KU and Arizona State University Find a Solution for the Mass Production of Next-Generation Lithium–Sulfur Batteries: A Major Step Toward Commercialization

△ Schematic diagram of the fabrication of binder-free composite sulfur–carbon positive electrodes via thermally assisted dry roll pressing

The era of mass-producing next-generation lightweight, high-efficiency lithium–sulfur batteries has moved one step closer. Professor Yu Seung-ho at KU (President: Kim Dong-One) and Professor Yoon Hwa of Arizona State University in the US have developed a dry manufacturing method that produces composite sulfur¬–carbon positive electrodes without separate solvents or polymer binders.

*Solvent: A liquid used to dissolve a substance to prepare a solution.

*Binder: An adhesive component that holds electrode materials together.

Lithium–sulfur batteries are drawing attention as next-generation batteries that will feature in future mobility industries, such as drones and aviation. This is because their energy density (i.e., performance relative to weight) is three to five times higher than that of lithium-ion batteries, and the manufacturing costs can be reduced due to the abundance of sulfur as a raw material on Earth. However, the conventional manufacturing process is complex and expensive because the slurry-based wet coating method used to manufacture lithium-ion batteries is employed.

*Slurry-based wet coating: A process in which electrode materials in powder form are mixed with a liquid solvent to create a thick paste (slurry), which is then spread evenly over a thin metal foil and dried.

To overcome these limitations, the research team focused on the properties of sulfur, which softens and becomes adhesive when heated. The electrode was formed without the need for a separate binder, by applying a thermally assisted dry pressing process, which involves creating a composite sulfur–carbon powder layer on an aluminum foil current collector, applying heat, and then pressing the layer with high pressure. In essence, sulfur is employed as both the active material and the binder.

*Current collector: A metal foil that serves as a pathway for electrons to flow.

*Active material: A substance that directly participates in electrochemical reactions.

X-ray-based 3D structural analysis, microscopic observations, and electrochemical evaluation collectively revealed that electrodes manufactured at approximately 80 °C exhibited particularly outstanding performance. Compared to conventional batteries manufactured using a wet process, the internal structure was more uniform and the electrolyte permeated more effectively, resulting in a longer battery lifetime and more stable performance.

This study is highly significant because the new technology simultaneously promotes environmental friendliness, economic feasibility, and suitability for mass production, all of which are crucial for practical industrial applications. No separate solvents or specially manufactured current collectors are required and, because standard aluminum foil current collectors widely used in battery manufacturing can be utilized, this approach is expected to be highly compatible with the roll-to-roll process, a high-speed mass production method.

The results of this study were published online on February 4, 2026, in Nature Communications (Impact Factor=15.7), an internationally renowned journal.

*Article Title: Binding properties of sulfur to enable solvent-free fabrication of high-performance polymer-free sulfur-carbon positive electrodes

*DOI: 10.1038/s41467-026-69097-6

*URL: https://doi.org/10.1038/s41467-026-69097-6

This study was supported by the LG Energy Solution Battery Innovation Contest and partially supported by the National Research Foundation of Korea (NRF) and the Ministry of Science and Information Technology.

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△(Left) Professor Yoon Hwa (corresponding author) of Arizona State University and Professor Yu Seung-ho (co-corresponding author).