High-Density, Low-Tortuosity Sulfur Electrodes for High Energy Lithium–Sulfur Batteries

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Lithium–sulfur (Li–S) batteries have attracted significant attention due to their promising theoretical energy and cost-effectiveness.[1] While recently studies have predominantly focused on increasing sulfur mass loading and utilization rate for high specific energy, there remains a noticeable gap in addressing the intrinsic challenge of improving volumetric energy density.[2] This challenge arises as many Li-S investigations rely on highly porous electrodes.[3] Here, we employ a shear-rolling approach to prepare free-standing electrodes characterized by high density (porosity<15%), low tortuosity, and substantial S content (>70%). The incorporation of a vascular-like porous network, facilitated by a pore soft template, plays a pivotal role in achieving high sulfur utilization (>1000 mAh g-1) in high-loading electrodes (>4 mg cm-2) under lean electrolyte condition (E/S 4 mL g-1). This approach results in an extraordinarily high volumetric energy density (668 Wh L-1 of dry cell) when applied to practical Li–S pouch cells. Our study underscores that realizing high volumetric energy in Li–S cell can be achieved by rationalizing the dense electrode architecture. Furthermore, the shear-rolling approach holds broad applicability for fabricating high-energy electrodes using porous or nanoparticle materials with desirable structures. Details of the progress will be discussed at the conference.