A Critical Evaluation of the Effect of Electrode Thickness and Side Reactions on Electrolytes for Aluminum–Sulfur Batteries

The high abundance and low cost of aluminum and sulfur make the Al–S battery an attractive combination. However, significant improvements in performance are required, and increasing the thickness and sulfur content of the sulfur electrodes is critical for the development of batteries with competitive specific energies. This work concerns the development of sulfur electrodes with the highest sulfur content (60 wt %) reported to date for an Al–S battery system and a systematic study of the effect of the sulfur electrode thickness on battery performance. If low‐cost electrolytes made from acetamide or urea are used, slow mass transport of the electrolyte species is identified as the main cause of the poor sulfur utilization when the electrode thickness is decreased, whereas complete sulfur utilization is achieved with a less viscous ionic liquid. In addition, the analysis of very thin electrodes reveals the occurrence of degradation reactions in the low‐cost electrolytes. The new analysis method is ideal for evaluating the stability and mass transport limitations of novel electrolytes for Al–S batteries.