Module-Designed Carbon-Coated Separators for High-Loading, High-Sulfur-Utilization Cathodes in Lithium–Sulfur Batteries

Lithium–sulfur batteries have great potential as next-generation energy-storage devices because of their high theoretical charge-storage capacity and the low cost of the sulfur cathode. To accelerate the development of lithium–sulfur technology, it is necessary to address the intrinsic material and extrinsic technological challenges brought about by the insulating active solid-state materials and the soluble active liquid-state materials. Herein, we report a systematic investigation of module-designed carbon-coated separators, where the carbon coating layer on the polypropylene membrane decreases the irreversible loss of dissolved polysulfides and increases the reaction kinetics of the high-loading sulfur cathode. Eight different conductive carbon coatings were considered to investigate how the materials’ characteristics contribute to the lithium–sulfur cell’s cathode performance. The cell with a nonporous-carbon-coated separator delivered an optimized peak capacity of 1112 mA∙h g(−1) at a cycling rate of C/10 and retained a high reversible capacity of 710 mA∙h g(−1) after 200 cycles under lean-electrolyte conditions. Moreover, we demonstrate the practical high specific capacity of the cathode and its commercial potential, achieving high sulfur loading and content of 4.0 mg cm(−2) and 70 wt%, respectively, and attaining high areal and gravimetric capacities of 4.45 mA∙h cm(−2) and 778 mA∙h g(−1), respectively.