A long-life nano-silicon anode for lithium ion batteries: supporting of graphene nanosheets exfoliated from expanded graphite by plasma-assisted milling

Engineering Nano-Sized Silicon Anodes with Conductive Networks toward a High Average Coulombic Efficiency of 90.2% via Plasma-Assisted Milling

Si-based anode is considered one of the ideal anodes for high energy density lithium-ion batteries due to its high theoretical capacity of 4200 mAh g-1. To accelerate the commercial progress of Si material, the multi-issue of extreme volume expansion and low intrinsic electronic conductivity needs to be settled. Herein, a series of nano-sized Si particles with conductive networks are synthesized via the dielectric barrier discharge plasma (DBDP) assisted milling. The p-milling method can effectively refine the particle sizes of pristine Si without destroying its crystal structure, resulting in large Brunauer-Emmett-Teller (BET) values with more active sites for Li+ ions. Due to their unique structure and flexibility, CNTs can be uniformly distributed among the Si particles and the prepared Si electrodes exhibit better structural stability during the continuous lithiation/de-lithiation process. Moreover, the CNT network accelerates the transport of ions and electrons in the Si particles. As a result, the nano-sized Si anodes with CNTs conductive network can deliver an extremely high average initial Coulombic efficiency (ICE) reach of 90.2% with enhanced cyclic property and rate capability. The C-PMSi-50:1 anode presents 615 mAh g-1 after 100 cycles and 979 mAh g-1 under the current density of 5 A g-1. Moreover, the manufactured Si||LiNi0.8Co0.1Mn0.1O2 pouch cell maintains a high ICE of >85%. This work may supply a new insight for designing the nano-sized Si and further promoting its commercial applications.

Reprecipitation: A Rapid Synthesis of Micro-Sized Silicon-Graphene Composites for Long-lasting Lithium-Ion Batteries

Silicon microparticles (SiMPs) have gained significant attention as a lithium-ion battery anode material due to their 10 times higher theoretical capacity compared to conventional graphite anodes as well as their much lower production cost than silicon nanoparticles (SiNPs). However, SiMPs have suffered from poorer cycle life relative to SiNPs because their larger size makes them more susceptible to volume changes during charging and discharging. Creating a wrapping structure in which SiMPs are enveloped by carbon layers has proven to be an effective strategy to significantly improve the cycling performance of SiMPs. However, the synthesis processes are complex and time-/energy-consuming and therefore not scalable. In this study, a wrapping structure is created by using a simple, rapid, and scalable "modified reprecipitation method". Graphene oxide (GO) and SiMP dispersion in tetrahydrofuran is injected into n-hexane, in which GO and SiMP by themselves cannot disperse. GO and SiMP therefore aggregate and precipitate immediately after injection to form a wrapping structure. The resulting SiMP/GO film is laser scribed to reduce GO to a laser-scribed graphene (LSG). Simultaneously, SiOx and SiC protection layers form on the SiMPs through the laser process, which alleviates severe volume change. Owing to these desirable characteristics, the modified reprecipitation method successfully doubles the cycle life of SiMP/graphene composites compared to the simple physically mixing method (50.2% vs. 24.0% retention at the 100th cycle). The modified reprecipitation method opens a new synthetic strategy for SiMP/carbon composites.

Si-Based High-Entropy Anode for Lithium-Ion Batteries

Up to now, only a small portion of Si has been utilized in the anode for commercial lithium-ion batteries (LIBs) despite its high energy density. The main challenge of using micron-sized Si anode is the particle crack and pulverization due to the volume expansion during cycling. This work proposes a type of Si-based high-entropy alloy (HEA) materials with high structural stability for the LIB anode. Micron-sized HEA-Si anode can deliver a capacity of 971 mAhg-1 and retains 93.5% of its capacity after 100 cycles. In contrast, the silicon-germanium anode only retains 15% of its capacity after 20 cycles. This study has discovered that including HEA elements in Si-based anode can decrease its anisotropic stress and consequently enhance ductility at discharged state. By utilizing in situ X-ray diffraction and transmission electron microscopy analyses, a high-entropy transition metal doped Lix (Si/Ge) phase is found at lithiated anode, which returns to the pristine HEA phase after delithiation. The reversible lithiation and delithiation process between the HEA phases leads to intrinsic stability during cycling. These findings suggest that incorporating high-entropy modification is a promising approach in designing anode materials toward high-energy density LIBs.

High-performance expanded graphite regenerated from spent lithium-ion batteries by integrated oxidation and purification method

Currently, the recycling of spent lithium-ion batteries (LIBs) has mainly been focused on the extraction of precious metals, such as lithium, cobalt and nickel from cathodes, while the waste graphite anode has been overlooked due to its low-cost production and abundant resources reserve. However, there are enormous potential value and pollution risk in the view of graphite recycling. Thus, we propose an original method to prepare expanded graphite (EG) as new anode material generated from waste graphite in LIBs which integrates the oxidation and purification in one-step. By regulating the oxidizability of potassium hypermanganate in the sulfur-phosphorus mixed acid system, the expansion of graphite and removal of impurities are realized simultaneously and thoroughly. As anticipated, the shortening of preparation process and purification procedure can also reduce the generation of polluting substances and production cost. It displays excellent electrochemical performance (reversible capacity of 435.8 mAh·g-1 at 0.1C and long-term cycling property of 370 mAh·g-1 at 1C after 1000 cycles), which is even higher than that of pristine commercial graphite. This delicate strategy of high-performance expanded graphite recycling achieves the integration of purification and value-added processes, providing the instructive guide to regenerate industrial-grade anode materials for the increasing LIBs demand in the future.

Roll-Pressed Silicon Anodes with High Reversible Volumetric Capacity Achieved by Interfacial Stabilization and Mechanical Strengthening of a Silicon/Graphene Hybrid Assembly

Application of Si anodes is hindered by severe capacity fading due to pulverization of Si particles during the large volume changes of Si during charge/discharge and repeated formation of the solid-electrolyte interphase. To address these issues, considerable efforts have been devoted to the development of Si composites with conductive carbons (Si/C composites). However, Si/C composites with high C content inevitably show low volumetric capacity because of low electrode density. For practical applications, the volumetric capacity of a Si/C composite electrode is more important than gravimetric capacity, but volumetric capacity in pressed electrodes is rarely reported. Herein, a novel synthesis strategy is demonstrate for a compact Si nanoparticle/graphene microspherical assembly with interfacial stability and mechanical strength achieved by consecutively formed chemical bonds using 3-aminopropyltriethoxysilane and sucrose. The unpressed electrode (density: 0.71 g cm-3 ) shows a reversible specific capacity of 1470 mAh g-1 with a high initial coulombic efficiency of 83.7% at a current density of 1 C-rate. The corresponding pressed electrode (density: 1.32 g cm-3 ) exhibits high reversible volumetric capacity of 1405 mAh cm-3 and gravimetric capacity of 1520 mAh g-1 with a high initial coulombic efficiency of 80.4% and excellent cycling stability of 83% over 100 cycles at 1 C-rate.

A Nonflammable High-Voltage 4.7 V Anode-Free Lithium Battery

Anode-free lithium-metal batteries employ in situ lithium-plated current collectors as negative electrodes to afford optimal mass and volumetric energy densities. The main challenges to such batteries include their poor cycling stability and the safety issues of the flammable organic electrolytes. Here, a high-voltage 4.7 V anode-free lithium-metal battery is reported, which uses a Cu foil coated with a layer (≈950 nm) of silicon-polyacrylonitrile (Si-PAN, 25.5 µg cm^-2 ) as the negative electrode, a high-voltage cobalt-free LiNi_0.5 Mn_1.5 O₄ (LNMO) as the positive electrode and a safe, nonflammable ionic liquid electrolyte composed of 4.5 m lithium bis(fluorosulfonyl)imide (LiFSI) salt in N-methyl-N-propyl pyrrolidiniumbis(fluorosulfonyl)imide (Py₁₃ FSI) with 1 wt% lithium bis(trifluoromethanesulfonyl)imide (LiTFSI) as additive. The Si-PAN coating is found to seed the growth of lithium during charging, and reversibly expand/shrink during lithium plating/stripping over battery cycling. The wide-voltage-window electrolyte containing a high concentration of FSI^- and TFSI^- facilitates the formation of stable solid-electrolyte interphase, affording a 4.7 V anode-free Cu@Si-PAN/LiNi_0.5 Mn_1.5 O₄ battery with a reversible specific capacity of ≈120 mAh g^-1 and high cycling stability (80% capacity retention after 120 cycles). These results represent the first anode-free Li battery with a high 4.7 V discharge voltage and high safety.

Highly Stable Germanium Microparticle Anodes with a Hybrid Conductive Shell for High Volumetric and Fast Lithium Storage

The ability to realize a highly capacitive/conductive electrode is an essential factor in large-scale devices, requiring a high-power/energy density system. Germanium is a feasible candidate as an anode material of lithium-ion batteries to meet the demands. However, the application is constrained due to low charge conductivity and large volume change on cycles. Here, we design a hybrid conductive shell of multi-component titanium oxide on a germanium microstructure. The shell enables facile hybrid ionic/electronic conductivity for swift charge mobility in the germanium anode, revealed through computational calculation and consecutive measurement of electrochemical impedance spectroscopy. Furthermore, a well-constructed electrode features a high initial Coulombic efficiency (90.6%) and stable cycle life for 800 cycles (capacity retention of 90.4%) for a fast-charging system. The stress-resilient properties of dense microparticle facilitate to alleviate structural failure toward high volumetric (up to 1737 W h L^-1) and power density (767 W h L^-1 at 7280 W L^-1) of full cells, paired with highly loaded NCM811 in practical application.

Core-shell GaP@C nanoparticles with a thin and uniform carbon coating as a promising anode material for rechargeable lithium-ion batteries

Transition metal phosphides are used as anode materials for lithium-ion batteries because of their high theoretical capacity and low polarization. In this work, a core-shell GaP@C nanocomposite was successfully synthesized by a simple chemical vapor deposition (CVD) method, utilizing commercial GaP as the raw material and xylene as the carbon source. The uniform thin carbon shell could alleviate the volumetric variation and improve the conductivity of the inner GaP. When used as an anode in lithium-ion batteries, the GaP@C nanocomposite has a capacity of 812 mA h g-1 at a current density of 0.5 A g-1 after 100 cycles. At a high current density of 2 A g-1, the GaP@C anode delivers a good capacity value of 1087 mA h g-1.

Porous Si/Cu Anode with High Initial Coulombic Efficiency and Volumetric Capacity by Comprehensive Utilization of Laser Additive Manufacturing-Chemical Dealloying

Si has been extensively investigated as an anode material for lithium-ion batteries because of its superior theoretical capacity. However, a scalable fabrication method for a Si-based anode with high initial coulombic efficiency (ICE) and large volumetric capacity remains a critical challenge. Herein, we proposed a novel porous Si/Cu anode in which planar Si islands were embedded in the porous Cu matrix through combined laser additive manufacturing and chemical dealloying. The compositions and dimensions of the structure were controlled by metallurgical and chemical reactions during comprehensive interaction. Such a structure has the advantages of micro-sized Si and porous architecture. The planar Si islands decreased the surface area and thus increased ICE. The porous Cu matrix, which acted as both an adhesive-free binder and a conductive network, provided enough access for electrolyte and accommodated volume expansion. The anode structure was well maintained without observable mechanical damage after cycling, demonstrating the high structure stability and integrity. The porous Si/Cu anode showed a high ICE of 93.4% and an initial volumetric capacity of 2131 mAh cm^-3, which retained 1697 mAh cm^-3 after 100 cycles at 0.20 mA cm^-2. Furthermore, the full-cell configuration (porous Si/Cu //LiFePO₄) exhibited a high energy density of 464.9 Wh kg^-1 and a capacity retention of 84.2% after 100 cycles.

Long-Term Stable Hollowed Silicon for Li-Ion Batteries Based on an Improved Low-Temperature Molten Salt Strategy

Nanostructured hollow silicon has attracted tremendous attention as high-performance anode materials in Li-ion battery applications. However, the large-scale production of pure hollowed silicon with long cycling stability is still a great challenge. Here, we report an improved low-temperature molten salt strategy to synthesize nanosized hollowed silicon with a stable structure on a large scale. As an anode material for rechargeable lithium-ion batteries, it exhibits a high capacity, excellent long cycling, and steady rate performance at different current densities. Especially, a high reversible capacity of 2028.6 mA h g^-1 at 0.5 A g^-1 after 150 cycles, 994.3 mA h g^-1 at 3 A g^-1 after 500 cycles, and 538.8 mAh g^-1 at 5 A g^-1 after 1200 cycles could be obtained. This kind of nanosized hollowed silicon can be applied as a basic anode material in silicon-based composites for long-term stable Li-ion battery applications.

Magnetoelectric Plasma Preparation of Silicon-Carbon Nanocomposite as Anode Material for Lithium Ion Batteries

A high-performance silicon-carbon nanocomposite facilely prepared by one-step magnetoelectric plasma pyrolysis of the mixture of methane, silane, and hydrogen is proposed for lithium-ion batteries. The ratio of silane, methane, and hydrogen was studied to optimize the properties of the composite. When the ratio of hydrogen/silane/methane is 1:1:3, the composite is composed of spherical Si nanoparticles that uniformly attach to the surface of the tremelliform carbon nanosheets framework, in which the tremelliform carbon nanosheets can effectively resist the volumetric change of the Si nanoparticles during the cycles and serve as electronic channels. The silicon-carbon nanocomposite exhibits a high reversible capacity (1007 mAh g−1 after 50 cycles), a low charge transfer resistance, and an excellent rate performance. In addition, the proposed process for synthesizing silicon-carbon nanocomposite without expensive materials or toxic reagents is an environmentally friendly and cost-effective method for mass production.

Enhanced Stability Lithium-Ion Battery Based on Optimized Graphene/Si Nanocomposites by Templated Assembly

Considering the sharp increase in energy demand, Si-based composites have shown promise as high-performance anodes for lithium-ion batteries during the last few years. However, a significant volume change of Si during repetitive cycles may cause technical and security problems that limit the particular application. Here, an optimized reduced graphene oxide/silicon (RGO/Si) composite with excellent stability has been fabricated via a facile templated self-assembly strategy. The active silicon nanoparticles were uniformly supported by graphene that can further form a three-dimensional network to buffer the volume change of Si and produce a stable solid-electrolyte interphase film due to the increased specific surface area and enhanced intermolecular interaction, resulting in an increase of electrical conductivity and structural stability. As the anode electrode material of lithium-ion batteries, the optimized 10RGO/Si-600 composite showed a reversible high capacity of 2317 mA h/g with an initial efficiency of 93.2% and a quite high capacity retention of 85% after 100 cycles at 0.1 A/g rate. Especially, it still displayed a specific capacity of 728 mA h/g after 100 cycles at a reasonably high current density of 2 A/g. This study has proposed the optimized method for developing advanced graphene/Si nanocomposites for enhanced cycling stability lithium-ion batteries.

Adding Metal Carbides to Suppress the Crystalline Li15Si4 Formation: A Route toward Cycling Durable Si-Based Anodes for Lithium-Ion Batteries

In addition to large volume change and sluggish kinetics, the capacity decay of silicon anodes is also related to the formation of a crystalline Li₁₅Si₄ phase during cycling. Herein, we have demonstrated that refining cheap coarse-grained Si by ball milling with metal carbides (Mo₂C, Cr₂C₃, etc.) can reduce the Si crystallite size significantly and can thus suppress the formation of the crystalline Li₁₅Si₄ during cycling, which increases the life of Si-based anode materials significantly. Si-Cr₃C₂@few-layer graphene (SC@G) composite anode materials were designed and prepared by plasma milling (P-milling) to achieve a considerable capacity of 881.8 mA h g^-1 after 300 cycles at 1 A g^-1. A study of the microstructure of the SC@G indicated that the refined amorphous-nanocrystal Si grains were distributed uniformly around multiscale Cr₃C₂ particles, which were covered by few-layer graphenes. The rigid Cr₃C₂ skeleton, which acts as a good conductive material, can increase the conductivity of the SC@G composite, avoid the agglomeration of refined Si, and regenerate Si nanosized grains during lithiation and delithiation. These results showed that the SC@G anode material exhibited an excellent overall performance based on its high capacity and long cycle stability, as well as excellent lithium-ion diffusion kinetics for lithium storage.

One-step mild fabrication of porous core-shelled Si@TiO2 nanocomposite as high performance anode for Li-ion batteries

Nanoporous Si@TiO₂ composites with the unique core-shell architecture are conveniently fabricated through one-step selective dealloying of SiTiAl ternary alloy under mild conditions. The as-prepared composites consist of bimodal Si network skeleton as the core and interconnected TiO₂ nanosponge layer as the shell uniformly distribute on the Si surface to form the porous core-shelled structure. The nanoporous TiO₂ as the outer protective layer not only reduce the violent volume change of electrode materials for stable cycling performance but also shorten the diffusion distance of Li⁺ for high rate capacities. The inner bimodal porous Si possesses an open bicontinuous network structure that can provide the enough empty space and robust backbone to relax the volume variation of composite and guarantee the sufficient electrode-electrolyte contact area. As a result, the optimized nanoporous Si@TiO₂ composite delivers the reversible capacity of 1338.1 and 1174.4 mA h g^-1 at the current densities of 200 and 1000 mA g^-1 after continuous tests for 120 and 100 cycles, respectively. With the advantages of easy preparation, unique architecture, and high lithium storage performances, the porous core-shelled Si@TiO₂ composites demonstrate the promising application potential as an anode material for LIBs.

Raspberry-like Nanostructured Silicon Composite Anode for High-Performance Lithium-Ion Batteries

Adjusting the particle size and nanostructure or applying carbon materials as the coating layers is a promising method to hold the volume expansion of Si for its practical application in lithium-ion batteries (LIBs). Herein, the mild carbon coating combined with a molten salt reduction is precisely designed to synthesize raspberry-like hollow silicon spheres coated with carbon shells (HSi@C) as the anode materials for LIBs. The HSi@C exhibits a remarkable electrochemical performance; a high reversible specific capacity of 886.2 mAh g^-1 at a current density of 0.5 A g^-1 after 200 cycles is achieved. Moreover, even after 500 cycles at a current density of 2.0 A g^-1, a stable capacity of 516.7 mAh g^-1 still can be obtained.

Multifunctional substrate of Al alloy based on general hierarchical micro/nanostructures: superamphiphobicity and enhanced corrosion resistance

Aluminum alloys are vulnerable to penetrating and peeling failures in seawater and preparing a barrier coating to isolate the substrate from corrosive medium is an effective anticorrosion method. Inspired by the lotus leaves effect, a wetting alloy surface with enhanced anticorrosion behavior has been prepared via etch, deposition, and low-surface-energy modification. Results indicate that excellent superamphiphobicity has been achieved after the modification of the constructed hierarchical labyrinth-like microstructures and dendritic nanostructures. The as-prepared surface is also found with good chemical stability and mechanical durability. Furthermore, superior anticorrosion behaviors of the resultant samples in seawater are investigated by electrochemical measurements. Due to trapped air in micro/nanostructures, the newly presented solid-air-liquid contacting interface can help to resist the seawater penetration by greatly reducing the interface interaction between corrosive ions and the superamphiphobic surface. Finally, an optimized two-layer perceptron artificial neural network is set up to model and predict the cause-and-effect relationship between preparation conditions and the anticorrosion parameters. This work provides a great potential to extend the applications of aluminum alloys especially in marine engineering fields.

Influence of copper addition for silicon–carbon composite as anode materials for lithium ion batteries

A series of porous Si–C and Si–C/Cu composites have been successfully fabricated by a simple sol–gel and pyrolysis process.

A core–shell Si@Nb2O5 composite as an anode material for lithium-ion batteries

Si@Nb₂O₅ with high electrochemical stability is fabricated via solvothermal method with silicon nanoparticle and NbCl₅ as the precursors in ethyl alcohol.