Advanced parametrization for the production of high-energy solid-state lithium pouch cells containing polymer electrolytes.

Lithium batteries with solid-state electrolytes are an appealing alternative to state-of-the-art non-aqueous lithium-ion batteries with liquid electrolytes because of safety and energy aspects. However, engineering development at the cell level for lithium batteries with solid-state electrolytes is limited. Here, to advance this aspect and produce high-energy lithium cells, we introduce a cell design based on advanced parametrization of microstructural and architectural parameters of electrode and electrolyte components. To validate the cell design proposed, we assemble and test (applying a stack pressure of 3.74 MPa at 45 °C) 10-layer and 4-layer solid-state lithium pouch cells with a solid polymer electrolyte, resulting in an initial specific energy of 280 Wh kg-1 (corresponding to an energy density of 600 Wh L-1) and 310 Wh kg-1 (corresponding to an energy density of 650 Wh L-1) respectively.

Facile Lithium Densification Kinetics by Hyperporous/Hybrid Conductor for High-Energy-Density Lithium Metal Batteries.

Lithium metal anode (LMA) emerges as a promising candidate for lithium (Li)-based battery chemistries with high-energy-density. However, inhomogeneous charge distribution from the unbalanced ion/electron transport causes dendritic Li deposition, leading to "dead Li" and parasitic reactions, particularly at high Li utilization ratios (low negative/positive ratios in full cells). Herein, an innovative LMA structural model deploying a hyperporous/hybrid conductive architecture is proposed on single-walled carbon nanotube film (HCA/C), fabricated through a nonsolvent induced phase separation process. This design integrates ionic polymers with conductive carbon, offering a substantial improvement over traditional metal current collectors by reducing the weight of LMA and enabling high-energy-density batteries. The HCA/C promotes uniform lithium deposition even under rapid charging (up to 5 mA cm-2) owing to its efficient mixed ion/electron conduction pathways. Thus, the HCA/C demonstrates stable cycling for 200 cycles with a low negative/positive ratio of 1.0 when paired with a LiNi0.8Co0.1Mn0.1O2 cathode (areal capacity of 5.0 mAh cm-2). Furthermore, a stacked pouch-type full cell using HCA/C realizes a high energy density of 344 Wh kg-1 cell/951 Wh L-1 cell based on the total mass of the cell, exceeding previously reported pouch-type full cells. This work paves the way for LMA development in high-energy-density Li metal batteries.

Formulating Electron Beam-Induced Covalent Linkages for Stable and High-Energy-Density Silicon Microparticle Anode.

High-capacity silicon (Si) materials hold a position at the forefront of advanced lithium-ion batteries. The inherent potential offers considerable advantages for substantially increasing the energy density in batteries, capable of maximizing the benefit by changing the paradigm from nano- to micron-sized Si particles. Nevertheless, intrinsic structural instability remains a significant barrier to its practical application, especially for larger Si particles. Here, a covalently interconnected system is reported employing Si microparticles (5 µm) and a highly elastic gel polymer electrolyte (GPE) through electron beam irradiation. The integrated system mitigates the substantial volumetric expansion of pure Si, enhancing overall stability, while accelerating charge carrier kinetics due to the high ionic conductivity. Through the cost-effective but practical approach of electron beam technology, the resulting 500 mAh-pouch cell showed exceptional stability and high gravimetric/volumetric energy densities of 413 Wh kg-1, 1022 Wh L-1, highlighting the feasibility even in current battery production lines.

Solvent-Triggered Chemical Recycling of Ion-Conductive and Self-Healable Polyurethane Covalent Adaptive Networks.

Given the substantial environmental challenge posed by global plastic waste, recycling technology for thermosetting polymers has become a huge research topic in the polymer industry. Covalent adaptive networks (CANs), which can reversibly dissociate and reconstruct their network structure, represent a key technology for the self-healing, reprocessing, and recycling of thermosetting polymers. In the present study, we introduce a new series of polyurethane CANs whose network structure can dissociate via the self-catalyzed formation of dithiolane from the CANs' polydisulfide linkages when the CANs are treated in N,N-dimethylformamide (DMF) or dimethyl sulfoxide at 60 °C for 1 h. More interestingly, we found that this network dissociation even occurs in tetrahydrofuran-DMF solvent mixtures with low DMF concentrations. This feature enables a reduction in the use of high-boiling, toxic polar aprotic solvents. The dissociated network structure of the CANs was reconstructed under UV light at 365 nm with a high yield via ring-opening polydisulfide linkage formation from dithiolane pendant groups. These CAN films, which were prepared by a sequential organic synthesis and polymerization process, exhibited high thermal stability and good mechanical properties, recyclability, and self-healing performance. When lithium bis(trifluoromethanesulfonyl)imide (LiTFSI) salt was added to the CAN films, the films exhibited a maximum ion conductivity of 7.48 × 10-4 S cm-1 because of the contribution of the high concentration of the pendant ethylene carbonate group in the CANs. The ion-conducting CAN films also showed excellent recyclability and a self-healing performance.

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.

Breathable Artificial Interphase for Dendrite-Free and Chemo-Resistive Lithium Metal Anode.

A dendrite-free and chemically stabilized lithium metal anode is required for extending battery life and for the application of high energy density coupled with various cathode systems. However, uneven Li metal growth and the active surface in nature accelerate electrolyte dissipation and surface corrosion, resulting in poor cycle efficiency and various safety issues. Here, the authors suggest a thin artificial interphase using a multifunctional poly(styrene-b-butadiene-b-styrene) (SBS) copolymer to inhibit the electrochemical/chemical side reaction during cycling. Based on the physical features, hardness, adhesion, and flexibility, the optimized chemical structure of SBS facilitates durable mechanical strength and interphase integrity against repeated Li electrodeposition/dissolution. The effectiveness of the thin polymer film enables high cycle efficiency through the realization of a dendrite-free structure and a chemo-resistive surface of Li metal. The versatile anode demonstrates an improvement in the electrochemical properties, paired with diverse cathodes of high-capacity lithium cobalt oxide (3.5 mAh cm-2 ) and oxygen for advanced Li metal batteries with high energy density.

A Three-Dimensional Nano-web Scaffold of Ferroelectric Beta-PVDF Fibers for Lithium Metal Plating and Stripping.

Lithium metal has been considered as an anode material to improve energy densities of lithium chemistry-based rechargeable batteries (that is to say, lithium metal batteries or LMBs). Higher capacities and cell voltages are ensured by replacing practically used anode materials such as graphite with lithium metal. However, lithium metal as the LMB anode material has been challenged by its dendritic growth, electrolyte decomposition on its fresh surface, and its serious volumetric change. To address the problems of lithium metal anodes, herein, we guided and facilitated lithium ion transport along a spontaneously polarized and highly dielectric material. A three-dimensional web of nanodiameter fibers of ferroelectric beta-phase polyvinylidene fluoride (beta-PVDF) was loaded on a copper foil by electrospinning (PVDF#Cu). The electric field applied between the nozzle and target copper foil forced the dipoles of PVDF to be oriented centro-asymmetrically and then the beta structure induced ferroelectric polarization. Three-fold benefits of the ferroelectric nano-web architecture guaranteed the plating/stripping reversibility especially at high rates: (1) three-dimensional scaffold to accommodate the volume change of lithium metal during plating and stripping, (2) electrolyte channels between fibers to allow lithium ions to move, and (3) ferroelectrically polarized or negatively charged surface of beta-PVDF fibers to encourage lithium ion hopping along the surface. Resultantly, the beta-PVDF web architecture drove dense and integrated growth of lithium metal within its structure. The kinetic benefit expected from the ferroelectric lithium ion transport of beta-PVDF as well as the porous architecture of PVDF#Cu was realized in a cell of LFP as a cathode and lithium-plated PVDF#Cu as an anode. Excellent plating/stripping reversibility along repeated cycles was successfully demonstrated in the cell even at a high current such as 2.3 mA cm-2, which was not obtained by the nonferroelectric polymer layer.

Atomic-scale combination of germanium-zinc nanofibers for structural and electrochemical evolution.

Alloys are recently receiving considerable attention in the community of rechargeable batteries as possible alternatives to carbonaceous negative electrodes; however, challenges remain for the practical utilization of these materials. Herein, we report the synthesis of germanium-zinc alloy nanofibers through electrospinning and a subsequent calcination step. Evidenced by in situ transmission electron microscopy and electrochemical impedance spectroscopy characterizations, this one-dimensional design possesses unique structures. Both germanium and zinc atoms are homogenously distributed allowing for outstanding electronic conductivity and high available capacity for lithium storage. The as-prepared materials present high rate capability (capacity of ~ 50% at 20 C compared to that at 0.2 C-rate) and cycle retention (73% at 3.0 C-rate) with a retaining capacity of 546 mAh g-1 even after 1000 cycles. When assembled in a full cell, high energy density can be maintained during 400 cycles, which indicates that the current material has the potential to be used in a large-scale energy storage system.

Infinitesimal sulfur fusion yields quasi-metallic bulk silicon for stable and fast energy storage.

A fast-charging battery that supplies maximum energy is a key element for vehicle electrification. High-capacity silicon anodes offer a viable alternative to carbonaceous materials, but they are vulnerable to fracture due to large volumetric changes during charge-discharge cycles. The low ionic and electronic transport across the silicon particles limits the charging rate of batteries. Here, as a three-in-one solution for the above issues, we show that small amounts of sulfur doping (<1 at%) render quasi-metallic silicon microparticles by substitutional doping and increase lithium ion conductivity through the flexible and robust self-supporting channels as demonstrated by microscopy observation and theoretical calculations. Such unusual doping characters are enabled by the simultaneous bottom-up assembly of dopants and silicon at the seed level in molten salts medium. This sulfur-doped silicon anode shows highly stable battery cycling at a fast-charging rate with a high energy density beyond those of a commercial standard anode.

Stress-Tolerant Nanoporous Germanium Nanofibers for Long Cycle Life Lithium Storage with High Structural Stability.

Nanowires (NWs) synthesized via chemical vapor deposition (CVD) have demonstrated significant improvement in lithium storage performance along with their outstanding accommodation of large volume changes during the charge/discharge process. Nevertheless, NW electrodes have been confined to the research level due to the lack of scalability and severe side reactions by their high surface area. Here, we present nanoporous Ge nanofibers (NPGeNFs) having moderate nanoporosity via a combination of simple electrospinning and a low-energetic zincothermic reduction reaction. In contrast with the CVD-assisted NW growth, our method provides high tunability of macro/microscopic morphologies such as a porosity, length, and diameter of the nanoscale 1D structures. Significantly, the customized NPGeNFs showed a highly suppressed volume expansion of less than 15% (for electrodes) after full lithation and excellent durability with high lithium storage performance over 500 cycles. Our approach offers effective 1D nanostructuring with highly customized geometries and can be extended to other applications including optoelectronics, catalysis, and energy conversion.

Mechanical mismatch-driven rippling in carbon-coated silicon sheets for stress-resilient battery anodes.

High-theoretical capacity and low working potential make silicon ideal anode for lithium ion batteries. However, the large volume change of silicon upon lithiation/delithiation poses a critical challenge for stable battery operations. Here, we introduce an unprecedented design, which takes advantage of large deformation and ensures the structural stability of the material by developing a two-dimensional silicon nanosheet coated with a thin carbon layer. During electrochemical cycling, this carbon coated silicon nanosheet exhibits unique deformation patterns, featuring accommodation of deformation in the thickness direction upon lithiation, while forming ripples upon delithiation, as demonstrated by in situ transmission electron microscopy observation and chemomechanical simulation. The ripple formation presents a unique mechanism for releasing the cycling induced stress, rendering the electrode much more stable and durable than the uncoated counterparts. This work demonstrates a general principle as how to take the advantage of the large deformation materials for designing high capacity electrode.

Folding Graphene Film Yields High Areal Energy Storage in Lithium-Ion Batteries.

We show that a high energy density can be achieved in a practical manner with freestanding electrodes without using conductive carbon, binders, and current collectors. We made and used a folded graphene composite electrode designed for a high areal capacity anode. The traditional thick graphene composite electrode, such as made by filtering graphene oxide to create a thin film and reducing it such as through chemical or thermal methods, has sluggish reaction kinetics. Instead, we have made and tested a thin composite film electrode that was folded several times using a water-assisted method; it provides a continuous electron transport path in the fold regions and introduces more channels between the folded layers, which significantly enhances the electron/ion transport kinetics. A fold electrode consisting of SnO2/graphene with high areal loading of 5 mg cm-2 has a high areal capacity of 4.15 mAh cm-2, well above commercial graphite anodes (2.50-3.50 mAh cm-2), while the thickness is maintained as low as ∼20 µm. The fold electrode shows stable cycling over 500 cycles at 1.70 mA cm-2 and improved rate capability compared to thick electrodes with the same mass loading but without folds. A full cell of fold electrode coupled with LiCoO2 cathode was assembled and delivered an areal capacity of 2.84 mAh cm-2 after 300 cycles. This folding strategy can be extended to other electrode materials and rechargeable batteries.

Foldable Electrode Architectures Based on Silver-Nanowire-Wound or Carbon-Nanotube-Webbed Micrometer-Scale Fibers of Polyethylene Terephthalate Mats for Flexible Lithium-Ion Batteries.

A crumply and highly flexible lithium-ion battery is realized by using microfiber mat electrodes in which the microfibers are wound or webbed with conductive nanowires. This electrode architecture guarantees extraordinary mechanical durability without any increase in resistance after folding 1000 times. Its areal energy density is easily controllable by the number of folded stacks of a piece of the electrode mat. Deformable lithium-ion batteries of lithium iron phosphate as cathode and lithium titanium oxide as anode at high areal capacity (3.2 mAh cm-2 ) are successfully operated without structural failure and performance loss, even after repeated crumpling and folding during charging and discharging.

Revisiting Surface Modification of Graphite: Dual-Layer Coating for High-Performance Lithium Battery Anode Materials.

Surface modification of electrode active materials has garnered considerable attention as a facile way to meet stringent requirements of advanced lithium-ion batteries. Here, we demonstrated a new coating strategy based on dual layers comprising antimony-doped tin oxide (ATO) nanoparticles and carbon. The ATO nanoparticles are synthesized via a hydrothermal method and act as electronically conductive/electrochemically active materials. The as-synthesized ATO nanoparticles are introduced on natural graphite along with citric acid used as a carbon precursor. After carbonization, the carbon/ATO-decorated natural graphite (c/ATO-NG) is produced. In the (carbon/ATO) dual-layer coating, the ATO nanoparticles coupled with the carbon layer exhibit unprecedented synergistic effects. The resultant c/ATO-NG anode materials display significant improvements in capacity (530 mA h g(-1) ), cycling retention (capacity retention of 98.1 % after 50 cycles at a rate of C/5), and low electrode swelling (volume expansion of 38 % after 100 cycles) which outperform that of typical graphite materials. Furthermore, a full-cell consisting of a c/ATO-NG anode and an LiNi0.5 Mn1.5 O4 cathode presents excellent cycle retention (capacity retention of >80 % after 100 cycles). We envision that the dual-layer coating concept proposed herein opens a new route toward high-performance anode materials for lithium-ion batteries.