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A battery is a galvanic cell that is used as a source of electrical power for specific applications. Modern batteries exist in a multitude of forms to accommodate various applications, from tiny button batteries such as those that power wristwatches to the very large batteries used to supply backup energy to municipal power grids. Some batteries are designed for single-use applications and cannot be recharged (primary cells), while others are based on conveniently reversible cell reactions that...
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Non-aqueous Electrode Processing and Construction of Lithium-ion Coin Cells
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High-Loading Lithium-Sulfur Batteries with Solvent-Free Dry-Electrode Processing.

Hyunki Sul1, Dongsoo Lee1, Arumugam Manthiram1

  • 1Walker Department of Mechanical Engineering, The University of Texas at Austin, Austin, TX, 78712, USA.

Small (Weinheim an Der Bergstrasse, Germany)
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Summary

This study introduces a sustainable, solvent-free method for fabricating high-sulfur-loading lithium-sulfur (Li-S) battery cathodes. The dry-processed electrodes show excellent cycling stability, paving the way for next-generation energy storage.

Keywords:
Li2S cathodedry‐electrode processinghigh sulfur loadinglithium‐sulfur batteriesmulti‐layer pouch cellsolvent‐free

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Area of Science:

  • Materials Science
  • Electrochemistry
  • Energy Storage

Background:

  • Lithium-sulfur (Li-S) batteries offer high theoretical energy density and utilize abundant sulfur, making them promising for next-generation energy storage.
  • Achieving practical energy densities requires increasing the areal capacity of sulfur cathodes through high sulfur loading.

Purpose of the Study:

  • To develop an industrially viable and sustainable method for fabricating ultra-high sulfur loading Li-S battery cathodes.
  • To evaluate the electrochemical performance and mechanical stability of electrodes produced via a solvent-free dry-processing technique.

Main Methods:

  • Fabrication of ultra-high sulfur loading (up to 12 mg cm⁻²) cathodes using a solvent-free dry-processing method with polytetrafluoroethylene binder fibrillation.
  • Comparison of dry-processed electrodes with slurry-processed electrodes in terms of initial capacity and cycling stability.
  • Development and testing of single-layer (9 mg cm⁻²) and multi-layer (14 mg cm⁻²) pouch cells.

Main Results:

  • Dry-processed electrodes exhibited superior cycling stability and maintained mechanical integrity without cracking, unlike slurry-processed counterparts.
  • The low porosity cathode architecture resulted in a lower initial capacity compared to slurry-processed electrodes.
  • Successful fabrication of single-layer and multi-layer pouch cells with high sulfur loadings (9-14 mg cm⁻²).

Conclusions:

  • Solvent-free dry-processing is a viable and sustainable approach for producing stable, high-sulfur-loading Li-S battery cathodes.
  • Strategies like incorporating electrocatalysts or using prelithiated materials can address the reduced initial capacity of dry-processed electrodes.
  • This method holds potential for advancing practical Li-S battery applications.