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Updated: May 15, 2025

Non-aqueous Electrode Processing and Construction of Lithium-ion Coin Cells
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Solvent-Free Dry-Process Enabling High-Areal Loading Selenium-Doped SPAN Cathodes Toward Practical Lithium-Sulfur

Dong Jun Kim1, Tae Hwa Hong1, Jung Seok Lee1

  • 1Department of Convergent Biotechnology and Adavanced Materials Science, Kyung Hee University, 1732, Deogyeong-daero, Giheung-gu, Yongin-si, Gyeonggi-do, 17104, Republic of Korea.

Small (Weinheim an Der Bergstrasse, Germany)
|April 7, 2025
PubMed
Summary

A novel dry-processed selenium-doped sulfurized polyacrylonitrile (Se-SPAN) cathode, enhanced with multi-walled carbon nanotubes (MWCNT), demonstrates superior performance and stability under high-loading conditions for cost-effective batteries.

Keywords:
MWCNTSPAN cathodedry‐processhigh‐areal loadinglithium‐sulfur batteries

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Area of Science:

  • Materials Science
  • Electrochemistry
  • Energy Storage

Background:

  • Current dry-processed cathodes face challenges with structural integrity and performance under high-loading conditions.
  • Selenium-sulfur cathodes are promising for high-energy-density batteries but suffer from volume expansion issues.

Purpose of the Study:

  • To develop a robust dry-processed selenium-doped sulfurized polyacrylonitrile (Se-SPAN) cathode using multi-walled carbon nanotubes (MWCNT) and polytetrafluoroethylene (PTFE).
  • To investigate the electrochemical-mechanical properties of the dry-processed Se-SPAN (D/Se-SPAN) and compare it with slurry-processed counterparts.
  • To provide design guidelines for high-loading, cost-effective, and eco-friendly sulfur-based dry cathodes.

Main Methods:

  • Fabrication of D/Se-SPAN cathodes via a dry process incorporating MWCNT and PTFE binder.
  • Characterization of the D/Se-SPAN structure for density, robustness, and uniformity.
  • Electrochemical-mechanical investigations to assess performance under ultra-high-loading conditions.
  • Comparative analysis against traditional slurry-processed Se-SPAN (S/Se-SPAN) cathodes.

Main Results:

  • The D/Se-SPAN exhibits a dense, robust, and uniform structure that mitigates internal stress evolution.
  • Achieved reversible areal capacities of approximately 31.8 mAh cm⁻² under ultra-high-loading conditions (64.2 mgSe-SPAN cm⁻²).
  • Demonstrated remarkable cycle stability, outperforming traditional slurry-processed cathodes.

Conclusions:

  • The dry-processing method significantly enhances the structural integrity and electrochemical performance of Se-SPAN cathodes.
  • D/Se-SPAN offers a viable pathway for high-loading, stable, and durable sulfur-based battery cathodes.
  • The study provides critical insights for developing next-generation, cost-effective, and sustainable energy storage solutions.