Mass Production of Customizable Core-Shell Active Materials in Seconds by Nano-Vapor Deposition for Advancing Lithium Sulfur Battery

Architecting the Microenvironment Skeleton of Active Materials in High-Capacity Electrodes by Self-Assembled Nano-Building Blocks

In analogy to the cell microenvironment in biology, understanding and controlling the active-material microenvironment (ME@AM) microstructures in battery electrodes is essential to the successes of energy storage devices. However, this is extremely difficult for especially high-capacity active materials (AMs) like sulfur, due to the poor controlling on the electrode microstructures. To conquer this challenge, here, a semi-dry strategy based on self-assembled nano-building blocks is reported to construct nest-like robust ME@AM skeleton in a solvent-and-stress-less way. To do that, poly(vinylidene difluoride) nanoparticle binder is coated onto carbon-nanofibers (NB@CNF) via the nanostorm technology developed in the lab, to form self-assembled nano-building blocks in the dry slurry. After compressed into an electrode prototype, the self-assembled dry-slurry is then bonded by in-situ nanobinder solvation. With this strategy, mechanically strong thick sulfur electrodes are successfully fabricated without cracking and exhibit high capacity and good C-rate performance even at a high AM loading (25.0 mg cm-2 by 90 wt% in the whole electrode). This study may not only bring a promising solution to dry manufacturing of batteries, but also uncover the ME@AM structuring mechanism with nano-binder for guiding the design and control on electrode microstructures.