# Binding properties of sulfur to enable solvent-free fabrication of high-performance polymer-free sulfur-carbon positive electrodes

## TL;DR

This paper introduces a new method to make high-performance sulfur-carbon electrodes without solvents or binders, improving battery sustainability and cost.

## Contribution

The novel contribution is using sulfur's natural binding properties to fabricate electrodes without solvents or polymer binders.

## Key findings

- Binder-free electrodes achieved 932 mAh g⁻¹ after 500 cycles at 1.0 C rate.
- The process eliminates hazardous solvents and reduces fabrication costs by 2.1 times.

## Abstract

The development of a scalable, cost-effective and environmentally benign manufacturing of binder-free sulfur positive electrodes can make substantial advance for lithium-sulfur (Li | |S) batteries as sustainable competitors to lithium-ion systems. Here we show a solvent- and binder-free method to fabricate sulfur-carbon composite electrodes directly on aluminum foil via thermal-assisted dry pressing. A key finding is the role of sulfur as a structural binder, where its softening, distribution, and adhesion properties enable the formation of mechanically robust electrodes without polymer binders. Systematic experimental characterizations and computational modeling reveal the underlying mechanisms governing electrodes formation and electrochemical performance. The developed binder-free positive electrodes achieve a reversible capacity of 932 mAh g⁻¹ after 500 cycles at 1.0 C rate; for comparison, conventional slurry-cast positive electrodes containing 10 wt.% binder deliver lower capacity under the same electrochemical test conditions. This scalable process has the potential to reduce fabrication costs by a factor of 2.1 while eliminating hazardous solvents and binders, offering a sustainable and cost-effective approach to advancing Li | |S battery technology.

Sulfur electrodes are typically fabricated by solvent slurry casting with polymer binders, adding complexity. Here, authors show that the intrinsic binding properties of sulfur enable polymer- and solvent-free electrode fabrication, delivering durable cycling while potentially reducing manufacturing cost.