For practical application of lithium-sulfur batteries (LSBs), it is crucial to develop sulfur cathodes with high areal capacity and cycle stability in a simple and inexpensive manner. In this study, a carbon cloth infiltrated with a sulfur-containing electrolyte solution (CC-S) was utilized as an additive-free, flexible, high-sulfur-loading cathode. A freestanding carbon cloth performed double duty as a current collector and a sulfur-supporting/trapping material. The active material in the form of Li₂S₆ dissolved in a 1 M LiTFSI-DOL/DME solution was simply infiltrated into the carbon cloth (CC) during cell fabrication, and its optimal loading amount was found to be in a range between 2 and 10 mg/cm² via electrochemical characterization. It was found that the interwoven carbon microfibers retained structural integrity against volume expansion/contraction and that the embedded uniform micropores enabled a high loading and an efficient trapping of sulfur species during cycling. The LSB coin cell employing the CC-S electrode with an areal sulfur loading of 6 mg/cm² exhibited a high areal capacity of 4.3 and 3.2 mAh/cm² at C/10 for 145 cycles and C/3 for 200 cycles, respectively, with minor capacity loss (<0.03%/cycle). More importantly, such high performance could also be realized in flexible pouch cells with dimensions of 2 cm × 6 cm before and after 300 bending cycles. Simple and inexpensive preparation of sulfur cathodes using CC-S electrodes, therefore, has great potential for the manufacture of high-performance flexible LSBs.
Keywords: carbon cloth; catholytes; flexible batteries; lithium–sulfur batteries; microporous carbon.