Sulfur
particles were coated with conductive polymer layers by
dielectric barrier discharge (DBD) plasma technology under atmospheric
conditions (ambient pressure and low temperature). The DBD plasma
process is a dry and sustainable (solvent-free, limited energy consumption)
technique compatible with upscaling. Different conductive coated sulfur
materials were produced and labeled as “PEDOT-S” [poly(3,4-ethylene
dioxythiophene-sulfur)], “PANI-S” (polyaniline-sulfur),
“PTs-S” (polythiophene-sulfur), and “PPy-S”
(polypyrrole-sulfur). The corresponding electrical conductivities
were measured at 10–5, 10–6, 10–7, and 10–8 S/cm, respectively. The
role of the conductive coating is to enhance the electrochemical performance
of Li–S cells by improving the electronic conductivity of the
sulfur particles and preventing the well-known polysulfide shuttle
phenomenon. A vast range of characterization methods including conductivity
analysis, X-ray diffraction, scanning electron microscopy, X-ray photoelectron
spectroscopy, and carbon-13 NMR (nuclear magnetic resonance spectroscopy)
were used to assess the chemical characteristics using the different
conductive polymer-coated sulfur materials. In the coated sulfur samples,
fragmentation of aromatic rings was observed, 88% for the PTs-S and
42% for the PEDOT-S, while it is very limited for the PANI-S. Such
a phenomenon has never been reported in the literature. The uncoated
and coated sulfur powders were used (as active material) in positive
electrodes of Li–S cells with a relatively high sulfur loading
of ∼4.5 mg/cm2 using LiPAA (lithium polyacrylate)
as an (aqueous) binder. Long-term galvanostatic cycling at C/10 and
multi-C-rate tests showed the capacity fade and rate capability losses
to be highly mitigated for cells containing conductive polymer-coated
sulfur in comparison to cells using the uncoated sulfur. Kinetic investigations
by cyclic voltammetry and electrochemical impedance spectroscopy analyses
undoubtedly confirm improved electron and Li-ion transport within
the electrodes containing conductive polymer-coated sulfur. The electrochemical
performance can be ranked as PEDOT-S > PANI-S > PTs-S > PPy-S
> raw
sulfur.