Low-Loading of Pt Nanoparticles on 3D Carbon Foam Support for Highly Active and Stable Hydrogen Production

Minimizing Pt loading is essential for designing cost-effective water electrolyzers and fuel cell systems. Recently, three-dimensional macroporous open-pore electroactive supports have been widely regarded as promising architectures to lower loading amounts of Pt because of its large surface area, easy electrolyte access to Pt sites, and superior gas diffusion properties to accelerate diffusion of H₂ bubbles from the Pt surface. However, studies to date have mainly focused on Pt loading on Ni-based 3D open pore supports which are prone to corrosion in highly acidic and alkaline conditions. Here, we investigate electrodeposition of Pt nanoparticles in low-loading amounts on commercially available, inexpensive, 3D carbon foam (CF) support and benchmark their activity and stability for electrolytic hydrogen production. We first elucidate the effect of deposition potential on the Pt nanoparticle size, density and subsequently its coverage on 3D CF. Analysis of the Pt deposit using scanning electron microscopy images reveal that for a given deposition charge density, the particle density increases (with cubic power) and particle size decreases (linearly) with deposition overpotential. A deposition potential of -0.4 V vs. standard calomel electrode (SCE) provided the highest Pt nanoparticle coverage on 3D CF surface. Different loading amounts of Pt (0.0075-0.1 mg_Pt/cm²) was then deposited on CF at -0.4 V vs. SCE and subsequently studied for its hydrogen evolution reaction (HER) activity in acidic 1M H₂SO₄ electrolyte. The Pt/CF catalyst with loading amounts as low as 0.06 mg_Pt/cm² (10-fold lower than state-of-the-art commercial electrodes) demonstrated a mass activity of 2.6 ampere per milligram Pt at 200 mV overpotential, nearly 6-fold greater than the commercial Pt/C catalyst tested under similar conditions. The 3D architectured electrode also demonstrated excellent stability, showing <7% loss in activity after 60 h of constant current water electrolysis at 100 mA/cm².

Flexible Graphene-Wrapped Carbon Nanotube/Graphene@MnO2 3D Multilevel Porous Film for High-Performance Lithium-Ion Batteries

The ingenious design of a freestanding flexible electrode brings the possibility for power sources in emerging wearable electronic devices. Here, reduced graphene oxide (rGO) wraps carbon nanotubes (CNTs) and rGO tightly surrounded by MnO₂ nanosheets, forming a 3D multilevel porous conductive structure via vacuum freeze-drying. The sandwich-like architecture possesses multiple functions as a flexible anode for lithium-ion batteries. Micrometer-sized pores among the continuously waved rGO layers could extraordinarily improve ion diffusion. Nano-sized pores among the MnO₂ nanosheets and CNT/rGO@MnO₂ particles could provide vast accessible active sites and alleviate volume change. The tight connection between MnO₂ and carbon skeleton could facilitate electron transportation and enhance structural stability. Due to the special structure, the rGO-wrapped CNT/rGO@MnO₂ porous film as an anode shows a high capacity, excellent rate performance, and superior cycling stability (1344.2 mAh g^-1 over 630 cycles at 2 A g^-1 , 608.5 mAh g^-1 over 1000 cycles at 7.5 A g^-1 ). Furthermore, the evolutions of microstructure and chemical valence occurring inside the electrode after cycling are investigated to illuminate the structural superiority for energy storage. The excellent electrochemical performance of this freestanding flexible electrode makes it an attractive candidate for practical application in flexible energy storage.

Advances on Microsized On-Chip Lithium-Ion Batteries

Development of microsized on-chip batteries plays an important role in the design of modern micro-electromechanical systems, miniaturized biomedical sensors, and many other small-scale electronic devices. This emerging field intimately correlates with the topics of rechargeable batteries, nanomaterials, on-chip microfabrication, etc. In recent years, a number of novel designs are proposed to increase the energy and power densities per footprint area, as well as other electrochemical performances of microsized lithium-ion batteries. These advances may guide the pathway for the future development of microbatteries.

Electrolytic Manganese Dioxide Coatings on High Aspect Ratio Micro-Pillar Arrays for 3D Thin Film Lithium Ion Batteries

In this work, we present the electrochemical deposition of manganese dioxide (MnO₂) thin films on carbon-coated TiN/Si micro-pillars. The carbon buffer layer, grown by plasma enhanced chemical vapor deposition (PECVD), is used as a protective coating for the underlying TiN current collector from oxidation, during the film deposition, while improving the electrical conductivity of the stack. A conformal electrolytic MnO₂ (EMD) coating is successfully achieved on high aspect ratio C/TiN/Si pillar arrays by tailoring the deposition process. Lithiation/Delithiation cycling tests have been performed. Reversible insertion and extraction of Li⁺ through EMD structure are observed. The fabricated stack is thus considered as a good candidate not only for 3D micorbatteries but also for other energy storage applications.

Printed microelectrodes for scalable, high-areal-capacity lithium–sulfur batteries

Freestanding, printed microelectrodes for lithium–sulfur cathodes with high areal capacity are produced with a high-precision dispenser.

Boosting properties of 3D binder-free manganese oxide anodes by preformation of a solid electrolyte interphase

Huge irreversible capacity loss prevents the successful use of metal oxide anodes in Li-ion full cells. Here, we focus on the critical prelithiation step and demonstrate the challenge of electrolyte decomposition on a pristine anode in a full cell. Both an electrochemical activation process (54 h) with Li metal and a new electrolytic process (75 min) without Li metal were used to preform complete solid electrolyte interphase (SEI) layers on 3 D binder-free MnOy -based anodes. The preformed SEI layers mitigated the electrolyte decomposition effectively and widened the working voltage for the MnOy /LiMn2 O4 full cell, which resulted in a big boost of the specific energy to 300 and 200 W h kgcathode (-1) , largely improved cycling stability, and much higher specific power (4200 W h kgtotal (-1) ) compared to conventional Li-ion batteries. Detailed characterization, such as cyclic voltammetry, scanning transmission electron microscopy, and FTIR spectroscopy, gives mechanistic insight into SEI preformation. This work provides guidance for the design of anode SEI layers and enables the application of oxides for Li-ion battery full cells.

Electrolytic manganese dioxide (EMD): a perspective on worldwide production, reserves and its role in electrochemistry

EMD – a weird but played wonderful role in electrochemistry and its intercalation mechanism suitable for alkaline rechargeable batteries and supercapacitors.

Nanosized LiFePO4-decorated emulsion-templated carbon foam for 3D micro batteries: a study of structure and electrochemical performance

In this article, we report a novel 3D composite cathode fabricated from LiFePO4 nanoparticles deposited conformally on emulsion-templated carbon foam by a sol-gel method. The carbon foam is synthesized via a facile and scalable method which involves the carbonization of a high internal phase emulsion (polyHIPE) polymer template. Various techniques (XRD, SEM, TEM and electrochemical methods) are used to fully characterize the porous electrode and confirm the distribution and morphology of the cathode active material. The major benefits of the carbon foam used in our work are closely connected with its high surface area and the plenty of space suitable for sequential coating with battery components. After coating with a cathode material (LiFePO4 nanoparticles), the 3D electrode presents a hierarchically structured electrode in which a porous layer of the cathode material is deposited on the rigid and bicontinuous carbon foam. The composite electrodes exhibit impressive cyclability and rate performance at different current densities affirming their importance as viable power sources in miniature devices. Footprint area capacities of 1.72 mA h cm(-2) at 0.1 mA cm(-2) (lowest rate) and 1.1 mA h cm(-2) at 6 mA cm(-2) (highest rate) are obtained when the cells are cycled in the range 2.8 to 4.0 V vs. lithium.

Hybrid nanostructures for energy storage applications

Materials engineering plays a key role in the field of energy storage. In particular, engineering materials at the nanoscale offers unique properties resulting in high performance electrodes and electrolytes in various energy storage devices. Consequently, considerable efforts have been made in recent years to fulfill the future requirements of electrochemical energy storage using these advanced materials. Various multi-functional hybrid nanostructured materials are currently being studied to improve energy and power densities of next generation storage devices. This review describes some of the recent progress in the synthesis of different types of hybrid nanostructures using template assisted and non-template based methods. The potential applications and recent research efforts to utilize these hybrid nanostructures to enhance the electrochemical energy storage properties of Li-ion battery and supercapacitor are discussed. This review also briefly outlines some of the recent progress and new approaches being explored in the techniques of fabrication of 3D battery structures using hybrid nanoarchitectures.

3D nanoporous nanowire current collectors for thin film microbatteries

Conventional thin film batteries are fabricated based on planar current collector designs where the high contact resistance between the current collector and electrodes impedes overall battery performance. Hence, current collectors based on 3D architectures and nanoscale roughness has been proposed to dramatically increase the electrode-current collector surface contact areas and hence significantly reduce interfacial resistance. The nanorod-based current collector configuration is one of several 3D designs which has shown high potential for the development of high energy and high power microbatteries in this regard. Herein we fabricate a nanoporous nanorod based current collector, which provides increased surface area for electrode deposition arising from the porosity of each nanorods, yet keeping an ordered spacing between nanorods for the deposition of subsequent electrolyte and electrode layers. The new nanostructured 3D current collector is demonstrated with a polyaniline (PANI)-based electrode system and is shown to deliver improved rate capability characteristics compared to planar configurations. We have been able to achieve stable capacities of ~32 μAh/cm(2) up to 75 cycles of charge/discharge even at a current rate of ~0.04 mA/cm(2) and have observed good rate capability even at high current rates of ~0.8 mA/cm(2).