Facile dry synthesis of sulfur-LiFePO4 core–shell composite for the scalable fabrication of lithium/sulfur batteries

•LiFePO4 (LFP)-coated sulfur (S-LFP) particles were synthesized.•A mechano-fusion method was used.•This synthesis process is completed in a 5 min without a solvent drying step.•The S-LFP cathode showed an initial capacity of 1200 mAh/g at 0.1 C.•80% capacity retention after 90 cycles at 0.5 C cycles.

LiFePO4(LFP)-coated sulfur (S-LFP) particles were synthesized using a dry mechano-fusion method and electrochemically tested in a liquid electrolyte. This synthesis process (encapsulation) is completed in a few minutes without a solvent drying step, thus it is easily scalable for volume production. The S-LFP cathode showed an initial capacity of 1200 mAh/g at 0.1 C, and 80% capacity retention after 90 cycles at 0.5 C. 417 Wh/kg in specific energy and 623 Wh/l in energy density are achievable with this new technology. The results suggest that the LFP layer enhances the utilization of active sulfur and lowers the polarization for oxidation of Li2S2/Li2S.

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