From Fundamental Understanding to Engineering Design of High-Performance Thick Electrodes for Scalable Energy-Storage Systems

A Flexible Multifunctional Cyanoethyl-Modified Bacterial Cellulose Nanofiber Framework for High-Energy and High-Power Density Aqueous Li-Ion Batteries

Aqueous rechargeable lithium-ion batteries (ARLIBs) are extensively researched due to their inherent safety, typical affordability, and potential high energy density. However, fabricating ARLIBs with both high energy density and power performance remains challenging. Herein, based on cyanoethyl-modified bacterial cellulose nanofibers (CBCNs), a multifunctional fast ion transport framework is developed to construct the flexible free-standing ARLIBs with high areal loading and excellent rate performance. Benefiting from the unique merits of CBCNs, such as ultra-high aspect ratio, excellent toughness, superior adhesion, good lithiophilicity and ideal stability, the flexible free-standing and highly robust electrodes are fabricated and exhibit a long-term stable cycling of 1200 cycles with a high specific capacity of 117 mAh∙g-1 at 15 C. Remarkably, the corresponding full cell with the free-standing high mass loading (45.5 mg∙cm-2) electrodes under the condition of ultra-low addition of battery binder demonstrates a cycle lifespan of over 1000 cycles with a specific capacity of 120 mAh∙g-1 and a capacity decay as low as 0.03% per cycle, which is far superior to those of almost all previous reports. This work provides a strategy for constructing ARLIBs with high energy density and power performance by introducing a unique fast ion transport nanofiber framework.

Activating Redox Kinetics of Li2S via Cu+, I- Co-Doping Toward High-Performance All-Solid-State Lithium Sulfide-Based Batteries

All-solid-state lithium sulfide-based batteries (ASSLSBs) have drawn much attention due to their intrinsic safety and excellent performance in overcoming the polysulfide shuttle effect. However, the sluggish kinetics of Li2S cathode severely impede commercial utilization. Here, a Cu+, I- co-doping strategy is employed to activate the kinetics of Li2S to construct high-performance ASSLSBs. The electronic conductivity and Li-ion diffusion coefficient of the co-doped Li2S are increased by five and two orders of magnitude, respectively. Cu+ as a redox medium greatly improves the reaction kinetics, which is supported by ex situ X-ray photoelectron spectroscopy. Density functional theory calculation (DFT) shows that Cu+, I- co-doping reduces the Li-ions diffusion energy barrier. The co-doped Li2S exhibits a remarkable improvement in capacity (1165.23 mAh g-1 (6.65 times that of pristine Li2S) at 0.02 C and 592.75 mAh g-1 at 2 C), and excellent cycling stability (84.58% capacity retention after 6200 cycles at 2 C) at room temperature. Moreover, an ASSLSB, fabricated with a lithium-free (Si─C) anode, obtains a high specific capacity of 1082.7 mAh g-1 at 0.05 C and 97% capacity retention after 400 cycles at 0.5 C. This work provides a broad prospect for the development of ASSLSBs with practical energy density exceeding that of traditional lithium-ion batteries.

One-Pot Hydrothermal-Derived rGO/MXene/Sulfur Composite Aerogels as Free-Standing Cathodes in Lithium-Sulfur Batteries

The confinement and high utilization of sulfur in the cathodes is critical for improved cycling performance of lithium-sulfur batteries. In this case one-pot hydrothermal strategy is developed to produce rGO/MXene/sulfur composite aerogels where sulfur is in situ trapped in the 3D rGO/MXene conductive skeleton. The optimized composite aerogels as free-standing cathodes delivery a specific capacity of 951 mAhg-1 after 100 cycles at 0.2 C with a low fading rate of 0.062 % per cycle. The excellent cycling performance is correlated with highly oxidized MXene and in situ formed sulfate/thiosulfate complex layer in the long-term cycles.

Immobile polyanionic backbone enables a 900-μm-thick electrode for compact energy storage with unprecedented areal capacitance

Thickening of electrodes is crucial for maximizing the proportion of active components and thus improving the energy density of practical energy storage cells. Nevertheless, trade-offs between electrode thickness and electrochemical performance persist because of the considerably increased ion transport resistance of thick electrodes. Herein, we propose accelerating ion transport through thick and dense electrodes by establishing an immobile polyanionic backbone within the electrode pores; and as a proof of concept, gel polyacrylic electrolytes as such a backbone are in situ synthesized for supercapacitors. During charge and discharge, protons rapidly hop among RCOO- sites for oriented transport, fundamentally reducing the effects of electrode tortuosity and polarization resulting from concentration gradients. Consequently, nearly constant ion transport resistance per unit thickness is achieved, even in the case of a 900-μm-thick dense electrode, leading to unprecedented areal capacitances of 14.85 F cm-2 at 1 mA cm-2 and 4.26 F cm-2 at 100 mA cm-2. This study provides an efficient method for accelerating ion transport through thick and dense electrodes, indicating a significant solution for achieving high energy density in energy storage devices, including but not limited to supercapacitors.

Delocalized electronic engineering of TiNb2O7 enables low temperature capability for high-areal-capacity lithium-ion batteries

High areal capacity and low-temperature ability are critical for lithium-ion batteries (LIBs). However, the practical operation is seriously impeded by the sluggish rates of mass and charge transfer. Herein, the active electronic states of TiNb2O7 material is modulated by dopant and O-vacancies for enhanced low-temperature dynamics. Femtosecond laser-based transient absorption spectroscopy is employed to depict carrier dynamics of TiNb2O7, which verifies the localized structure polarization accounting for reduced transport overpotential, facilitated electron/ion transport, and improved Li+ adsorption. At high-mass loading of 10 mg cm-2 and -30 °C, TNO-x@N microflowers exhibit stable cycling performance with 92.9% capacity retention over 250 cycles at 1 C (1.0-3.0 V, 1 C = 250 mA g-1). Even at -40 °C, a competitive areal capacity of 1.32 mAh cm-2 can be achieved. Such a fundamental understanding of the intrinsic structure-function put forward a rational viewpoint for designing high-areal-capacity batteries in cold regions.

Interpenetrated Structures for Enhancing Ion Diffusion Kinetics in Electrochemical Energy Storage Devices

The architectural design of electrodes offers new opportunities for next-generation electrochemical energy storage devices (EESDs) by increasing surface area, thickness, and active materials mass loading while maintaining good ion diffusion through optimized electrode tortuosity. However, conventional thick electrodes increase ion diffusion length and cause larger ion concentration gradients, limiting reaction kinetics. We demonstrate a strategy for building interpenetrated structures that shortens ion diffusion length and reduces ion concentration inhomogeneity. This free-standing device structure also avoids short-circuiting without needing a separator. The feature size and number of interpenetrated units can be adjusted during printing to balance surface area and ion diffusion. Starting with a 3D-printed interpenetrated polymer substrate, we metallize it to make it conductive. This substrate has two individually addressable electrodes, allowing selective electrodeposition of energy storage materials. Using a Zn//MnO2 battery as a model system, the interpenetrated device outperforms conventional separate electrode configurations, improving volumetric energy density by 221% and exhibiting a higher capacity retention rate of 49% compared to 35% at temperatures from 20 to 0 °C. Our study introduces a new EESD architecture applicable to Li-ion, Na-ion batteries, supercapacitors, etc.

Optimizing Li Plating Behavior via Controlling Areal Capacity of a Cathode for Cycling Stability on 600 W h kg-1 Lithium-Metal Batteries

To meet the requirements of long-range electric vehicles and aviation, the high-mass-loading electrode with high areal capacity is a promising solution to realize ultrahigh-energy lithium-metal batteries (LMBs). However, enabling the operation of high mass loading with a long cycling life is still a challenge without in-depth investigation. Herein, we figured out that the polarization appearing in the cycled lithium-metal anodes (LMAs) is responsible for the poor cycling of LMBs with high mass loading. Moreover, the origin of fast degradation of LMAs is affected by mass loading through the Li plating process, which is decided by the Li plating morphology. Hence, manipulating the mass loading can directly promote lithium reversibility and further mitigate cell polarization in LMBs, endowing high-mass-loading LMBs with excellent cycling stability. Consequently, we achieved an ultrahigh energy density (605 W h kg-1) of a 10.1 A h pouch cell with an excellent retention of 91.7% capacity and 86% energy after 50 cycles. The feasible strategy points out a promising approach for designing high-energy-density LMBs in the future.

3D Dense Encapsulated Architecture of 2D Bi Nanosheets Enabling Potassium-Ion Storage with Superior Volumetric and Areal Capacities

2D alloy-based anodes show promise in potassium-ion batteries (PIBs). Nevertheless, their low tap density and huge volume expansion cause insufficient volumetric capacity and cycling stability. Herein, a 3D highly dense encapsulated architecture of 2D-Bi nanosheets (HD-Bi@G) with conducive elastic networks and 3D compact encapsulation structure of 2D nano-sheets are developed. As expected, HD-Bi@G anode exhibits a considerable volumetric capacity of 1032.2 mAh cm-3, stable long-life span with 75% retention after 2000 cycles, superior rate capability of 271.0 mAh g-1 at 104 C, and high areal capacity of 7.94 mAh cm-2 (loading: 24.2 mg cm-2) in PIBs. The superior volumetric and areal performance mechanisms are revealed through systematic kinetic investigations, ex situ characterization techniques, and theorical calculation. The 3D high-conductivity elastic network with dense encapsulated 2D-Bi architecture effectively relieves the volume expansion and pulverization of Bi nanosheets, maintains internal 2D structure with fast kinetics, and overcome sluggish ionic/electronic diffusion obstacle of ultra-thick, dense electrodes. The uniquely encapsulated 2D-nanosheet structure greatly reduces K+ diffusion energy barrier and accelerates K+ diffusion kinetics. These findings validate a feasible approach to fabricate 3D dense encapsulated architectures of 2D-alloy nanosheets with conductive elastic networks, enabling the design of ultra-thick, dense electrodes for high-volumetric-energy-density energy storage.

Unveiling Confinement Engineering for Achieving High-Performance Rechargeable Batteries

The confinement effect, restricting materials within nano/sub-nano spaces, has emerged as an innovative approach for fundamental research in diverse application fields, including chemical engineering, membrane separation, and catalysis. This confinement principle recently presents fresh perspectives on addressing critical challenges in rechargeable batteries. Within spatial confinement, novel microstructures and physiochemical properties have been raised to promote the battery performance. Nevertheless, few clear definitions and specific reviews are available to offer a comprehensive understanding and guide for utilizing the confinement effect in batteries. This review aims to fill this gap by primarily summarizing the categorization of confinement effects across various scales and dimensions within battery systems. Subsequently, the strategic design of confinement environments is proposed to address existing challenges in rechargeable batteries. These solutions involve the manipulation of the physicochemical properties of electrolytes, the regulation of electrochemical activity, and stability of electrodes, and insights into ion transfer mechanisms. Furthermore, specific perspectives are provided to deepen the foundational understanding of the confinement effect for achieving high-performance rechargeable batteries. Overall, this review emphasizes the transformative potential of confinement effects in tailoring the microstructure and physiochemical properties of electrode materials, highlighting their crucial role in designing novel energy storage devices.

Efficient Ion Percolating Network for High-Performance All-Solid-State Cathodes

All-solid-state lithium batteries (ASSLBs) face critical challenges of low cathode loading and poor rate performances, which handicaps their energy/power densities. The widely-accepted aim of high ionic conductivity and low interfacial resistance seems insufficient to overcome these challenges. Here, it is revealed that an efficient ion percolating network in the cathode exerts a more critical influence on the electrochemical performance of ASSLBs. By constructing vertical alignment of Li0.35La0.55TiO3 nanowires (LLTO NWs) in solid-state cathode through magnetic manipulation, the ionic conductivity of the cathode increases twice compared with the cathode consisted of randomly distributed LLTO NWs. The all-solid-state LiFePO4/Li cells using poly(ethylene oxide) as the electrolyte is able to deliver high capacities of 151 mAh g-1 (2 C) and 100 mAh g-1 (5 C) at 60 °C, and a room-temperature capacity of 108 mAh g-1 can be achieved at a charging rate of 2 C. Furthermore, the cell can reach a high areal capacity of 3 mAh cm-2 even with a practical LFP loading of 20 mg cm-2. The universality of this strategy is also presented showing the demonstration in LiNi0.8Co0.1Mn0.1O2 cathodes. This work offers new pathways for designing ASSLBs with improved energy/power densities.

Unleashing the high energy potential of zinc-iodide batteries: high-loaded thick electrodes designed with zinc iodide as the cathode

The realization of high energy is of great importance to unlock the practical potential of zinc-iodine batteries. However, significant challenges, such as low iodine loading (mostly less than 50 wt%), restricted iodine reutilization, and severe structural pulverization during cycling, compromise its intrinsic features. This study introduces an optimized, fully zincified zinc iodide loaded onto a hierarchical carbon scaffold with high active component loading and content (82 wt%) to prepare a thick cathode for enabling high-energy Zn-I2 batteries. The synergistic interactions between nitrogen heteroatoms and cobalt nanocrystals within the porous matrix not only provide forceful chemisorption to lock polyiodide intermediates but also invoke the electrocatalytic effects to manipulate efficient iodine conversion. The ZnI2 cathode could effectively alleviate continuous volumetric expansion and maximize the utilization of active species. The electrochemical examinations confirm the thickness-independent battery performance of assembled Zn-I2 cells due to the ensemble effect of composite electrodes. Accordingly, with a thickness of 300 μm and ZnI2 loading of up to 20.5 mg cm-2, the cathode delivers a specific capacity of 92 mA h gcathode-1 after 2000 cycles at 1C. Moreover, the Zn-I2 pouch cell with ZnI2 cathode has an energy density of 145 W h kgcathode-1 as well as a stable long cycle life.

Woven fabric-based separators with low tortuosity for sodium-ion batteries

In order to achieve high-performance and stable sodium-ion batteries, numerous attempts have been made to construct continuous ion transport pathways, in which a separator is one of the key components that affects the battery performance. In this study, a novel low-tortuosity woven fabric separator is fabricated by combining a weaving technique with a cellulose-solution method, followed by an infusion of a TEMPO-oxidized bacterial cellulose slurry into woven fabric substrates. The macropores in the fabric combine with the micropores in the oxidized bacterial cellulose to form a separator with a suitable pore structure and low tortuosity, forming a continuous sodium ion transport channel within the sodium-ion battery and effectively enhancing ion transport dynamics. The results show that, compared with a commercial polypropylene separator, the TEMPO-oxidized bacterial cellulose-woven fabric separator has a special weaving structure and lower tortuosity (0.77), as well as significant advantages in tensile strength (3.07 MPa), ionic conductivity (1.15 mS c), ionic transfer number (0.75), thermal stability, and electrochemical stability. This novel and simple preparation method provides new possibilities for achieving high-performance separators of sodium-ion batteries through rational structural design by textile technology.

10 μm-Level TiNb2 O7 Secondary Particles for Fast-Charging Lithium-Ion Batteries

TiNb2 O7 with Wadsley-Roth phase delivers double theoretical specific capacity and similar working potential in comparison to spinel Li4 Ti5 O12 , the commercial high-rate anode material, and thus can enable much higher energy density of lithium-ion batteries. However, the inter-particle resistance within the high-mass-loading TiNb2 O7 electrode would impede the capacity release for practical application, especially under fast-charging conditions. Herein, 10-20 μm-size carbon-coated TiNb2 O7 secondary particle (SP-TiNb2 O7 ) consisting of initial micro-scale TiNb2 O7 particles (MP-TiNb2 O7 ) was fabricated. The high crystallinity of active material could enable fast-charge diffusion and electrochemical reaction rate within particles, and the small number of stacking layers of SP-TiNb2 O7 could reduce the large inter-particle resistance that regular particle electrode often possess and achieve high compaction density of electrodes with high mass loading. The investigation on materials structure and electrochemical reaction kinetics verified the advances of the as-fabricated SP-TiNb2 O7 in achieving superior electrochemical performance. The SP-TiNb2 O7 exhibited high reversible capacity of 292.7 mAh g-1 in the potential range of 1-3 V (Li+ /Li) at 0.1 C, delivering high-capacity release of 94.3 %, and high capacity retention of 86 % at 0.5 C for 250 cycles in half cell configuration. Particularly, the advances of such an anode were verified in practical 5 Ah-level laminated full pouch cell. The as-assembled LiFePO4 ||TiNb2 O7 full cell exhibited a high capacity of 5.08 Ah at high charging rate of 6 C (77.9 % of that at 0.2 C of 6.52 Ah), as well as an ultralow capacity decay rate of 0.0352 % for 250 cycles at 1 C, suggesting the great potential for practical fast-charging lithium-ion batteries.

Polymeric Binder Design for Sustainable Lithium-Ion Battery Chemistry

The design of binders plays a pivotal role in achieving enduring high power in lithium-ion batteries (LIBs) and extending their overall lifespan. This review underscores the indispensable characteristics that a binder must possess when utilized in LIBs, considering factors such as electrochemical, thermal, and dispersion stability, compatibility with electrolytes, solubility in solvents, mechanical properties, and conductivity. In the case of anode materials, binders with robust mechanical properties and elasticity are imperative to uphold electrode integrity, particularly in materials subjected to substantial volume changes. For cathode materials, the selection of a binder hinges on the crystal structure of the cathode material. Other vital considerations in binder design encompass cost effectiveness, adhesion, processability, and environmental friendliness. Incorporating low-cost, eco-friendly, and biodegradable polymers can significantly contribute to sustainable battery development. This review serves as an invaluable resource for comprehending the prerequisites of binder design in high-performance LIBs and offers insights into binder selection for diverse electrode materials. The findings and principles articulated in this review can be extrapolated to other advanced battery systems, charting a course for developing next-generation batteries characterized by enhanced performance and sustainability.

Understanding How the Suppression of Insertion-Induced Phase Transitions Leads to Fast Charging in Nanoscale LixMoO2

Fast-charging Li-ion batteries are technologically important for the electrification of transportation and the implementation of grid-scale storage, and additional fundamental understanding of high-rate insertion reactions is necessary to overcome current rate limitations. In particular, phase transformations during ion insertion have been hypothesized to slow charging. Nanoscale materials with modified transformation behavior often show much faster kinetics, but the mechanism for these changes and their specific contribution to fast-charging remain poorly understood. In this work, we combine operando synchrotron X-ray diffraction with electrochemical kinetics analyses to illustrate how nanoscale crystal size leads to suppression of first-order insertion-induced phase transitions and their negative kinetic effects in MoO2, a tunnel structure host material. In electrodes made with micrometer-scale particles, large first-order phase transitions during cycling lower capacity, slow charge storage, and decrease cycle life. In medium-sized nanoporous MoO2, the phase transitions remain first-order, but show a considerably smaller miscibility gap and shorter two-phase coexistence region. Finally, in small MoO2 nanocrystals, the structural evolution during lithiation becomes entirely single-phase/solid-solution. For all nanostructured materials, the changes to the phase transition dynamics lead to dramatic improvements in capacity, rate capability, and cycle life. This work highlights the continuous evolution from a kinetically hindered battery material in bulk form to a fast-charging, pseudocapacitive material through nanoscale size effects. As such, it provides key insight into how phase transitions can be effectively controlled using nanoscale size and emphasizes the importance of these structural dynamics to the fast rate capability observed in nanostructured electrode materials.

Optical Approach for Mapping the Intercalation Capacity of Porous Electrodes

The intercalation capacity of a porous electrode in real batteries is not uniform spatially due to the inevitable structural and compositional inhomogeneity and site-dependent ion and electron transport features. Reliable methods to quantify the capacity distribution are highly desirable but absent so far in battery research. In this paper, a novel optical technique, oblique incident reflection difference (OIRD), was employed to monitor in situ the electrochemical ion (de)intercalation behavior of Prussian blue analogue (PBA) porous films. The OIRD signal responded synchronously to the ion (de)intercalation, and the change in the OIRD signal (ΔI) was positively correlated with the local electrochemical capacity, thereby enabling mapping of the spatially resolved ion storage capacity of the films. Optical analysis further showed that the OIRD response originated from the ion (de)intercalation-induced dielectric constant change of PBA films. This work therefore offers an intriguing in situ and spatially resolved tool for the study of rechargeable batteries.

Scalable Fast-Charging Aligned Battery Electrodes Enabled by Bidirectional Freeze-Casting

Over the past few years, lithium-ion batteries have been extensively adopted in electric transportation. Meanwhile, the energy density of lithium-ion battery packs has been significantly improved, thanks to the development of materials science and packing technology. Despite recent progress in electric vehicle cruise ranges, the increase in battery charging rates remains a pivotal problem in electrodes with commercial-level mass loadings. Herein, we develop a scalable strategy that incorporates bidirectional freeze-casting into the conventional tape-casting method to fabricate energy-dense, fast-charging battery electrodes with aligned structures. The vertically lamellar architectures in bidirectional freeze-cast electrodes can be roll-to-roll calendered, forming the tilted yet aligned channels. These channels enable directional pathways for efficient lithium-ion transport in electrolyte-filled pores and thus realize fast-charging capabilities. In this work, we not only provide a simple yet controllable approach for building the aligned electrode architectures for fast charging but also highlight the significance of scalability in electrode fabrication considerations.

Regulating electrostatic phenomena by cationic polymer binder for scalable high-areal-capacity Li battery electrodes

Despite the enormous interest in high-areal-capacity Li battery electrodes, their structural instability and nonuniform charge transfer have plagued practical application. Herein, we present a cationic semi-interpenetrating polymer network (c-IPN) binder strategy, with a focus on the regulation of electrostatic phenomena in electrodes. Compared to conventional neutral linear binders, the c-IPN suppresses solvent-drying-induced crack evolution of electrodes and improves the dispersion state of electrode components owing to its surface charge-driven electrostatic repulsion and mechanical toughness. The c-IPN immobilizes anions of liquid electrolytes inside the electrodes via electrostatic attraction, thereby facilitating Li+ conduction and forming stable cathode-electrolyte interphases. Consequently, the c-IPN enables high-areal-capacity (up to 20 mAh cm-2) cathodes with decent cyclability (capacity retention after 100 cycles = 82%) using commercial slurry-cast electrode fabrication, while fully utilizing the theoretical specific capacity of LiNi0.8Co0.1Mn0.1O2. Further, coupling of the c-IPN cathodes with Li-metal anodes yields double-stacked pouch-type cells with high energy content at 25 °C (376 Wh kgcell-1/1043 Wh Lcell-1, estimated including packaging substances), demonstrating practical viability of the c-IPN binder for scalable high-areal-capacity electrodes.

Ultrafine FeF3·0.33H2O Nanocrystal-Doped Graphene Aerogel Cathode Materials for Advanced Lithium-Ion Batteries

FeF₃ has been extensively studied as an alternative positive material owing to its superior specific capacity and low cost, but the low conductivity, large volume variation, and slow kinetics seriously hinder its commercialization. Here, we propose the in situ growth of ultrafine FeF₃·0.33H₂O NPs on a three-dimensional reduced graphene oxide (3D RGO) aerogel with abundant pores by a facile freeze drying process followed by thermal annealing and fluorination. Within the FeF₃·0.33H₂O/RGO composites, the three-dimensional (3D) RGO aerogel and hierarchical porous structure ensure rapid diffusion of electrons/ions within the cathode, enabling good reversibility of FeF₃. Benefiting from these advantages, a superior cycle behavior of 232 mAh g^-1 under 0.1C over 100 cycles as well as outstanding rate performance is achieved. These results provide a promising approach for advanced cathode materials for Li-ion batteries.

Inspired by Wood: Thick Electrodes for Supercapacitors

The emergence and development of thick electrodes provide an efficient way for the high-energy-density supercapacitor design. Wood is a kind of biomass material with porous hierarchical structure, which has the characteristics of a straight channel, uniform pore structure, good mechanical strength, and easy processing. The wood-inspired low-tortuosity and vertically aligned channel architecture are highly suitable for the construction of thick electrochemical supcapacitor electrodes with high energy densities. This review summarizes the design concepts and processing parameters of thick electrode supercapacitors inspired by natural woods, including wood-based pore structural design regulation, electric double layer capacitances (EDLCs)/pseudocapacitance construction, and electrical conductivity optimization. In addition, the optimization strategies for preparing thick electrodes with wood-like structures (e.g., 3D printing, freeze-drying, and aligned-low tortuosity channels) are also discussed in detail. Further, this review presents current challenges and future trends in the design of thick electrodes for supercapacitors with wood-inspired pore structures. As a guideline, the brilliant blueprint optimization will promote sustainable development of wood-inspired structure design for thick electrodes and broaden the application scopes.

Controlled Isotropic Canalization of Microsized Silicon Enabling Stable High-Rate and High-Loading Lithium Storage

Silicon is attractive for lithium-ion batteries and beyond but suffers large volume change upon cycling. Hierarchical tactics show promise yet lack control over the unit construction and arrangement, limiting stability improvement at the practical level. Here, a protocol is developed as controlled isotropic canalization of microsized silicon. Distinct from the existing strategies, it involves isotropic canalization by honeycomb-like radial arrangement of silicon nanosheets, and canal consolidation by controlled dual bonding of silicon with carbon. The proof-of-concept nitrogen-doped carbon dual-bonded silicon honeycomb-like microparticles, specifically with a medium density of CNSi and COSi bonds, exhibit stable cycling impressively at high rates and industrial-scale loadings. Two key issues involve isotropic canalization facilitating ion transport in all directions of individual granules and controlled consolidation conferring selective ion permeation and securing charge transport. The study highlights the configurational isotropy and interfacial bonding density, and provides insight into rational design and manufacture of silicon and others with industry-viable features.

Structured Electrode Additive Manufacturing for Lithium-Ion Batteries

As the world increasingly swaps fossil fuels, significant advances in lithium-ion batteries have occurred over the past decade. Though demand for increased energy density with mechanical stability continues to be strong, attempts to use traditional ink-casting to increase electrode thickness or geometric complexity have had limited success. Here, we combined a nanomaterial orientation with 3D printing and developed a dry electrode processing route, structured electrode additive manufacturing (SEAM), to rapidly fabricate thick electrodes with an out-of-plane aligned architecture with low tortuosity and mechanical robustness. SEAM uses a shear flow of molten feedstock to control the orientation of the anisotropic materials across nano to macro scales, favoring Li-ion transport and insertion. These structured electrodes with 1 mm thickness have more than twice the specific capacity at 1 C compared to slurry-cast electrodes and have higher mechanical properties (compressive strength of 0.84 MPa and modulus of 5 MPa) than other reported 3D-printed electrodes.

Vertically assembled nanosheet networks for high-density thick battery electrodes

As one of the prevailing energy storage systems, lithium-ion batteries (LIBs) have become an essential pillar in electric vehicles (EVs) during the past decade, contributing significantly to a carbon-neutral future. However, the complete transition to electric vehicles requires LIBs with yet higher energy and power densities. Here, we propose an effective methodology via controlled nanosheet self-assembly to prepare low-tortuosity yet high-density and high-toughness thick electrodes. By introducing a delicate densification in a three-dimensionally interconnected nanosheet network to maintain its vertical architecture, facile electron and ion transports are enabled despite their high packing density. This dense and thick electrode is capable of delivering a high volumetric capacity >1,600 mAh cm-3, with an areal capacity up to 32 mAh cm-2, which is among the best reported in the literature. The high-performance electrodes with superior mechanical and electrochemical properties demonstrated in this work provide a potentially universal methodology in designing advanced battery electrodes with versatile anisotropic properties.

NMR Study of Lithium Transport in Liquid-Ceramic Hybrid Solid Composite Electrolytes

Despite their high conductivity, factors such as being fragile enough to face processing issues and interfacial incompatibility with lithium electrodes are some of the main drawbacks hindering the commercialization of inorganic (mainly oxide-based) solid electrolytes for use in all-solid-state lithium batteries. To this end, strategies such as the addition of solid polymer electrolytes have been proposed to improve the electrode-electrolyte interface. Hybrid electrolytes, which are usually composed of ceramic particles dispersed in a polymer, generally have a better affinity with electrodes and higher ionic conductivity than pure inorganic electrolytes. However, a significant downside of this strategy is that differences in lithium transportability between electrolyte layers can result in the formation of a high interfacial energy barrier across the cell. One strategy to ensure sufficient "wetting" of ceramics is to incorporate a liquid electrolyte directly into the solid inorganic electrolyte resulting in the formation of a hybrid liquid-ceramic electrolyte. To this end, liquid-ceramic hybrid electrolytes were prepared by adding LiG₄TFSI, a solvate ionic liquid (SIL), to garnet, NASICON, and perovskite-type ceramic electrolytes. Although SIL addition resulted in increased ionic conductivity, comparisons between the pure SIL and the hybrid systems revealed that improvements were due to the SIL alone. A thorough investigation of the hybrid systems by solid-state nuclear magnetic resonance (NMR) revealed little to no lithium exchange between the ceramic and the SIL. This confirms that lithium conductivity preferentially occurs through the SIL in these hybrid systems. The primary role of the ceramic is to provide mechanical strength.

Tortuosity Engineering for Improved Charge Storage Kinetics in High-Areal-Capacity Battery Electrodes

The increasing demands of electronic devices and electric transportation necessitate lithium-ion batteries with simultaneous high energy and power capabilities. However, rate capabilities are often limited in high-loading electrodes due to the lengthy and tortuous ion transport paths with their electrochemical behaviors governed by complicated electrode architectures still elusive. Here, we report the electrode-level tortuosity engineering design enabling improved charge storage kinetics in high-energy electrodes. Both high areal capacity and high-rate capability can be achieved beyond the practical level of mass loadings in electrodes with vertically oriented architectures. The electrochemical properties in electrodes with various architectures were quantitatively investigated through correlating the characteristic time with tortuosity. The lithium-ion transport kinetics regulated by electrode architectures was further studied via combining the three-dimensional electrode architecture visualization and simulation. The tortuosity-controlled charge storage kinetics revealed in this study can be extended to general electrode systems and provide useful design consideration for next-generation high-energy/power batteries.

Durable Zn-ion hybrid capacitors using 3D printed carbon composites

Rechargeable Zn-ion hybrid capacitors (ZHCs) have gained considerable attention towards future energy storage applications owing to their non-flammable nature, high abundance of raw materials and remarkable energy storage performance. However, the uncontrolled growth of dendrites, interfacial corrosion of Zn anodes and limited mass loading of cathode materials, hinders their practical applicability. Herein, we demonstrate ZHCs with enhanced capacity and durability using a synergistic combination of a hybrid-ion electrolyte and a high-mass loading three-dimensionally (3D) printed graphene-carbon nanotube (Gr-C) cathode. The hybrid electrolyte composed of NaCl and ZnSO4, features higher ionic conductivity and lower pH compared with pristine ZnSO4, which enable uniform plating/stripping of Zn2+ ions on Zn anode, as demonstrated by in situ electrochemical and ex situ ToF-SIMs characterizations. Additionally, the multi-layered 3D Gr-C composite electrodes in ZHCs enable higher energy storage performance due to their porous architectures, high ion accessibility and dual-ion charge storage contributions. As a result, the 3D Gr-C//Zn cell unveiled a maximum capacity of 0.84 mA h cm-2 at 3 mA cm-2 with a high life cycle (78.7% at 20 mA cm-2) compared to the pristine electrolyte-based ZHCs (0.72 mA h cm-2 and 14.8%). The rapid rate measurements that we propose along with benchmarked energy density (0.87 mW h cm-2) and power density (31.7 mW cm-2) of hybrid electrolyte-based 3D Gr-C//Zn, pave the way for the development of dendrite-free and highly durable 3D energy storage devices.

Gradient Design for High-Energy and High-Power Batteries

Charge transport is a key process that dominates battery performance, and the microstructures of the cathode, anode, and electrolyte play a central role in guiding ion and/or electron transport inside the battery. Rational design of key battery components with varying microstructure along the charge-transport direction to realize optimal local charge-transport dynamics can compensate for reaction polarization, which accelerates electrochemical reaction kinetics. Here, the principles of charge-transport mechanisms and their decisive role in battery performance are presented, followed by a discussion of the correlation between charge-transport regulation and battery microstructure design. The design strategies of the gradient cathodes, lithium-metal anodes, and solid-state electrolytes are summarized. Future directions and perspectives of gradient design are provided at the end to enable practically accessible high-energy and high-power-density batteries.

Balancing Electrolyte Donicity and Cathode Adsorption Capacity for High-Performance LiS Batteries

LiS batteries with high theoretical capacity are attracting attention as next-generation energy storage systems. Much effort has been devoted to the introduction of cathode materials with strong adsorption to sulfide species, but it is presented that this selection should be refined in the application of high donicity electrolytes. The oxides with different adsorption capacities are explored while controlling the electrolyte donicity, confirming the trade-off effect between the donicity and the adsorption capacity for sulfur conversion. Specifically, a cathode substrate containing oxide nanoparticles of MgO, NiO, Fe₂ O₃ , Co₃ O₄ , and V₂ O₅ is prepared with spectra in adsorption capacity as well as low and high donicity electrolytes by controlling the concentration of LiNO₃ salt. Strong adsorbent oxides such as Co₃ O₄ and V₂ O₅ cause competitive adsorption of electrolyte salts in high donicity electrolytes, resulting in poor cell performance. High cell performance is achieved on weakly adsorbing oxides of MgO or NiO with high donicity electrolytes; the MgO-containing cathode cell delivers a high discharge capacity of 1394 mAh g^-1 at 0.2 C. It is believed that understanding the interactions between electrolytes and adsorbent substrates will be the cornerstone of high-performance LiS batteries.

Redox-homogeneous, gel electrolyte-embedded high-mass-loading cathodes for high-energy lithium metal batteries

Lithium metal batteries have higher theoretical energy than their Li-ion counterparts, where graphite is used at the anode. However, one of the main stumbling blocks in developing practical Li metal batteries is the lack of cathodes with high-mass-loading capable of delivering highly reversible redox reactions. To overcome this issue, here we report an electrode structure that incorporates a UV-cured non-aqueous gel electrolyte and a cathode where the LiNi0.8Co0.1Mn0.1O2 active material is contained in an electron-conductive matrix produced via simultaneous electrospinning and electrospraying. This peculiar structure prevents the solvent-drying-triggered non-uniform distribution of electrode components and shortens the time for cell aging while improving the overall redox homogeneity. Moreover, the electron-conductive matrix eliminates the use of the metal current collector. When a cathode with a mass loading of 60 mg cm−2 is coupled with a 100 µm thick Li metal electrode using additional non-aqueous fluorinated electrolyte solution in lab-scale pouch cell configuration, a specific energy and energy density of 321 Wh kg−1 and 772 Wh L−1 (based on the total mass of the cell), respectively, can be delivered in the initial cycle at 0.1 C (i.e., 1.2 mA cm−2) and 25 °C.

Gradient Architecture Design in Scalable Porous Battery Electrodes

Because it has been demonstrated to be effective toward faster ion diffusion inside the pore space, low-tortuosity porous architecture has become the focus in thick electrode designs, and other possibilities are rarely investigated. To advance current understanding in the structure-affected electrochemistry and to broaden horizons for thick electrode designs, we present a gradient electrode design, where porous channels are vertically aligned with smaller openings on one end and larger openings on the other. With its 3D morphology carefully visualized by Raman mapping, the electrochemical properties between opposite orientations of the gradient electrodes are compared, and faster energy storage kinetics is found in larger openings and more concentrated active material near the separator. As further verified by simulation, this study on gradient electrode design deepens the knowledge of structure-related electrochemistry and brings perspectives in high-energy battery electrode designs.

Integrating Dually Encapsulated Si Architecture and Dense Structural Engineering for Ultrahigh Volumetric and Areal Capacity of Lithium Storage

High-theoretical-capacity silicon anodes hold promise in lithium-ion batteries (LIBs). Nevertheless, their huge volume expansion (∼300%) and poor conductivity show the need for the simultaneous introduction of low-density conductive carbon and nanosized Si to conquer the above issues, yet they result in low volumetric performance. Herein, we develop an integration strategy of a dually encapsulated Si structure and dense structural engineering to fabricate a three-dimensional (3D) highly dense Ti₃C₂T_x MXene and graphene dual-encapsulated Si monolith architecture (HD-Si@Ti₃C₂T_x@G). Because of its high density (1.6 g cm^-3), high conductivity (151 S m^-1), and 3D dense dual-encapsulated Si architecture, the resultant HD-Si@Ti₃C₂T_x@G monolith anode displays an ultrahigh volumetric capacity of 5206 mAh cm^-3 (gravimetric capacity: 2892 mAh g^-1) at 0.1 A g^-1 and a superior long lifespan of 800 cycles at 1.0 A g^-1. Notably, the thick and dense monolithic anode presents a large areal capacity of 17.9 mAh cm^-2. In-situ TEM and ex-situ SEM techniques, and systematic kinetics and structural stability analysis during cycling demonstrate that such superior volumetric and areal performances stem from its dual-encapsulated Si architecture by the 3D conductive and elastic networks of MXene and graphene, which can provide fast electron and ion transfer, effective volume buffer, and good electrolyte permeability even with a thick electrode, whereas the dense structure results in a large volumetric performance. This work offers a simple and feasible strategy to greatly improve the volumetric and areal capacity of alloy-based anodes for large-scale applications via integrating a dual-encapsulated strategy and dense-structure engineering.

Low-Tortuosity Thick Electrodes with Active Materials Gradient Design for Enhanced Energy Storage

The ever-growing energy demand of modern society calls for the development of high-loading and high-energy-density batteries, and substantial research efforts are required to optimize electrode microstructures for improved energy storage. Low-tortuosity architecture proves effective in promoting charge transport kinetics in thick electrodes; however, heterogeneous electrochemical mass transport along the depth direction is inevitable, especially at high C-rates. In this work, we create an active material gradient in low-tortuosity electrodes along ion-transport direction to compensate for uneven reaction kinetics and the nonuniform lithiation/delithiation process in thick electrodes. The gradual decrease of active material concentration from the separator to the current collector reduces the integrated ion diffusion distance and accelerates the electrochemical reaction kinetics, leading to improved rate capabilities. The structure advantages combining low-tortuosity pores and active material gradient offer high mass loading (60 mg cm^-2) and enhanced performance. Comprehensive understanding of the effect of active material gradient architecture on electrode kinetics has been elucidated by electrochemical characterization and simulations, which can be useful for development of batteries with high-energy/power densities.

Water-Processable and Multiscale-Designed Vanadium Oxide Cathodes with Predominant Zn2+ Intercalation Pseudocapacitance toward High Gravimetric/Areal/Volumetric Capacity

Layered vanadium oxides have great potential as cathode materials for recently surged aqueous zinc-ion batteries (AZIBs). However, achieving high energy/power densities simultaneously is challenging, and side reactions related to more frequently than disclosed Zn²⁺ /proton co-insertion mechanism aggravate stability concerns. Herein, an engineered binder-free cathode configuration based on water-processable and high packing-density sheet-shaped composites of carbon nanotubes network, surface poly(3,4-ethylenedioxythiophene) (PEDOT) bridging coating, and ultrasmall PEDOT-intercalated V₂ O₅ nanoflakes is developed, and therein, large pseudocapacitance via predominant (≈91%) Zn²⁺ intercalation is revealed. Besides competitive gravimetric/areal capacity, the binder-free cathodes exhibit high volumetric capacity of 1106.1 mAh cm^-3 and high-rate capability of 180.0 mA g^-1 at 30 A g^-1 as well as long-cycling stability. Such combined level of performance and unwanted reaction mechanism are attributed to the contained multiscale material/electrode design formula from crystal structure modification to 3D architecture construction of whole electrode, which endows the binder-free cathodes with abundant accessible sites for Zn²⁺ storage, but the least hydroxyl terminated surface for H⁺ insertion, as well as highly conductive network for electron transfer and fast Zn²⁺ diffusion kinetics throughout the electrode. Combined with scalable fabrication protocols, this study opens up great opportunities for high-performance vanadium oxide cathodes practically applicable to AZIBs.

Ultrahigh-Capacity and Scalable Architected Battery Electrodes via Tortuosity Modulation

A thick electrode with high areal capacity is a straightforward approach to maximize the energy density of batteries, but the development of thick electrodes suffers from both fabrication challenges and electron/ion transport limitations. In this work, a low-tortuosity LiFePO₄ (LFP) electrode with ultrahigh loadings of active materials and a highly efficient transport network was constructed by a facile and scalable templated phase inversion method. The instant solidification of polymers during phase inversion enables the fabrication of ultrathick yet robust electrodes. The open and aligned microchannels with interconnected porous walls provide direct and short ion transport pathways, while the encapsulation of active materials in the carbon framework offers a continuous pathway for electron transport. Benefiting from the structural advantages, the ultrathick bilayer LiFePO₄ electrodes (up to 1.2 mm) demonstrate marked improvements in rate performance and cycling stability under high areal loadings (up to 100 mg cm^-2). Simulation and operando structural characterization also reveal fast transport kinetics. Combined with the scalable fabrication, our proposed strategy presents an effective alternative for designing practical high energy/power density electrodes at low cost.

Design of Scalable, Next-Generation Thick Electrodes: Opportunities and Challenges

Lithium-ion battery electrodes are on course to benefit from current research in structure re-engineering to allow for the implementation of thicker electrodes. Increasing the thickness of a battery electrode enables significant improvements in gravimetric energy density while simultaneously reducing manufacturing costs. Both metrics are critical if the transition to sustainable transport systems is to be fully realized commercially. However, significant barriers exist that prevent the use of such microstructures: performance issues, manufacturing challenges, and scalability all remain open areas of research. In this Perspective, we discuss the challenges in adapting current manufacturing processes for thick electrodes and the opportunities that pore engineering presents in order to design thicker and better electrodes while simultaneously considering long-term performance and scalability.

Building Efficient Ion Pathway in Highly Densified Thick Electrodes with High Gravimetric and Volumetric Energy Densities

A common practice in thick electrode design is to increase porosity to boost charge transport kinetics. However, a high porosity offsets the advantages of thick electrodes in both gravimetric and volumetric energy densities. Here we design a freestanding thick electrode composed of highly densified active material regions connected by continuous electrolyte-buffering voids. By wet calendering of the phase-inversion electrode, the continuous compact active material region and continuous ion transport network are controllably formed. Rate capabilities and cycling stability at high LiFePO₄ loading of 126 mg cm^-2 were achieved for the densified cathode with porosity as low as 38%. The decreased porosity and efficient void utilization enable high gravimetric/volumetric energy densities of 330 Wh kg^-1 and 614 Wh L^-1, as well as improved power densities. The versatility of this method and the industrial compatible "roll-to-roll" fabrication demonstrate an important step toward the practical application of thick electrodes.

Thickness-independent scalable high-performance Li-S batteries with high areal sulfur loading via electron-enriched carbon framework

Increasing the energy density of lithium-sulfur batteries necessitates the maximization of their areal capacity, calling for thick electrodes with high sulfur loading and content. However, traditional thick electrodes often lead to sluggish ion transfer kinetics as well as decreased electronic conductivity and mechanical stability, leading to their thickness-dependent electrochemical performance. Here, free-standing and low-tortuosity N, O co-doped wood-like carbon frameworks decorated with carbon nanotubes forest (WLC-CNTs) are synthesized and used as host for enabling scalable high-performance Li-sulfur batteries. EIS-symmetric cell examinations demonstrate that the ionic resistance and charge-transfer resistance per unit electro-active surface area of S@WLC-CNTs do not change with the variation of thickness, allowing the thickness-independent electrochemical performance of Li-S batteries. With a thickness of up to 1200 µm and sulfur loading of 52.4 mg cm-2, the electrode displays a capacity of 692 mAh g-1 after 100 cycles at 0.1 C with a low E/S ratio of 6. Moreover, the WLC-CNTs framework can also be used as a host for lithium to suppress dendrite growth. With these specific lithiophilic and sulfiphilic features, Li-S full cells were assembled and exhibited long cycling stability.

Tunable Porous Electrode Architectures for Enhanced Li-Ion Storage Kinetics in Thick Electrodes

Thick electrodes, although promising toward high-energy battery systems, suffer from restricted lithium-ion transport kinetics due to prolonged diffusion lengths and tortuous transport pathways. Despite the emerging low-tortuosity designs, capacity retention under higher current densities is still limited. Herein, we employ a modified ice-templating method to fabricate low-tortuosity porous electrodes with tunable wall thickness and channel width and systematically investigate the critical impacts of the fine structural parameters on the thick electrode electrochemistry. While the porous electrodes with thick walls show diminished capability under a C-rate larger than 1.5 C, those with thinner walls could maintain ∼70% capacity under 2.5 C. The superior capacity retention is ascribed to the fast diffusion into the thin lamellar walls compared with their thicker counterparts. This study provides deeper insights into structure-affected electrochemistry and opens up new perspective of 3D porous architectural designs for high-energy and high-power electrodes.