Da-Wei
Wang
ab,
Qingcong
Zeng
a,
Guangmin
Zhou
c,
Lichang
Yin
c,
Feng
Li
c,
Hui-Ming
Cheng
c,
Ian R.
Gentle
*a and
Gao Qing Max
Lu
*b
aSchool of Chemistry and Molecular Biosciences, The University of Queensland, St Lucia, Brisbane, Qld 4072, Australia. E-mail: i.gentle@uq.edu.au; d.wang6@uq.edu.au
bARC Centre of Excellence for Functional Nanomaterials, Australian Institute for Bioengineering and Nanotechnology, The University of Queensland, St Lucia, Brisbane, QLD 4072, Australia. E-mail: m.lu@uq.edu.au; d.wang6@uq.edu.au
cShenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, 72 Wenhua Road, Shenyang 110016, China. E-mail: cheng@imr.ac.cn; fli@imr.ac.cn
First published on 23rd April 2013
We review the development of carbon–sulfur composites and the application for Li–S batteries. Discussions are devoted to the synthesis approach of the various carbon–sulfur composites, the structural transformation of sulfur, the carbon–sulfur interaction and the impacts on electrochemical performances. Perspectives are summarized regarding the synthesis chemistry, electrochemistry and industrial production with particular emphasis on the structural optimization of carbon–sulfur composites.
Da-Wei Wang | Da-Wei Wang completed his Bachelor studies at Northwestern Polytechnic University (China) in 2003 and his Ph.D. at the Institute of Metal Research, Chinese Academy of Sciences in 2009. He started postdoctoral research in collaboration with Professor Max Lu and Professor Ian Gentle at the University of Queensland (UQ) in 2009. His research interests include carbon materials and their energy applications. He received a 2012 UQ Foundation Research Excellence Award for his research to develop advanced lithium batteries. He has published 36 peer-reviewed journal papers with an h-index of 19, and total citations of over 1700. |
Feng Li | Feng Li is a professor of the Institute of Metal Research, Chinese Academy of Sciences (IMR, CAS). He received his Ph.D. in Materials Science at IMR, CAS in 2001 supervised by Prof. Hui-Ming Cheng. He used to work at The University of Queensland, Australia and MIT, USA. He mainly works on the novel carbon based materials for lithium ion batteries, lithium sulfur battery and supercapacitors. He has published about 140 papers on peer-reviewed journals such as Angew. Chemie, Energy Environ. Sci., Adv. Mater., Adv. Funct. Mater., ACS Nano, etc. with more than 6000 citations and an h-index of 30. |
Hui-Ming Cheng | Hui-Ming Cheng is Professor and Director of Advanced Carbons Division of Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences. He worked at AIST and Nagasaki University, Japan, and MIT, USA. His research mainly focuses on carbon nanotubes, graphene, energy storage materials, photocatalytic materials, and high-performance bulk carbon materials. He has published over 350 peer-reviewed papers. He has been Editor of Carbon since 2000 and the Editor-in-Chief of New Carbon Materials since 1998, and co-chaired the World Conference on Carbon in 2002 (Beijing) and 2011 (Shanghai). He has given more than 60 plenary/keynote/invited talks at international conferences and symposia. |
Ian R. Gentle | Ian R. Gentle is a graduate of the University of Sydney with BSc (Hons) and PhD in Physical Chemistry. He has been at the University of Queensland since 1993 and is now Professor and Associate Dean Research in the Faculty of Science. He has held a number of leadership positions at UQ including Director of the Brisbane Surface Analysis Facility, Deputy Director of the Centre for Microscopy and Microanalysis and Program Leader in the ARC Centre of Excellence for Functional Nanomaterials. Most recently he held the position of Head of Science at the Australian Synchrotron (2008–2010). He has published around 100 journal articles in the fields of materials science, thin films, organic electronics and biological surfaces. He has also been on a number of boards and is currently the Chair of the Australian Nanotechnology Alliance. |
Gao Qing Max Lu | G. Q. Max Lu received his PhD in Chemical Engineering from University of Queensland, Australia. He is now Deputy Vice-Chancellor (Research) of UQ. He has received numerous prestigious awards including the Federation Fellowship (twice). He is an elected Fellow of ATSE, Fellow of Institution of Chemical Engineers, and Fellow of AAS. He is the Foundation Director for the ARC Centre of Excellence for Functional Nanomaterials. Professor Lu is ISI Highly Cited Author in Materials Science with 17600 citations (h-index of 67). His research interests include carbon, silicate and oxide nanoparticles and nanoporous materials for energy and environmental applications. |
A recent boom in carbon-related energy research has been triggered by the emerging focus on Li–S batteries.15 Li–S batteries utilize a lithium metal anode and a sulfur cathode. The multi-electron-transfer cathode reaction of S8 + 16 Li+ + 16 e− ↔ 8 Li2S offers an extremely high theoretical capacity of 1672 mA h g−1, while the lithium anode provides a theoretical capacity of 3842 mA h g−1. The average potential of a Li–S cell is 2.15 V with respect to Li0/Li+, which is relatively low compared to graphite–LiMO2 batteries (>3 V). The specific energy of Li–S battery is still very large, however, the medium voltage is offset by the very high capacity and reaches a theoretical value of 2567 W h kg−1. The use of lithium metal in a Li–S cell is far from optimal, as it is potentially risky due to dendrite formation.16 Many efforts have been devoted to lithium-metal free sulfur-based batteries.17–20 Unfortunately, the lithium metal anode and the lithium sulfide anode are both moisture sensitive. Large scale fabrication of battery anodes from these materials must be performed in a dry and inert environment, and this could potentially impact the industrial production of Li–S batteries.
The other obstacle that stands in the way of the large-scale uptake of Li–S technology is relevant to the sulfur cathode. Sulfur is a promising cathode material due to its advantages such as low cost, nontoxicity and virtually unlimited supply. However, several practical problems have delayed widespread application of sulfur. Sulfur itself is insulating (5 × 10−30 S cm−1 at 25 °C) and is thus unusable as an electrode material. This fact necessitates the use of carbon as a conducting additive in the sulfur cathode of Li–S batteries. The redox chemistry of sulfur in the cathode relies on a solid (cyclo-S8)–liquid (chain-polysulfides (PS, S4–82−))–solid (Li2S2/Li2S) reaction with a systematic decrease in the ion chain length. The reduction of S8 forms S82− at 2.39 V vs. Li0/Li+, which is successively reduced to S62−at 2.37 V vs. Li0/Li+ and then to S42− at 2.24 V vs. Li0/Li+.21 Because the PS ions are soluble, the reaction is fast (Fig. 1, first plateau). This process corresponds to a theoretical capacity of 418 mA h g−1. Continuing discharge will reduce the PS ion to Li2S2/Li2S which are insoluble. Due to the much slower reaction kinetics at the second plateau and the tail, which correspond to solid state reactions, the theoretical value usually cannot be achieved and a lower capacity of 1256 mA h g−1 is more realistic (corresponding to 1.5 e S−1).
Fig. 1 Electrochemistry of sulfur showing an ideal charge–discharge profile. Inset: polysulfide (PS) shuttle. |
A critical issue associated with the PS ions (S4–82−) is their solubility in an electrolyte. The dissolved PS ions easily diffuse from the cathode to anode driven by a concentration gradient (Fig. 1, inset). In fact, even sulfur can be weakly dissolved in an aprotic electrolyte.22 Reduction of the dissolved PS is as yet unclear, but is possible that it occurs through (1) ion chain scission, (2) disproportionation, and (3) reduction by the Li anode.22 The insoluble Li2S2/Li2S deposits on the Li anode can react with PS ions, yielding soluble medium-chain ions, which diffuse back to the sulfur cathode. The whole process is known as the “PS shuttle mechanism”. This shuttle phenomenon results in the following drawbacks: (1) the active mass loss from the cathode, (2) reduction of Coulombic efficiency, and (3) capacity decay upon cycling. Additionally the insoluble Li2S2/Li2S can also deposit on the cathode and is insulating.23 This makes the cathode electrochemically inaccessible due to the hindered ion and electron transport. A further issue associated with the sulfur cathode is the volume variation. The density of sulfur is 2.03 g cm−3 while that of Li2S is 1.67 g cm−3, which results in an 80% volume expansion. The current limitations of sulfur cathodes and the already proposed strategies to address these issues are summarized in Table 1. Many recent studies on carbon–sulfur composites are summarized in Table 2, where the synthesis method and the performance evaluation, typically the cyclic stability, are compared.
Limitations | Improvements |
---|---|
Insulating | Conducting additives |
PS shuttle | (i) Physical confinement (ii) chemical adsorption (iii) electrolyte design (iv) separator design |
Volume change | (i) Porous texture (ii) buffering additives |
Classification | Characteristics | Sulfur loading method | S percentage (by weight) | Cycle performance (1C = 1675 mA g−1) | Electrolyte/voltage window |
---|---|---|---|---|---|
Microporous carbon | |||||
Sucrose-derived hydrothermal carbon nanosphere36 | Sulfur loaded in 0.7 nm micropores | Sulfur melt adsorption (150–160 °C) + vaporizing (280–300 °C) | 42% | 650 mA h g−1/400 mA g−1/500th cycle | 1 M LiPF6 PC-EC-DEC,1.0–3.0 V |
D-Glucose-derived carbon coating on CNT38 | Sulfur loaded in 0.6 nm micropores | Sulfur melt adsorption | 40.2% | 1142 mA h g−1/0.1C/200th cycle | 1 M LiPF6 in EC/DC (1:1 in wt%),1.0–3.0 V |
Phenolic resin-derived porous carbon37 | Sulfur loaded in <1 nm micropores | Sulfur melt adsorption + extraction process | 16% | 200 mA h g−1/3000 mA g−1/800th cycle | 1 M LiPF6 in (EC/DMC/EMC, 1:1:1 vol.), 1.5–2.8 V |
Mesoporous carbon | |||||
Sucrose-derived carbon with sodium silicate as template27 | 10–30 nm | Sulfur melt adsorption | 20% | 500 mA h g−1/50 mA g−1/40th cycle | 1 M LiTFSI in EMITFSI |
PPy-derived carbon with colloidal silica as template31 | 7–22 nm | Sulfur melt adsorption | 83.2% | 613 mA h g−1/0.1C/50th cycle | 1 M LiTFSI/DOL-DME (1:1), 1.0–3.0 V |
Ordered mesoporous carbon (CMK-3)28 | 3–4 nm | Sulfur melt adsorption | 70% | 1100 mA h g−1/168 mA g−1/20th cycle | 1.2 M LiPF6 in ethyl methyl sulphone |
Phenol formaldehyde-derived carbon with TEOS and F127 as templates30 | 2.0 nm and 5.6 nm | Sulfur melt adsorption | 40% | 345 mA h g−1/1C/100th cycle | 1 M LiTFSI/DOL-DME (1:1), 1.5–3.0 V |
Phenol formaldehyde-derived carbon with TEOS and F127 as templates34 | 2.7 nm | Sulfur melt adsorption | 50% | 730 mA h g−1/1C/100th cycle | 1 M LiTFSI/DOL-DME (1:1), 1.5–3.0 V |
Hierarchical porous carbon | |||||
Sucrose-derived carbon with silica and copolymer latex as dual-template40 | Macropore size-300 nm | Sulfur melt adsorption | 50% | 884 mA h g−1/0.1C/50th cycle | 1 M LiTFSI/DOL-DME (1:1), 0.1 M LiNO3, 1.0–3.0 V |
Hollow carbon sphere | |||||
Petroleum pitch with silica as template42 | Diameter 200 nm | Vapour phase infusion | 70% | 974 mA h g−1/0.5C/100th cycle | 1 M LiTFSI in tetraglyme, 1.7–3.1 V |
Glucose derived carbon with SnO2 sphere as template43 | Diameter 300 nm | 400 °C heat treatment | 64% | 690 mA h g−1/0.1C/100th cycle | 1 M LiTFSI in tetraglyme, 1.5–3 V |
CNT/CNF | |||||
Carbon nanotube array49 | CNT diameter from 7–30 nm | Solvent evaporation | 63% | 900 mA h g−1/C/13/40th cycle | 1 M LiTFSI/DOL-DME (1:1), 0.25 M LiNO3, 1.0–3.0 V |
Disordered carbon nanotubes47 | CNT diameter 200 nm | High temperature (500 °C) treatment | 40% | 700 mA h g−1/200 mA g−1/100th cycle | 1 M LiTFSI in TEGDME, 1.5–3 V |
Styrene derived carbon hollow fiber with AAO as template50 | Hollow fiber | Sulfur melt adsorption | 75% | 730 mA h g−1/0.2C/150th cycle | 1 M LiTFSI/DOL-DME (1:1), 0.1 M LiNO3, 1.7–2.6 V |
Graphene | |||||
PEG modified GO-carbon black54 | Emulsion wrap 1 μm sulfur particles | Emulsion: Na2S2O3 + Triton-X100 + HCl | 70% (before annealing) | 520 mA h g−1/0.2C/100th cycle | 1 M LiTFSI/DOL-DME (1:1), 1.7–2.6 V |
KOH activated graphene64 | Amorphous sulfur mesoporous graphene composites | Sulfur melt adsorption | 67% | 1007 mA h g−1/0.2C/60th cycle | 1 M LiTFSI/DOL-DME (1:1), 1.0–3.0 V |
Graphene sheets reduced by Na2S63 | Sulfur–graphene composite | Hydrothermal NaS + NaSO3 | 75.2% | 662 mA h g−1/1000 mA g−1/100th cycle | 1 M LiCF3SO3/DOL-DME (1:1), 0.2% wt LiNO3, 1.7–2.5 V |
Raw graphene61 | Amorphous sulfur–graphene composite | Sulfur melt adsorption (in air) | 44.5% | 819 mA h g−1/0.05C/100th cycle | 1 M LiTFSI/DOL-DME (v/v 2:8), 1.0–3.0 V |
Ethanol derived porous graphene52 | Amorphous sulfur–graphene composite | Sulphur vaporizing | 22% | 600 mA h g−1/50 mA g−1/40th cycle | 1 M LiTFSI in PEGDME, 1.5–3.0 V |
Reduced graphene oxide62 | Uniformly dispersed on graphene | SO32− + 2S2− + 6H+ | 63.6% | 440 mA h g−1/1250 mA g−1/500th cycle | 1 M LiTFSI/DOL-DME (1:1), 1.5–3.0 V |
Graphene55 | Graphene enveloped 1 μm sulfur particles | NaSx + H+ | 87% | 500 mA h g−1/334 mA g−1/50th cycle | 1 M LiTFSI/DOL-DME (1:1), 1.5–3.0 V |
GO with epoxy and hydroxyl groups66 | Binding between sulfur thin film and graphene | NaSx + H+ and sulfur melt adsorption | 66% | 954 mA h g−1/0.1C/50th cycle | 1 mol kg−1 LiTFSI in PYR14TFSI/PEGDME (1:1, by weight), 1.0–3.0 V |
Graphene–CNT hybrid65 | 5 nm single walled CNT | Sulfur melt adsorption | 60% | 530 mA h g−1/1C/100th cycle | 1 M LiTFSI/DOL-DME (1:1), 1.5–3.0 V |
Nafion coated graphene57 | Sandwich type graphene–sulfur composites | Sulfur melt adsorption | 71.8% | 800 mA h g−1/0.1C/50th cycle | 1 M LiTFSI/DOL-DME (1:1), 1.0–3.0 V |
Flexible carbon support | |||||
Activated carbon fiber cloth74 | Binder-free cathode | Sulfur melt adsorption | 33% | 800 mA h g−1/150 mA g−1/80th cycle | 10 wt% LiTFSI/DOL-DME (1:1) with 2 wt% LiNO3, 1.7–2.48V |
MWCNT membrane76 | Self weaving | Emulsion: Na2S2O3 + Triton-X100 + HCl | 60% | 915 mA h g−1/1C/100th cycle | 1.85 M LiTFSI/DOL-DME (1:1) with 0.1 M LiNO3, 1.5–2.8 V |
Graphene membrane77 | Self-supporting | Na2S2O3 + HCl | 67% | 600 mA h g−1/0.1C/100th cycle | 1 M LiTFSI/DOL-DME (1:1), 1.0–3.0 V |
Disordered CNT membrane75 | Binder free | In situ carbothermal reduction of sulphate | 23% | 635 mA h g−1/1500 mA g−1/100th cycle | 1.0 M LiTFSI/DOL-DME (1:1) with 0.1 wt% LiNO3, 1.5–2.8 V |
Other carbon materials | |||||
Nitrogen doped carbon35 | NH3 treated mesoporous carbon | Sulfur melt adsorption | 24% | 573 mA h g−1/0.05C/20th cycle | 0.5M LiTFSI/[MPPY] [TFSI], 1.0–3.0 V |
Expanded graphite60 | / | Sulfur melt adsorption | 60% | 880 mA h g−1/280 mA g−1/70th cycle | 1 M LiTFSI/DOL-DME (1:1), 1.5–3.0 V |
Carbon black45 | / | Sulfur precipitation | 64.7% | 832 mA h g−1/0.1C/50th cycle | 1 M LiTFSI/DOL-DME (v/v 4:1), 1.0–3.0 V |
Fig. 2 Structure transformation of sulfur. |
The manifested advantages of mesoporous carbon were later highlighted by Ji and co-workers.28 The major progress relied on the optimal use of the ordered mesoporous carbon (CMK-3) synthesized by using the SBA-15 silica template. This CMK-3 carbon possessed uniform and narrow mesopores (3 nm) and large pore volume (2.1 cm3 g−1) (Fig. 3a). The sulfur content in the CMK-3-sulfur composite can be as high as 70 wt%. This value is lower than the theoretical value (79 wt%) because it is good for buffering the volume change during lithiation and delithiation of sulfur confined in the mesopores.28 As a result of the uniform distribution of sulfur in the mesopores, the conductivity of the composite is comparable to that of CMK-3 within errors (0.21 S cm−1vs. 0.2 S cm−1, ±0.02 S cm−1). This gave rise to a very high Coulombic efficiency (99.94%) in the first discharge–charge cycle, which indicated an extremely low fraction of PS dissolved in the electrolyte. A typical discharge–charge profile of the CMK-3–S composite shows the well resolved plateaus corresponding to the redox chemistry of sulfur, PS and lithium sulfides (Fig. 3b). It is notable that an organic electrolyte was used in this study. Ji et al. also demonstrated the enhanced stability of a PEG-coated CMK-3–sulfur composite,28 introducing the concept of carbon–sulfur–polymer ternary composites for Li–S batteries.
Fig. 3 Structure scheme of the CMK-3–sulfur composite.28 Reproduced from ref. 28. Copyright 2009 Nature Publishing Group. |
Many other types of mesoporous carbon–sulfur composites have subsequently been developed and examined for their efficacy in promoting sulfur stability in Li–S batteries.29–34 Bimodal mesoporous carbon with 2.0 nm and 5.6 nm mesopores was used with the intention of regulating ion conduction in the mesoporous framework for high-rate performance.30 The small mesopores were located in the walls of the large mesopores without harming the structural integrity of the mesoporous framework. By screening over various mesoporous carbons with different mesopore sizes and pore volumes, Li et al. concluded that (1) large pore volume is good for increasing sulfur percentage and higher capacity of the composite (total mass of carbon and sulfur), (2) empty pore space, i.e. partial sulfur loading, is crucial for facile supply of lithium ions and adsorption of PS, and (3) polymer coating of mesoporous carbon is important for better cathode performance.31 It is important to emphasize that the empty space in C–S composites is necessary for buffering the volume change during lithiation–delithiation of the cathode. By using a post-activation treatment, Liang et al. showed the generation of micropores on the walls of mesoporous carbon.32 These micropores were expected to accommodate sulfur while the mesopores can transfer lithium ions.32 However, the cycling stability of this carbon–sulfur composite was not as good as the CMK-3–sulfur composite. The relatively larger mesopores (7.3 nm) as well as the destroyed pore walls may be the causes. Morphological control over the mesoporous carbon–sulfur composites has also been studied, where spherical particles were used.33,34 Interestingly, the introduction of nitrogen as a dopant in mesoporous carbon appeared to be beneficial for performance enhancement.35
Fig. 4 Discharge and charge profiles of the microporous carbon–sulfur composite with 42 wt% sulfur at 400 mA g−1.36 Reproduced from ref. 36. Copyright 2010 Royal Society of Chemistry. |
Wang et al. designed a two-step adsorption–extraction method to differentiate the differing cathode properties of sulfur confined in micropores and large pores.37 Their work clearly demonstrated the excellent efficacy of micropores in enhancing the stability of sulfur (up to 800 cycles at high rate).37 They also observed the higher binding energy of Li–S bond confined in micropores, which is likely because of the strong adsorption.37 They proposed a desolvation effect to interpret the unusual stability of sulfur in microporous carbon.37 Since the observation of ion desolvation in carbide-derived carbon, it has been widely acknowledged that solvated ions tend to be desolvated in micropores with size close to ion size.39 As generally accepted, the sulfur reduction is a solid (S)–liquid (PS ions)–solid (Li2S2/Li2S) process, and the mesopores stabilize sulfur through the adsorption of dissolved PS ions (Fig. 5, left). According to the ion-desolvation theory, the PS ions in micropores which are devoid of solvent react with desolvated ions (Fig. 5, right). This suggests a quasi-solid-state reaction of the sulfur under solvent-deficient conditions. The low Li+ conductivity in S and solid sulfides could also explain the retarded lithiation of sulfur in micropores. Xin et al. fabricated microporous carbon nanofibers in which carbon nanotubes were the backbone.38 Much improved cathode stability of sulfur was also observed, as well as potential hysteresis.38 These three works36–38 shared the same properties of microporous carbon–sulfur composites: (1) lithiation potential hysteresis and (2) excellent stability. Xin and co-workers considered the lithiation of small sulfur molecules.38 On account of the tiny 0.5–0.6 nm micropores, Xin et al. proposed that cyclo-S5–8 molecules with at least two dimensions larger than 0.5 nm cannot exist inside, while small S2–4 molecules with at least one dimension less than 0.5 nm can be hosted.38 However, characterization of the molecular structure of amorphous sulfur confined in micropores is still a great challenge.
Fig. 5 Illustration of the different lithiation mechanisms of sulfur confined in mesopores and micropores. |
Fig. 6 TEM images of (a) a hollow carbon capsule42 and (b) a double-shell hollow carbon sphere.43 Reproduced from ref. 42 and 43. Copyright 2011, 2012 Wiley-VCH. |
SO2 + 2S2− + 4H+ → 3S + 2H2O | (1) |
Fig. 7 (a) TEM image of the core–shell carbon–sulfur composite44 and (b) SEM image of the homogeneous carbon–sulfur composite.45 Reproduced from ref. 44 and 45. Copyright 2010, 2012 Elsevier. |
Fig. 8 Discharge–charge profiles of the second cycles and (inset) Coulombic efficiency under 10 mA g−1 for DCNT-S composites synthesized at 160, 300 and 500 °C.47 Reproduced from ref. 47. Copyright 2011 American Chemical Society. |
Hollow carbon nanofibers (CNFs) were reported as a desirable host for a sulfur cathode mainly because of the limited diffusion pathways of PS ions (Fig. 9).50 This hollow design was believed to contribute the following ideal characteristics: (1) a closed structure for efficient PS containment, (2) limited surface area for sulfur–electrolyte contact, (3) sufficient space to accommodate sulfur volumetric expansion/shrinkage, and (4) a short electron and Li ion transport pathway.50 Ji et al. reported sulfur deposition onto PMMA-templated porous CNFs from a polysulfide solution.51 The reaction formula is as follows:
Sx2− + 2H+ → (x − 1)S + H2S | (2) |
Fig. 9 Schematic of the trapped sulfur inside vertically aligned hollow carbon nanofibers.50 Reproduced from ref. 50. Copyright 2011 American Chemical Society. |
The as-obtained porous CNF–S composite was further annealed to ensure that the exterior sulfur can diffuse into the interior pores of the nanofibers.51
S2O32− + 2H+ → SO2 + S + H2O | (3) |
Fig. 10 (a) Graphene-sheet wrapped sulfur particles,54 Reproduced from ref. 54. Copyright 2011 American Chemical Society. (b) Sandwich-type graphene–sulfur composite.57 Reproduced from ref. 57. Copyright 2010 Royal Society of Chemistry. |
Graphene sheets are advantageous for wrapping sulfur because of their large lateral size, good conductivity and the flexible structure. Under ideal conditions, however, graphene sheets conduct ions along the lateral direction making ion conduction across the sheets very difficult. To overcome this problem, as well as to provide more sites for sulfur storage, activated graphene sheets have been synthesized and used as the sulfur hosts.64 KOH activation produced 3.8 nm mesopores on the graphene sheets which is large enough to transport Li ions while being small enough to hold PS ions.64 Compared with pristine graphene sheets, the activation was clearly good for rate performance and stability.64 Graphene-based hybrid materials are of special interest in energy storage. A unique graphene–single walled CNT (SWCNT) hybrid structure was developed by Zhao and co-workers.65 The graphene constituent in the hybrid formed a hexagonal hollow container for sulfur while the exterior SWCNT forests provided electron conduction pathways as well as conferring a mesoporous texture to adsorb PS ions (Fig. 11). The highly graphitic nature of this hybrid is of significance for the excellent high-rate performance.65
Fig. 11 (Left) illustration of the graphene–SWCNT hybrid as a sulfur host and (right) SEM image of the hybrid-sulfur composite.65 Reproduced from ref. 65. Copyright 2012 American Chemical Society. |
Apart from the diverse range of synthesis chemistry and approaches for producing graphene–sulfur composites, the interaction between graphene and sulfur has also been of interest. Residual oxygen functional groups attached on graphene sheets were found to enhance the adsorption of sulfur and PS ions, both of which contribute greatly to the composite stability.66,67
Fig. 12 (a) Reaction mechanism during heating sulfur with PAN and (b) discharge–charge curves of a PAN-derived carbon–sulfur composite.69 Reproduced from ref. 69. Copyright 2003 Wiley-VCH. |
In order to improve the rate capability and utilization ratio of sulfur in PAN-derived composites, carbon nanotubes70 and graphene sheets71 have been used as electrically conducting backbones to support the composite. Several aspects of the nanocarbon–PAN–sulfur composites have been observed: (1) the intimate contact of the PAN–sulfur composite with nanocarbon surfaces ensures low interface resistance, (2) the encapsulation of sulfur by PAN-derived carbon is a good basis for high capacity and good stability, (3) the supporting backbone can hinder the agglomeration of the PAN–sulfur composite particles which may occur upon volume change of sulfur during extended cycles, and (4) the PAN–sulfur composites can help prevent the restacking of graphene sheets or carbon nanotubes and thus keep a large cathode area for reducing interface impedance.70,71 Another way to improve the reaction kinetics of PAN-derived carbon–sulfur composites is to use higher synthesis temperatures. Fanous and co-workers were able to show that the rate performance and stability of this kind of composite can be improved by increasing the synthesis temperature from 330 °C to 550 °C, but unfortunately at the cost of lower capacity.72 Taking advantage of the lithium–nitrile interaction, Guo et al. succeeded in developing a lithiated carbon–sulfur composite from PAN which represents an advanced strategy for new types of Li–S batteries.73
SO42− + 3C → S + 2CO + CO2 | (4) |
Fig. 13 (a) Stress–strain curve of a flexible carbon–sulfur nanotube membrane cathode. Inset shows a bent S-CNT membrane. (b) STEM analysis of a single carbon–sulfur nanotube.75 Reproduced from ref. 75. Copyright 2012 Royal Society of Chemistry. |
This nanotubular carbon–sulfur composite has a high surface area and porous texture which is difficult to obtain through infiltration methods. The richness of the void spaces is advantageous for its capabilities of (1) compensation for volume change, (2) rapid ion transport, (3) reduced resistance polarization, and (4) adsorption of dissolved PS. Sulfur-coated carbon nanotubes76 and graphene sheets77 have also been assembled into papers by directional filtration methods for use as flexible cathodes.
A summary of the efficacy of the different kinds of carbons for stability, capacity and conductivity is given in Table 3. It is clear that no one carbon form alone can meet the comprehensive performance criteria, but an effective combination of these materials is necessary to gain the best advantage from the properties of the individual building blocks.
Carbon Form | Stability | Conductivity | Volume change |
---|---|---|---|
Microporous carbon | Good | Normal | Normal–good |
Mesoporous carbon | Normal–good | Normal | Normal–good |
Graphene sheets | Normal–good | Good | Good |
Carbon nanotubes | Normal–good | Good | Normal |
PAN carbon | Good | Normal | Normal |
Several critical factors are suggested here for the rational design of advanced carbon–sulfur composites:
(1) Pore size: micropores/small mesopores for strongly confining polysulfides.
(2) Large pore volume for maximum sulfur loading: carbon is not an active cathode material in Li–S batteries and its weight ratio is required to be as low as possible without harming the overall performance of sulfur–carbon cathodes. However, the very low conductivity of the composite when sulfur content increases is a critical problem to be solved.
(3) Graphitization level: a preferential content of graphitic carbon to facilitate electron conduction to the insulating sulfur/lithium sulfides.
(4) Electrolyte impregnation and lithium ion migration: a short pathway to preserve fast migration of lithium ions from the bulk electrolyte to active sulfur and the release of lithium ions from lithium sulfides. Voids are required in the final carbon–sulfur composites.
(5) Flexible or rigid carbon scaffold: volume change occurs during the discharge or charge of sulfur–carbon cathodes; the carbon host should buffer the stress-induced strain and survive over extended cycles.
(6) Low cost production and easy scale-up: templated ordered mesoporous carbon and CNTs/nanofibers are highly effective due to their periodic structure but are unlikely to be produced at an industrial scale for Li–S batteries owing to their high cost and unsatisfactory performance–cost ratio; novel continuous synthesis techniques, inclusive of but not limited to atomization carbonization and hydrothermal carbonization, are promising.
(7) An advanced technique to form carbon–sulfur composites: common methods are impregnation with the sulfur melt or sulfur organic solution, disproportionate reaction and in-situ encapsulation, and vapour diffusion. These are post-carbon-synthesis and complicate the industrial processing. A one-step method for fabrication of sulfur–carbon composites is necessary.
We emphasize here that the correlations between the carbon structure (porosity, surface chemistry, graphitic degree) and the sulfur structure need to be comprehensively studied and optimized (Fig. 14). Facile and low cost material fabrication techniques are also desired. An optimal carbon–sulfur composite will benefit from a combination of fundamental insights and an advanced synthesis approach. We also acknowledge that the sulfur cathode problem is not the only issue that impedes Li–S technology. Problems with the lithium anode, the electrolyte as well as engineering difficulties in fabricating lithium metal batteries are all great challenges to be faced, but recent dramatic progress in carbon–sulfur composites is likely to form the basis for future commercialization of Li–S batteries.
Fig. 14 Correlations between the carbon structure and the sulfur structure for performance optimization. |
This journal is © The Royal Society of Chemistry 2013 |