Macroporous carbon coatings through carbonization of emulsion-templated poly(dicyclopentadiene) on metal substrates

Abstract In this article, we demonstrate the fabrication of thin and macroporous carbon coatings that adhere to various metal substrates such as nickel- or aluminum-based foils meshes. The coating process is a combination emulsion-templating doctor-blade method, which allows prepare up 350 µm thick poly(dicyclopentadiene) membranes with polyHIPE (polymerized high internal phase emulsions) architecture. Carbonization these directly on resulted in 30-µm-thick foamy retain highly porous architecture flexibility. Subsequently, foam-coated Ni-foils were filled elemental sulfur by melt diffusion technique. A supported loadings 65 wt%, obtaining cathodes for galvanostatic cycling experiments Li–S cells. latter revealed discharge capacities higher than 800 mA h −1 according mass. With our approach, final assembly electrodes greatly simplified because no binders conductive fillers are required. Graphical abstract