Mass Production of Calendering-Compatible Sulfur-Rich Secondary Particles via Hail-Inspired Nanostorm Technology for Advanced Metal-Sulfur Batteries

Abstract

Scalable fabrication of high-quality thick sulfur electrodes with high-energy-density and good calendering-compatibility is a prerequisite for the practical success of metal-sulfur batteries. However, this task turns out extremely challenging due to the lack of not only advanced sulfur-rich active materials via scalable approach, but also quality-control principles for thick electrodes. Here, we first develop a new hail-inspired sulfur nanostorm (HSN) technology that can efficiently produce high-performance sulfur-rich secondary particles (S-rich SPs) with applesnail-egg-like structures. This biomimetic S-rich SPs rationally integrate critical material functions and good calendering-compatibility. Meanwhile, a concept of “healthy” microenvironment as learned from cell biology is proposed, for the first time, as a key principle revealing the critical role of calendering-compatibility in the quality-control of thick sulfur electrodes. Consequently, an ultrahigh areal capacity of 12 mAh cm− 2 @ 1 mA cm− 2 is realized. Further, we successfully demonstrate a pouch cell with an exceptional energy density of 430 Wh kg− 1 or 1,004 Wh L− 1 in a quasi-lean electrolyte condition. The technology and concept of this study may bring in new insights and general principles for design of advanced thick electrodes with, but not limited to, sulfur-based active materials.