Ultrahigh-Capacity and Scalable Architected Battery Electrodes via Tortuosity Modulation

Progress and perspectives on iron-based electrode materials for alkali metal-ion batteries: a critical review

Iron-based materials with significant physicochemical properties, including high theoretical capacity, low cost and mechanical and thermal stability, have attracted research attention as electrode materials for alkali metal-ion batteries (AMIBs). However, practical implementation of some iron-based materials is impeded by their poor conductivity, large volume change, and irreversible phase transition during electrochemical reactions. In this review we critically assess advances in the chemical synthesis and structural design, together with modification strategies, of iron-based compounds for AMIBs, to obviate these issues. We assess and categorize structural and compositional regulation and its effects on the working mechanisms and electrochemical performances of AMIBs. We establish insight into their applications and determine practical challenges in their development. We provide perspectives on future directions and likely outcomes. We conclude that for boosted electrochemical performance there is a need for better design of structures and compositions to increase ionic/electronic conductivity and the contact area between active materials and electrolytes and to obviate the large volume change and low conductivity. Findings will be of interest and benefit to researchers and manufacturers for sustainable development of advanced rechargeable ion batteries using iron-based electrode materials.

Asymmetric Electrode Design for High-Area Capacity and High-Energy Efficiency Hybrid Zn Batteries

Compared to Zn-air batteries, by integrating Zn-transition metal compound reactions and oxygen redox reactions at the cell level, hybrid Zn batteries are proposed to achieve higher energy density and energy efficiency. However, attaining relatively higher energy efficiency relies on controlling the discharge capacity. At high area capacities, the proportion of the high voltage section can be neglected, resulting in a lower energy efficiency similar to that of Zn-air batteries. Here, a high-loading integrated electrode with an asymmetric structure and asymmetric wettability is fabricated, which consists of a thick nickel hydroxide (Ni(OH)2) electrode layer with vertical array channels achieving high capacity and high utilization, and a thin NiCo2O4 nanopartical-decorated N-doped graphene nanosheets (NiCo2O4/N-G) catalyst layer with superior oxygen catalytic activity. The asymmetric wettability satisfies the wettability requirements for both Zn-Ni and Zn-air reactions. The hybrid Zn battery with the integrated electrode exhibits a remarkable peak power density of 141.9 mW cm-2, superior rate performance with an energy efficiency of 71.4% even at 20 mA cm-2, and exceptional cycling stability maintaining a stable energy efficiency of ≈84% at 2 mA cm-2 over 100 cycles (400 h).

Design of Thick Electrodes with Vertical Channels for Aqueous Batteries: Experimental and Numerical Analysis

Developing thick electrodes with high-area loadings is a direct method for boosting the energy density. However, this approach also leads to a proportional increase in the resistance to charge transport. Optimizing the microstructure of the electrode can effectively enhance the charge transport kinetics in thick electrodes. Herein, a low-tortuosity nickel electrode with vertical channels (VC-Ni) is fabricated using a phase inversion method. A high-loading VC-Ni electrode (26.7 mg cm-2) delivers a superior specific capacity of 134.0 mAh g-1 at a 5 C rate, significantly outperforming the conventional nickel electrode (Con-Ni). Numerical simulations reveal the fast transport kinetics within the vertical channel electrodes. For the thick electrode, the VC-Ni electrode shows a substantially lower concentration gradient of OH- and H+ compared to the Con-Ni electrode. Notably, beyond a critical loading of 26.5 mg cm-2, the specific capacity initially increases with volume fraction, peaking at 50%, and then diminishes. The specific capacity increases as the channel size decreases, but the tendency to increase gradually decreases. The highest specific capacity is achieved with an inverted trapezoidal channel shape, characterized by larger pores near the separator and smaller pores near the current collector. This work is of guidance for the design of thick electrodes for high-performance aqueous 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.

Orthogonal-Channel, Low-Tortuosity Carbon Nanotube Platforms for High-Performance Li-O2 Batteries

Aerogels and foams are promising electrode materials owing to their lightweight, high porosity, and large surface area for creating abundant active/catalytic sites. Tailoring their porous structure is essential toward maximum electrode performance yet remains challenging in the field. Here, by modifying a pristine carbon nanotube (CNT) sponge with random internal distribution, we present a CNT platform consisting of regular, orthogonally intercrossed through-channels centered at a suitable lateral size (around 5 μm), with low tortuosity and enhanced electrochemical kinetics under predefined compression. Our CNT platforms, grafted by bifunctional transitional metal hydroxide catalyst, overcome considerable challenges of both long cycle life and high rates simultaneously, serving as Li-O2 cathodes and achieving lifetime of 500 cycles at 0.5 mA cm-2 (275 cycles even at 1 mA cm-2) and also displaying high areal capacity (27 mA h cm-2), which are superior to most of the recently reported porous electrodes based on various materials. The mechanism involving fast triple-phase transport and reversible discharge product deposition, enabled by catalyst-loaded orthogonal channels, has been disclosed. Such structure-tailored robust CNT platforms could find many applications in electrochemical catalysis and energy storage systems.

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.

AI for Nanomaterials Development in Clean Energy and Carbon Capture, Utilization and Storage (CCUS)

Zero-carbon energy and negative emission technologies are crucial for achieving a carbon neutral future, and nanomaterials have played critical roles in advancing such technologies. More recently, due to the explosive growth in data, the adoption and exploitation of artificial intelligence (AI) as part of the materials research framework have had a tremendous impact on the development of nanomaterials. AI has enabled revolutionary next-generation paradigms to significantly accelerate all stages of material discovery and facilitate the exploration of the enormous design space. In this review, we summarize recent advancements of AI applications in nanomaterials discovery, with a special emphasis on the selected applications of AI and nanotechnology for the net-zero emission future including the development of solar cells, hydrogen energy, battery materials for renewable energy, and CO₂ capture and conversion materials for carbon capture, utilization and storage (CCUS) technologies. In addition, we discuss the limitations and challenges of current AI applications in this area by identifying the gaps that exist in current development. Finally, we present the prospect for future research directions in order to facilitate the large-scale applications of artificial intelligence for advancements in nanomaterials.

Engineering Array-Patterned Cathodes and Anodes for Synergistically Enabling High-Performance Lithium Metal Batteries

Critical challenges such as safety and cyclability concerns resulting from the uncontrollable dendritic lithium (Li) growth, especially during the fast charging/discharging process, have seriously hampered the commercialization of Li metal batteries (LMBs). Here, a novel array-patterned LiFePO₄ (LFP) cathode prepared via a simple, scalable calendaring method is developed to enable highly stable Li metal anodes with patterned ditches and bulges during the cell assembling process. Both the structured electrodes provide a remarkably increased electroactive surface area to lower the current density locally, facilitating Li-ion transport kinetics and homogeneous Li plating/stripping. Due to the long-term internal pressure in the cell, the structured LFP and Li electrodes can maintain their original structure during sustained cycling. Such distinctive electrode architectures and cell design synergistically enable excellent rate capability with a discharge capacity of up to 128 mA h g^-1 at a high current density of 9 mA cm^-2 and impressive cycling stability, with 89.6% capacity retention after 300 cycles at 1.5 mA cm^-2. Moreover, ultrasonic transmission mapping is carried out and demonstrates no gas behavior in operating modified Li||LFP pouch cells over prolonged cycling. This simple fabrication method can potentially be applied to many other active materials to enable practical LMBs with high performance.

Electron and Ion Transport in Lithium and Lithium-Ion Battery Negative and Positive Composite Electrodes

Electrochemical energy storage systems, specifically lithium and lithium-ion batteries, are ubiquitous in contemporary society with the widespread deployment of portable electronic devices. Emerging storage applications such as integration of renewable energy generation and expanded adoption of electric vehicles present an array of functional demands. Critical to battery function are electron and ion transport as they determine the energy output of the battery under application conditions and what portion of the total energy contained in the battery can be utilized. This review considers electron and ion transport processes for active materials as well as positive and negative composite electrodes. Length and time scales over many orders of magnitude are relevant ranging from atomic arrangements of materials and short times for electron conduction to large format batteries and many years of operation. Characterization over this diversity of scales demands multiple methods to obtain a complete view of the transport processes involved. In addition, we offer a perspective on strategies for enabling rational design of electrodes, the role of continuum modeling, and the fundamental science needed for continued advancement of electrochemical energy storage systems with improved energy density, power, and lifetime.

Architected Low-Tortuosity Electrodes with Tunable Porosity from Nonequilibrium Soft-Matter Processing

Mass transport is performance-defining across energy storage devices, often causing limitations at high current rates. To optimize and balance the device-scale energy and power density for a given energy storage demand, tailored electrode architectures with precisely controllable phase dimensions are needed in combination with low-tortuosity channels that maximize the geometric component of diffusion and species flux. A material-agnostic nonequilibrium soft-matter process is reported to fabricate free-standing inorganic composite electrodes with adjustable thicknesses of 100s of µm, featuring straight and accessible channels ranging in diameter from 5-30 µm, coupled with tunable material-to-pore ratios. Such architected anode and cathode electrodes exhibit electrochemical and architectural stability over extended cycling in a full-cell battery. Further, mass-transport constraints appear at high current densities, and the lithiation step is identified as rate-performance limiting, a result of insufficient lithium-ion supply and concentration polarization. The results demonstrate the need for and feasibility of tailored electrode architectures where dimensional ratios between low-tortuosity channels, the charge-storing matrix, and electrode thickness are tunable to meet coupled power and energy-storage requirements.

Chemistry-mechanics-geometry coupling in positive electrode materials: a scale-bridging perspective for mitigating degradation in lithium-ion batteries through materials design

Despite their rapid emergence as the dominant paradigm for electrochemical energy storage, the full promise of lithium-ion batteries is yet to be fully realized, partly because of challenges in adequately resolving common degradation mechanisms. Positive electrodes of Li-ion batteries store ions in interstitial sites based on redox reactions throughout their interior volume. However, variations in the local concentration of inserted Li-ions and inhomogeneous intercalation-induced structural transformations beget substantial stress. Such stress can accumulate and ultimately engender substantial delamination and transgranular/intergranular fracture in typically brittle oxide materials upon continuous electrochemical cycling. This perspective highlights the coupling between electrochemistry, mechanics, and geometry spanning key electrochemical processes: surface reaction, solid-state diffusion, and phase nucleation/transformation in intercalating positive electrodes. In particular, we highlight recent findings on tunable material design parameters that can be used to modulate the kinetics and thermodynamics of intercalation phenomena, spanning the range from atomistic and crystallographic materials design principles (based on alloying, polymorphism, and pre-intercalation) to emergent mesoscale structuring of electrode architectures (through control of crystallite dimensions and geometry, curvature, and external strain). This framework enables intercalation chemistry design principles to be mapped to degradation phenomena based on consideration of mechanics coupling across decades of length scales. Scale-bridging characterization and modeling, along with materials design, holds promise for deciphering mechanistic understanding, modulating multiphysics couplings, and devising actionable strategies to substantially modify intercalation phase diagrams in a manner that unlocks greater useable capacity and enables alleviation of chemo-mechanical degradation mechanisms.

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.

Smart Manufacturing Processes of Low-Tortuous Structures for High-Rate Electrochemical Energy Storage Devices

To maximize the performance of energy storage systems more effectively, modern batteries/supercapacitors not only require high energy density but also need to be fully recharged within a short time or capable of high-power discharge for electric vehicles and power applications. Thus, how to improve the rate capability of batteries or supercapacitors is a very important direction of research and engineering. Making low-tortuous structures is an efficient means to boost power density without replacing materials or sacrificing energy density. In recent years, numerous manufacturing methods have been developed to prepare low-tortuous configurations for fast ion transportation, leading to impressive high-rate electrochemical performance. This review paper summarizes several smart manufacturing processes for making well-aligned 3D microstructures for batteries and supercapacitors. These techniques can also be adopted in other advanced fields that require sophisticated structural control to achieve superior properties.

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.

A Figure of Merit for Fast-Charging Li-ion Battery Materials

Rate capability is characterized necessarily in almost all battery-related reports, while there is no universal metric for quantitative comparison. Here, we proposed the characteristic time of diffusion, which mainly combines the effects of diffusion coefficients and geometric sizes, as an easy-to-use figure of merit (FOM) to standardize the comparison of fast-charging battery materials. It offers an indicator to rank the rate capabilities of different battery materials and suggests two general methods to improve the rate capability: decreasing the geometric sizes or increasing the diffusion coefficients. Based on this FOM, more comprehensive FOMs for quantifying the rate capabilities of battery materials are expected by incorporating other processes (interfacial reaction, migration) into the current diffusion-dominated electrochemical model. Combined with Peukert's empirical law, it may characterize rate capabilities of batteries in the future.

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.

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.

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.