The Effect of Carbon Type and Solvent/Binder Ratio on the Structure and Performance of Sulfur Cathodes in Lithium-Sulfur Batteries

Lithium-Sulfur (Li-S) batteries are among the popular candidates for next-generation rechargeable energy storage devices due to their high specific capacity and superior energy storage capabilities. However, commercialization of Li-S batteries has been hindered by several challenges such as the insulating nature of sulfur, and the shuttling of soluble lithium polysulfides and accumulation of insulating deposits on the electrodes – leading to capacity degradation over extended cycling 1 . Several research efforts have been devoted to mitigating these challenges. Among the different approaches, many studies focus on addressing the poor conductivity of sulfur and lithium polysulfide shuttling simultaneously by developing conductive carbon hosts 2,3 . While improvements have been achieved in the development of host structures with better electronic conductivity and improved polysulfide trapping capability, many of those structures have advanced architectures that demand complex processing, expensive precursors, and often lower gravimetric sulfur loading (<70 wt%).This leads to expensive-to-produce electrodes that have lower true energy density than desired. What is needed are simple preparation methods that address the issues discussed above without overly complicated processing, and preferably already commercialized materials. In this work, we systematically investigate the effect of different electrode components, including various common carbons and polymeric binders. The effect of carbon type and loading is discussed. The effect of solvent to binder ratio in the electrode slurry preparation is also studied. By tuning the binder composition, types of conductive carbon black, and the amount of solvent, we observed a difference in the structure of the host medium and consequently the sulfur electrode. Specifically, a shell covering surrounding the sulfur particles was observed at low solvent/binder ratio. Increasing the solvent/binder ratio led to the disappearance of the shell coverings and particle agglomeration, which resulted in lower achieved capacity and reduced cycle life. Ketjen black offered the highest specific capacity, while the presence of shell covering achieved at a low solvent/binder ratio was found necessary for cycling stability. This work demonstrates the importance of electrode processing parameters on the structure and electrochemical performance of sulfur cathode in Li-S batteries. The new understandings from this work can provide guidance on electrode designs to achieve Li-S batteries with enhanced capacity and longevity. References G. Li et al., Adv. Mater. , 30 , 1705590 (2018). D.-W. Wang et al., J. Mater. Chem. A , 1 , 9382 (2013). Y. Li and S. Guo, Matter , 4 , 1142–1188 (2021).