In situ-grown compressed NiCo2S4 barrier layer for efficient and durable polysulfide entrapment

Abstract Modifying a polypropylene (PP) separator with a polysulfide barrier layer can improve the cycling performance of lithium–sulfur (Li–S) batteries. However, conventional slurry-coating- and vacuum-filtration-designed barriers usually show poor particle connection and require extra binder. Herein, we propose a facile in situ growth method and a subsequent compression strategy to design multifunctional NiCo₂S₄ (NiCoS) nanosheet arrays on a PP membrane for high-performance Li–S batteries. The in situ grown NiCoS nanosheet arrays are interconnected, conductive and closely adhered to the PP membrane without using any binder. After mechanical compression treatment, the overall NiCoS film is compacted, lightweight (0.148 mg cm⁻²) and ultrathin (0.8 μm). Density functional theory calculations combined with adsorption and diffusion tests prove that the NiCoS nanosheets have highly efficient physical/chemical entrapping capabilities for preventing polysulfide shuttling. Moreover, in situ electrochemical impedance spectroscopy demonstrated that the NiCoS barrier could efficiently suppress polysulfide diffusion and concurrently facilitate redox reactions. When applying this multifunctional separator, a sulfur/carbon nanotube (S/CNT) cathode with high sulfur content (75 wt%) delivers significantly improved long-term cycling performance, with 0.056% capacity decay per cycle over 500 cycles. This work opens up new opportunities to design multifunctional separators by an in situ growth strategy for high-performance Li–S batteries.