Monolithically integrated NiCo2Se4 nanowire–carbon cloth cathode scaffolds for non-planar lithium-sulfur structural-battery integration

Abstract

Lithium–sulfur (Li–S) batteries are attractive for lightweight structural energy-storage systems because of their high theoretical energy density, but their integration into non-planar components is hindered by sulfur-cathode cracking, interfacial delamination, and contact loss under retained curvature and external loading. Here, we report a monolithically integrated NiCo₂Se₄ nanowire/carbon-cloth cathode scaffold (NCSe@CC) for curvature-retained Li–S pouch-cell integration. Direct growth and selenization of Ni–Co precursor nanowires on woven carbon cloth produce a binder-free, interconnected polar host that combines polysulfide-affinitive NiCo₂Se₄ surfaces with continuous electron-transport pathways along the carbon-fiber network. Compared with sulfur-loaded carbon cloth and precursor-coated carbon cloth, S/NCSe@CC exhibits enhanced polysulfide adsorption, reduced charge-transfer resistance, accelerated sulfur-redox kinetics, and improved electrochemical performance, delivering 1,544 mAh g^− 1 at 0.1 C with a polarization of 0.13 V. The cathode scaffold retains nanowire–fiber integration after 1,000 curvature-conditioning cycles at a radius of 2.5 mm, and pouch cells assembled with conditioned electrodes show discharge behavior comparable to pristine cells. Under cylindrical curvature, the pouch cell retains 94.0% of its flat-state capacity. Integration into cylindrical, oval, square, and drone-leg geometries further verifies electrical operability after geometric insertion and fixation. This work presents a materials-to-architecture strategy for interface-stable Li–S cathode scaffolds in non-planar structural energy-storage components.