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Reactivating the Current Collector: A Catalytic Strategy for Carbon-Free Sulfur-Based Cathodes.

Xi Chen1,2, Dongxu Yu1,2, Dashuai Wang1,2

  • 1College of Chemical and Biological Engineering, Zhejiang University, Hangzhou, 310027, China.

Advanced Materials (Deerfield Beach, Fla.)
|November 4, 2025
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Summary

A novel carbon-free sulfur cathode utilizes a copper foil current collector, catalyzed by iron sulfide, to achieve high energy density and stability in rechargeable batteries.

Keywords:
carbon‐free sulfur‐based cathodescopper foil reactivationin situ solid‐phase synthesismackinawite catalysissodium‐sulfur batteries

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Area of Science:

  • Electrochemistry
  • Materials Science
  • Energy Storage

Background:

  • Sulfur cathodes in rechargeable batteries face challenges from slow redox kinetics and polysulfide dissolution, limiting energy efficiency and cycle life.
  • Current methods using carbon-sulfur composites incorporate inactive additives, reducing overall energy density.

Purpose of the Study:

  • To develop a high-energy, carbon-free sulfur cathode with enhanced electrochemical performance and stability.
  • To investigate a novel catalytic approach for in situ formation of active cathode materials.

Main Methods:

  • A spontaneous solid-state reaction between elemental sulfur and copper foil, catalyzed by layered mackinawite iron sulfide.
  • In situ formation of conductive covellite copper sulfide with pseudocapacitive properties.
  • Operando spectroscopy and first-principles calculations to analyze reaction mechanisms.

Main Results:

  • Electrodes achieved 95 wt.% active material content.
  • Demonstrated a specific capacity of 1588 mAh g-1 at 10 A g-1.
  • Exhibited 100% capacity retention over 1000 cycles at 5 A g-1.

Conclusions:

  • The catalytic solid-state reaction enables the formation of high-performance, carbon-free sulfur cathodes.
  • Reconfiguring the current collector as an active component provides a scalable framework for advanced battery design.
  • This approach overcomes limitations of conventional sulfur cathodes, paving the way for higher energy density batteries.