Performance of Microporous Carbon Cathodes and Impact of Cathode/Solid Electrolyte Interphase Formation Using Carbonate and Ether-Based Electrolytes in Lithium–Sulfur Batteries

Lithium–sulfur batteries (Li–S), controlled by the sulfur cathode’s conversion reaction, are a promising technology due to their high theoretical capacities and the sustainability of sulfur. In contrast to commercially available lithium-ion cathodes, the Li–S system still suffers from unstable cycling performance due to the diffusion of soluble polysulfides out of the cathode. This study explored sulfur cathodes with varying pore sizes, mainly in the micropore regime (<2 nm). We conducted the work using carbonate-based and ether-based electrolytes to investigate the impact of the cathode/solid electrolyte interphase on the cycling performance of the battery. By infiltrating the carbon with different C/S ratios, we found that the maximum sulfur infiltration attained was 61 mass % with a C/S ratio of 1:1.5. The best sulfur utilization and cycling performance were achieved with carbonate electrolyte and 50 mass % S in carbon with a specific surface area of 2210 m2/g and a total pore volume of 1.20 cm3/g. Our findings emphasize the importance of designing cathodes with optimized pore structures to balance sulfur accommodation, minimize sulfur dissolution, and mitigate capacity degradation.