Hybrid MoS2/h-BN Nanofillers As Synergic Heat Dissipation and Reinforcement Additives in Epoxy Nanocomposites

Two-dimensional (2D) nanomaterials as molybdenum disulfide (MoS₂), hexagonal boron nitride (h-BN), and their hybrid (MoS₂/h-BN) were employed as fillers to improve the physical properties of epoxy composites. Nanocomposites were produced in different concentrations and studied in their microstructure, mechanical and thermal properties. The hybrid 2D mixture imparted efficient reinforcement to the epoxy leading to increases of up to 95% in tensile strength, 60% in ultimate strain, and 58% in Young's modulus. Moreover, an enhancement of 203% in thermal conductivity was achieved for the hybrid composite as compared to the pure polymer. The incorporation of MoS₂/h-BN mixture nanofillers in epoxy resulted in nanocomposites with multifunctional characteristics for applications that require high mechanical and thermal performance.

Detecting Li Dendrites in a Two-Electrode Battery System

The use of high-energy-density Li metal anodes in rechargeable batteries is not possible because of dendrite formation that can potentially result in a battery fire. Although so-called dendrite-free Li metal anodes have been reported in many recent publications, Li dendrite growth is still kinetically favorable and it remains a severe safety concern in mass production. Here, a detection system capable of alerting for Li dendrite formation in a two-electrode battery with no additional electrodes required is reported. When dendrites contact a red phosphorous-coated separator, dendrite growth is revealed by a significant voltage change. This can activate a signal through the battery management system, warning of the presence of Li dendrites and leading to shutdown of the battery before the dendrites become dangerous.

Ultra-Stiff Graphene Foams as Three-Dimensional Conductive Fillers for Epoxy Resin

Conductive epoxy composites are of great interest due to their applications in electronics. They are usually made by mixing powdered conductive fillers with epoxy. However, the conductivity of the composite is limited by the low filler content because increasing filler content causes processing difficulties and reduces the mechanical properties of the epoxy host. We describe here the use of ultra-stiff graphene foams (uGFs) as three-dimensional (3D) continuous conductive fillers for epoxy resins. The powder metallurgy method was used to produce the dense uGFs monoliths that resulted in a very high filler content of 32 wt % in the uGF-epoxy composite, while the density of epoxy was only increased by 0.09 g/cm³. The composite had an electrical conductivity of 41.0 ± 6.3 S/cm, which is among the highest of all of the polymer-based composites with non-conductive polymer matrices and comparable with the conductive polymer matrices reported to date. The compressive modulus of the composite showed a remarkable improvement of >1700% compared to pure epoxy. We have demonstrated that the 3D uGF filler substantially improves the conductivity and reinforces the polymer matrix with a high filler content while retaining a density similar to that of the epoxy alone.

Tip-Sonicated Red Phosphorus-Graphene Nanoribbon Composite for Full Lithium-Ion Batteries

Red phosphorus (RP) is considered a promising anode material for lithium-ion batteries (LIBs) due to its high energy density and low cost. Although RP is electrically insulating, researchers have reduced its particle size and added conductive fillers to improve the electrochemical activity of RP. Here, we report a method for making <1 μm sized RP under ambient conditions by using tip sonication. A specific surfactant solution was used to stabilize the dispersion of <1 μm sized RP. Graphene nanoribbons (GNRs) were added to improve the conductivity. The RP-GNR composite achieved nearly maximum capacity at 0.1C and showed a capacity retention of 96% after 216 cycles at 0.4 C in the half-cell. When combined with a LiCoO₂ cathode, the full cell delivered a total capacity of 86 mAh/g after 200 cycles at 0.4C. This study has demonstrated the fabrication of high-performance LIBs using RP in a safe, convenient, and cost-effective manner, and the method might be extended for the preparation of other battery or catalyst materials that are difficult to acquire through bottom-up or top-down approaches.

Ultrafast Charging High Capacity Asphalt-Lithium Metal Batteries

Li metal has been considered an outstanding candidate for anode materials in Li-ion batteries (LIBs) due to its exceedingly high specific capacity and extremely low electrochemical potential, but addressing the problem of Li dendrite formation has remained a challenge for its practical rechargeable applications. In this work, we used a porous carbon material made from asphalt (Asp), specifically untreated gilsonite, as an inexpensive host material for Li plating. The ultrahigh surface area of >3000 m²/g (by BET, N₂) of the porous carbon ensures that Li was deposited on the surface of the Asp particles, as determined by scanning electron microscopy, to form Asp-Li. Graphene nanoribbons (GNRs) were added to enhance the conductivity of the host material at high current densities, to produce Asp-GNR-Li. Asp-GNR-Li has demonstrated remarkable rate performance from 5 A/g_Li (1.3C) to 40 A/g_Li (10.4C) with Coulombic efficiencies >96%. Stable cycling was achieved for more than 500 cycles at 5 A/g_Li, and the areal capacity reached up to 9.4 mAh/cm² at a highest discharging/charging rate of 20 mA/cm² that was 10× faster than that of typical LIBs, suggesting use in ultrafast charging systems. Full batteries were also built combining the Asp-GNR-Li anodes with a sulfurized carbon cathode that possessed both high power density (1322 W/kg) and high energy density (943 Wh/kg).

Lightweight Hexagonal Boron Nitride Foam for CO2 Absorption

Weak van der Waals forces between inert hexagonal boron nitride (h-BN) nanosheets make it easy for them to slide over each other, resulting in an unstable structure in macroscopic dimensions. Creating interconnections between these inert nanosheets can remarkably enhance their mechanical properties. However, controlled design of such interconnections remains a fundamental problem for many applications of h-BN foams. In this work, a scalable in situ freeze-drying synthesis of low-density, lightweight 3D macroscopic structures made of h-BN nanosheets chemically connected by poly(vinyl alcohol) (PVA) molecules via chemical cross-link is demonstrated. Unlike pristine h-BN foam which disintegrates upon handling after freeze-drying, h-BN/PVA foams exhibit stable mechanical integrity in addition to high porosity and large surface area. Fully atomistic simulations are used to understand the interactions between h-BN nanosheets and PVA molecules. In addition, the h-BN/PVA foam is investigated as a possible CO₂ absorption and as laser irradiation protection material.

Three-Dimensional Printed Graphene Foams

An automated metal powder three-dimensional (3D) printing method for in situ synthesis of free-standing 3D graphene foams (GFs) was successfully modeled by manually placing a mixture of Ni and sucrose onto a platform and then using a commercial CO₂ laser to convert the Ni/sucrose mixture into 3D GFs. The sucrose acted as the solid carbon source for graphene, and the sintered Ni metal acted as the catalyst and template for graphene growth. This simple and efficient method combines powder metallurgy templating with 3D printing techniques and enables direct in situ 3D printing of GFs with no high-temperature furnace or lengthy growth process required. The 3D printed GFs show high-porosity (∼99.3%), low-density (∼0.015g cm^-3), high-quality, and multilayered graphene features. The GFs have an electrical conductivity of ∼8.7 S cm^-1, a remarkable storage modulus of ∼11 kPa, and a high damping capacity of ∼0.06. These excellent physical properties of 3D printed GFs indicate potential applications in fields requiring rapid design and manufacturing of 3D carbon materials, for example, energy storage devices, damping materials, and sound absorption.

Lithium Batteries with Nearly Maximum Metal Storage

The drive for significant advancement in battery capacity and energy density inspired a revisit to the use of Li metal anodes. We report the use of a seamless graphene-carbon nanotube (GCNT) electrode to reversibly store Li metal with complete dendrite formation suppression. The GCNT-Li capacity of 3351 mAh g^-1_GCNT-Li approaches that of bare Li metal (3861 mAh g^-1_Li), indicating the low contributing mass of GCNT, while yielding a practical areal capacity up to 4 mAh cm^-2 and cycle stability. A full battery based on GCNT-Li/sulfurized carbon (SC) is demonstrated with high energy density (752 Wh kg^-1 total electrodes, where total electrodes = GCNT-Li + SC + binder), high areal capacity (2 mAh cm^-2), and cyclability (80% retention at >500 cycles) and is free of Li polysulfides and dendrites that would cause severe capacity fade.

Graphene Carbon Nanotube Carpets Grown Using Binary Catalysts for High-Performance Lithium-Ion Capacitors

Here we show that a versatile binary catalyst solution of Fe₃O₄/AlO_x nanoparticles enables homogeneous growth of single to few-walled carbon nanotube (CNT) carpets from three-dimensional carbon-based substrates, moving past existing two-dimensional limited growth methods. The binary catalyst is composed of amorphous AlO_x nanoclusters over Fe₃O₄ crystalline nanoparticles, facilitating the creation of seamless junctions between the CNTs and the underlying carbon platform. The resulting graphene-CNT (GCNT) structure is a high-density CNT carpet ohmically connected to the carbon substrate, an important feature for advanced carbon electronics. As a demonstration of the utility of this approach, we use GCNTs as anodes and cathodes in binder-free lithium-ion capacitors, producing stable devices with high-energy densities (∼120 Wh kg^-1), high-power density capabilities (∼20,500 W kg^-1 at 29 Wh kg^-1), and a large operating voltage window (4.3 to 0.01 V).