Electrospinning for lithium-sulfur batteries: processes and applications

Lithium-sulfur (Li-S) batteries offer high energy density, low cost, and environmental friendliness, making them a promising next-generation energy storage technology. However, their practical application is hindered by challenges such as the lithium polysulfide (LiPS) shuttle effect, poor sulfur conductivity, and lithium dendrite growth. Electrospinning is a quintessential technique for manufacturing extremely small (nanoscale) fibers using an extremely high voltage (e.g., >10 kV). It provides a versatile solution with tunable materials and architectures, as well as superior and extreme functionality and scalable fabrication. Electrospun nanofibers have been effectively integrated into key battery components, including cathodes, anodes, separators, electrolytes, and interlayers, to enhance performance. This review examines recent advances in electrospinning for Li-S batteries, focusing on four key stages: precursor engineering, process advancements, post-treatment modifications, and add-on processes. It explores the principles and challenges of Li-S batteries and highlights the unique advantages of nanofiber networks, such as high surface area, porosity, material versatility, architecture tailorability, and structural advantages over conventional electrodes. By summarizing recent progress and strategies, this review provides guidelines for leveraging electrospinning to advance Li-S battery technology and drive next-generation energy storage development.