We are trying to coat some cathode materials on Al-foil ( ex - LiFePO4 , S@CNT, etc). When we coated the Al foil with the cathode (ex - S@CNT) material , the cycling result was annoying. But the same Sulfur cathode was coated on Cu-foil, the result was satisfactory (except for obvious high voltage range > 3V). Same happens for other cathode materials also. We tried many thigs like drying the foil before coating in vacuum, and dry for longer time after coating. Nothing gave any improvrment in result.
What we noticed is, when doing CV for the S-cathode on Al, an irreversible reaction peak around 1 V was occurring. However this was not there for non-sulfur cathode like, LiFePO4 and Na3V2(PO4)3.
In the file attached below, the first one is when sulfur cathode is coated, and 2nd one is when NVP cathode is coated and worked for Li and Na battries respectively. all the corresponding electrolytes used were as usual as in the literature.
The coating composition was as usual as in literature - 80:10:10 material:CB:PVdF grinded with mortar and pestle for about 1.5 to 2h in NMP , with doctor blade technique with approx. loading of 1.5 to 2 mg/sqcm
What may be the problem..? please anybody explain this and give valuable suggetions.
where we are missing ? any additional steps should we follow , which in literature are not mentioned ?