High-performance sulfur-aerogel composite cathodes via lamination for advanced lithium-sulfur-bateries

Abstract

Lithium–sulfur (Li–S) batteries offer high energy density (~2600 Wh kg⁻¹) using low-cost sulfur cathodes and lithium metal anodes. Key challenges include sulfur’s insulating nature and polysulfide shuttling. Carbon aerogels, with high surface area, pore volume and electrical conductivity, effectively confine sulfur and polysulfides, enhancing cycling stability. Here, sulfur–aerogel cathodes were laminated at 190 °C onto flexible CNT current collectors. The strong confinement of sulfur within the aerogel matrix enabled thermal processing without sulfur loss, allowing high-temperature lamination that improves electrode integrity and adhesion. Calendering optimized porosity and thickness. Pouch cell tests with ether-based electrolytes (1M LiTFSI, in DME/DOL) showed >900 mAh g⁻¹ at C/10 and stable performance over 60 cycles.