Top-Down Synthesis of Silicon/Carbon Composite Anode Materials for Lithium-Ion Batteries: Mechanical Milling and Etching

Surface Science and Engineering for Electrochemical Materials

ConspectusIn electrochemical energy storage systems, the reversible storage capacity of battery materials often degrades due to parasitic reactions at the electrode-electrolyte interface, transitional metal dissolution, and metallic dendrite growth at the surface. Surface engineering techniques offer the opportunity to modify the composition and structure of a surface, thereby enabling control over chemical reactions occurring at the surface and manipulating chemical interactions at the solid-solid or solid-liquid interface. These modifications can help stabilize the surface of electrode materials and prevent unwanted reactions with electrolytes without changing the original properties of the bulk structure. This allows for achieving full theoretical capacity and maximizing battery material capacity retention with minimal overpotentials. In the past decade, our teams have been working on developing a variety of surface engineering techniques. These include applying atomic and molecular layer deposition (ALD and MLD), templating, doping, and coating via wet-chemical processes to stabilize the surfaces of electrode materials. The aim is to mitigate parasitic side-reactions without impeding charge transfer kinetics, suppress dendrite growth, and ultimately improve the electrode performance.This Account summarizes the research conducted in our research laboratory with an aim to improve battery cycling durability and efficiency by modifying electrode surfaces. We have employed techniques such as ALD, MLD, templating, and wet-chemical processes to illustrate how the stabilized surface improves the performance of lithium-ion (Li-ion), solid-state electrolytes and magnesium-metal (Mg-metal) batteries. For instance, by applying ultrathin layers of inorganic (e.g., Al2O3) or organic-inorganic coatings (e.g., alucone, lithicone, and polyamides) to the surface of LiNixMnyCozO2 (x + y + z = 1, NMC) and silicon (Si) electrodes─usually just a few angstroms or nanometers thick─we have observed notable improvements in cycling efficiency and durability. When using ultrathick electrodes, the traditional electrode fabrication has a problem with high tortuosity, which hinders both rate capability and long-term cycling. To solve this issue, three-dimensional templates have been employed to reduce electrode tortuosity, enabling high-rate performance and long-term cycling. In the case of Mg-metal batteries, the buildup of an insulating MgO layer due to side reactions with electrolytes blocks Mg2+ ion transport, which can ultimately cause the battery to fail. To address this issue, we have developed an artificial solid-electrolyte interface using cyclized polyacrylonitrile and magnesium trifluoromethanesulfonate. This interface prevents the reduction of the carbonate electrolyte while allowing Mg2+ diffusion, ultimately boosting overall cell performance.This Account also discusses the significance of choosing suitable materials and effective surface engineering methods with the objective of enhancing surface properties while preserving the bulk properties of the electrodes. It is believed that surface modification and engineering can not only significantly improve the electrochemical performance of existing battery materials but also facilitate the development of new battery materials that were previously incompatible with current electrolytes. By highlighting these aspects, this Account underscores the transformative potential of surface modification and engineering in battery technology, paving the way for future innovations in energy storage solutions.

Unlocking High-Current Performance in Silicon Anode: Synergistic Phosphorus Doping and Nitrogen-Doped Carbon Encapsulation to Enhance Lithium Diffusivity

The silicon (Si) offers enormous theoretical capacity as a lithium-ion battery (LIB) anode. However, the low charge mobility in Si particles hinders its application for high current loading. In this study, ball-milled phosphorus-doped Si nanoparticles encapsulated with nitrogen-doped carbon (P-Si@N-C) are employed as an anode for LIBs. P-doped Si nanoparticles are first obtained via ball-milling and calcination of Si with phosphoric acid. N-doped carbon encapsulation is then introduced via carbonization of the surfactant-assisted polymerization of pyrrole monomer on P-doped Si. While P dopant is required to support the stability at high current density, the encapsulation of Si particles with N-doped carbon is influential in enhancing the overall Li+ diffusivity of the Si anode. The combined approaches improve the anode's Li+ diffusivity up to tenfold compared to the untreated anode. It leads to exceptional anode stability at a high current, retaining 87 % of its initial capacity under a large current rate of 4000 mA g-1. The full-cell comprising P-Si@N-C anode and LiFePO4 cathode demonstrates 94 % capacity retention of its initial capacity after 100 cycles at 1 C. This study explores the effective strategies to improve Li+ diffusivity for high-rate Si-based anode.

Facile synthesis of multi-phase (Si+SiO2)@C anode materials for lithium-ion batteries

To bring about a revolution in energy storage through Li-ion batteries, it is crucial to develop a scalable preparation method for Si-based composite anodes. However, the severe volume expansion and poor ionic transport properties of Si-based composites present significant challenges. Previous research focused on SiO and nano Si/C composites to address these issues. In this study, mechanical milling was used to introduce a SiOx layer onto the surface of Si by mixing Si and SiO2 in a 1 : 1 mass ratio. The resulting Si+SiO2 composites (denoted as SS50) exhibited an initial coulombic efficiency (ICE) of 73.5% and high rate performance. To further stabilize the overall structure, kerosene was introduced as a carbon source precursor to generate a coating layer. The resulting multiphase composite structure (SiOx+SiO2+C), designated as SS50-900C, demonstrated a capacity retention of 79.5% over 280 cycles at its capacity of 487 mA h g-1. These results suggest that a cost-effective mechanical ball milling refinement of Si+SiO2 and a gas-phase encapsulation process can significantly improve the electrochemical performance of Si-based composites.

Enhancing the Stability and Initial Coulombic Efficiency of Silicon Anodes through Coating with Glassy ZIF-4

The high capacity of electrodes allows for a lower mass of electrodes, which is essential for increasing the energy density of the batteries. According to this, silicon is a promising anode candidate for Li-ion batteries due to its high theoretical capacity. However, its practical application is hampered by the significant volume expansion of silicon during battery operation, resulting in pulverization and contact loss. In this study, we developed a stable Li-ion anode that not only solves the problem of the short lifetime of silicon but also preserves the initial efficiency by using silicon nanoparticles covered with glassy ZIF-4 (SZ-4). SZ-4 suppresses silicon pulverization, contact loss, etc. because the glassy ZIF-4 wrapped around the silicon nanoparticles prevents additional SEI formation outside the silicon surface due to the electrically insulating characteristics of glassy ZIF-4. The SZ-4 realized by a simple heat treatment method showed 74% capacity retention after 100 cycles and a high initial efficiency of 78.7%.

Thermal-Stable Separators: Design Principles and Strategies Towards Safe Lithium-Ion Battery Operations

Lithium-ion batteries (LIBs) are momentous energy storage devices, which have been rapidly developed due to their high energy density, long lifetime, and low self-discharge rate. However, the frequent occurrence of fire accidents in laptops, electric vehicles, and mobile phones caused by thermal runaway of the inside batteries constantly reminds us of the urgency in pursuing high-safety LIBs with high performance. To this end, this Review surveyed the state-of-the-art developments of high-temperature-resistant separators for highly safe LIBs with excellent electrochemical performance. Firstly, the basic properties of separators (e. g., thickness, porosity, pore size, wettability, mechanical strength, and thermal stability) in constructing commercialized LIBs were introduced. Secondly, the working mechanisms of advanced separators with different melting points acting in the thermal runaway stage were discussed in terms of improving battery safety. Thirdly, rational design strategies for constructing high-temperature-resistant separators for LIBs with high safety were summarized and discussed, including graft modification, blend modification, and multilayer composite modification strategies. Finally, the current obstacles and future research directions in the field of high-temperature-resistant separators were highlighted. These design ideas are expected to be applied to other types of high-temperature-resistant energy storage systems working under extreme conditions.

Strategies for Controlling or Releasing the Influence Due to the Volume Expansion of Silicon inside Si-C Composite Anode for High-Performance Lithium-Ion Batteries

Currently, silicon is considered among the foremost promising anode materials, due to its high capacity, abundant reserves, environmental friendliness, and low working potential. However, the huge volume changes in silicon anode materials can pulverize the material particles and result in the shedding of active materials and the continual rupturing of the solid electrolyte interface film, leading to a short cycle life and rapid capacity decay. Therefore, the practical application of silicon anode materials is hindered. However, carbon recombination may remedy this defect. In silicon/carbon composite anode materials, silicon provides ultra-high capacity, and carbon is used as a buffer, to relieve the volume expansion of silicon; thus, increasing the use of silicon-based anode materials. To ensure the future utilization of silicon as an anode material in lithium-ion batteries, this review considers the dampening effect on the volume expansion of silicon particles by the formation of carbon layers, cavities, and chemical bonds. Silicon-carbon composites are classified herein as coated core-shell structure, hollow core-shell structure, porous structure, and embedded structure. The above structures can adequately accommodate the Si volume expansion, buffer the mechanical stress, and ameliorate the interface/surface stability, with the potential for performance enhancement. Finally, a perspective on future studies on Si-C anodes is suggested. In the future, the rational design of high-capacity Si-C anodes for better lithium-ion batteries will narrow the gap between theoretical research and practical applications.

Control of cyclic stability and volume expansion on graphite-SiO x -C hierarchical structure for Li-ion battery anodes

To increase the energy density of today's batteries, studies on adding Si-based materials to graphite have been widely conducted. However, adding a Si-based material in the slurry mixing step suffers from low distribution due to the self-aggregation property of the Si-based material. Herein, a hierarchical structure is proposed to increase the integrity by using APS to provide a bonding effect between graphite and SiO x . Additionally, to endow a protection layer, carbon is coated on the surface using the CVD method. The designed structure demonstrates enhanced integrity based on electrochemical performance. The MSG (methane decomposed SiO x @G) electrode demonstrates a high ICE of 85.6% with 429.8 mA h g-1 initial discharge capacity. In addition, the MSG anode has superior capacity retention (89.3%) after 100 cycles, with enhanced volumetric expansion (12.7%) after 50 cycles. We believe that the excellent electrochemical performance of MSG is attributed to increased integrity by using APS (3-aminopropyltrimethoxysilane) with a CVD carbon coating.

Design Strategies of Si/C Composite Anode for Lithium-Ion Batteries

Silicon-based materials that have higher theoretical specific capacity than other conventional anodes, such as carbon materials, Li₂ TiO₃ materials and Sn-based materials, become a hot topic in research of lithium-ion battery (LIB). However, the low conductivity and large volume expansion of silicon-based materials hinders the commercialization of silicon-based materials. Until recent years, these issues are alleviated by the combination of carbon-based materials. In this review, the preparation of Si/C materials by different synthetic methods in the past decade is reviewed along with their respective advantages and disadvantages. In addition, Si/C materials formed by silicon and different carbon-based materials is summarized, where the influences of carbons on the electrochemical performance of silicon are emphasized. Lastly, future research direction in the material design and optimization of Si/C materials is proposed to fill the current gap in the development of efficient Si/C anode for LIBs.

Electrochemical Performance of an Ultrathin Surface Oxide-Modulated Nano-Si Anode Confined in a Graphite Matrix for Highly Reversible Lithium-Ion Batteries

Si-based anode materials have attracted considerable attention for use in high-capacity lithium-ion batteries (LIBs), but their practical application is hindered by huge volume changes and structural instabilities that occur during lithiation/delithiation and low-conductivity. In this regard, we report a novel Si-nanocomposite by modulating the ultrathin surface oxide of nano-Si at a low temperature and highly conductive graphene-graphite matrix. The Si nanoparticles are synthesized by high-energy mechanical milling of micro-Si. The prepared Si/SiO_x@C nanocomposite electrode delivers a high-discharge capacity of 1355 mAh g^-1@300th cycle with an average Coulombic efficiency of 99.5% and a discharge capacity retention of ∼88% at 1C-rate (500 mA g^-1). Remarkably, the nanocomposite exhibits a high initial Coulombic efficiency of ∼87% and excellent charge/discharge rate performance in the range of 0.5-5C. Moreover, a comparative investigation of the three different electrodes nano-Si, Si/SiO_x, and Si/SiO_x@C are presented. The exceptional electrochemical performance of Si/SiO_x@C is owing to the nanosized silicon and ultrathin SiO_x followed by a high-conductivity graphene-graphite matrix, since such a nanostructure is beneficial to suppress the volume changes of silicon, maintain the structural integrity, and enhance the charge transfer during cycling. The proposed nanocomposite and the synthesis method are novel, facile, and cost-effective. Consequently, the Si/SiO_x@C nanocomposite can be a promising candidate for widespread application in next-generation LIB anodes.