Enhanced performance of Lithium–Sulfur cells via novel nano-sized iron-plated sulfur composites

Abstract

Lithium–sulfur cells are promising energy-storage systems because of their high energy density and the desirable electrochemical utilization rates of cost-effective sulfur cathodes. However, the commercialization of high-performance lithium–sulfur cells, which are characterized by a high discharge capacity and cyclic stability, necessitates simultaneous optimization of both the cell-fabrication parameters and cell-performance values. Here, we introduce a novel iron-plated sulfur composite featuring nano-sized conductive iron plating applied to micro-sized insulating sulfur particles through an innovative electroless-iron plating method. The iron-plated sulfur composite facilitates the realization of a lean-electrolyte lithium–sulfur cell at a low electrolyte-to-sulfur ratio of 5 μL mg−1, enabling high-loading sulfur cathodes (sulfur loadings of 10–14 mg cm−2) to attain a reversible discharge capacity (945–1033 mAh g−1) and a cycle life of 400 cycles. These well-controlled cell-fabrication parameters, coupled with the high cell performance, result in improved performance metrics, such as high areal capacity (10–13 mAh cm−2), improved energy density (22–28 mWh cm−2), and a low electrolyte-to-capacity ratio (4.8 μL mAh−1). These advancements are attributable to the incorporation of plated nano-sized iron, which endows the cathode with rapid electron/ion transfer, robust polysulfide retention, and heightened electrocatalysis capabilities for conversion-type battery chemistry.