limited rate capability, caused by the insulating nature of S and the shuttle effect associated with the dissolution of intermediate lithium polysulfides. Here, we report the use of biocell-inspired polydopamine (PD) as a coating agent on both the cathode and separator to address these problems (the "systematic effects"). The PD-modified cathode and separator play key roles in facilitating ion diffusion and keeping the cathode structure stable, leading to uniform lithium deposition and a solid electrolyte interphase. As a result, an ultralong cycle performance of more than 3000 cycles, with a capacity fade of only 0.018% per cycle, was achieved at 2 C. It is believed that the systematic modification of the cathode and separator for Li-S batteries is a new strategy for practical applications.