Updated Insights into 3D Architecture Electrodes for Micropower Sources

Three-dimensional high-aspect-ratio microarray thick electrodes for high-rate hybrid supercapacitors

Hybrid supercapacitors (HSCs) with facile integration and high process compatibility are considered ideal power sources for portable consumer electronics. However, as a crucial component for storing energy, traditional thin-film electrodes exhibit low energy density. Although increasing the thickness of thin films can enhance the energy density of the electrodes, it gives rise to issues such as poor mechanical stability and long electron/ion transport pathways. Constructing a stable three-dimensional (3D) ordered thick electrode is considered the key to addressing the aforementioned contradictions. In this work, a manufacturing process combining lithography and chemical deposition techniques is developed to produce large-area and high-aspect-ratio 3D nickel ordered cylindrical array (NiOCA) current collectors. Positive electrodes loaded with nickel-cobalt bimetallic hydroxide (NiOCA/NiCo-LDH) are constructed by electrodeposition, and HSCs are assembled with NiOCA/nitrogen-doped porous carbon (NiOCA/NPC) as negative electrodes. The HSCs exhibits 55% capacity retention with the current density ranging from 2 to 50 mA cm-2. Moreover, it maintains 98.2% of the initial capacity after long-term cycling of 15,000 cycles at a current density of 10 mA cm-2. The manufacturing process demonstrates customizability and favorable repeatability. It is anticipated to provide innovative concepts for the large-scale production of 3D microarray thick electrodes for high-performance energy storage system.

Insights into Nano- and Micro-Structured Scaffolds for Advanced Electrochemical Energy Storage

Adopting a nano- and micro-structuring approach to fully unleashing the genuine potential of electrode active material benefits in-depth understandings and research progress toward higher energy density electrochemical energy storage devices at all technology readiness levels. Due to various challenging issues, especially limited stability, nano- and micro-structured (NMS) electrodes undergo fast electrochemical performance degradation. The emerging NMS scaffold design is a pivotal aspect of many electrodes as it endows them with both robustness and electrochemical performance enhancement, even though it only occupies complementary and facilitating components for the main mechanism. However, extensive efforts are urgently needed toward optimizing the stereoscopic geometrical design of NMS scaffolds to minimize the volume ratio and maximize their functionality to fulfill the ever-increasing dependency and desire for energy power source supplies. This review will aim at highlighting these NMS scaffold design strategies, summarizing their corresponding strengths and challenges, and thereby outlining the potential solutions to resolve these challenges, design principles, and key perspectives for future research in this field. Therefore, this review will be one of the earliest reviews from this viewpoint.

High-Areal Capacity, High-Rate Lithium Metal Anodes Enabled by Nitrogen-Doped Graphene Mesh

Hosts hold great prospects for addressing the dendrite growth and volume expansion of the Li metal anode, but Li dendrites are still observable under the conditions of high deposition capacity and/or high current density. Herein, a nitrogen-doped graphene mesh (NGM) is developed, which possesses a conductive and lithiophilic scaffold for efficient Li deposition. The abundant nanopores in NGM can not only provide sufficient room for Li deposition, but also speed up Li ion transport to achieve a high-rate capability. Moreover, the evenly distributed N dopants on the NGM can guide the uniform nucleation of Li so that to inhibit dendrite growth. As a result, the composite NGM@Li anode shows satisfactory electrochemical performances for Li-S batteries, including a high capacity of 600 mAh g-1 after 300 cycles at 1 C and a rate capacity of 438 mAh g-1 at 3 C. This work provides a new avenue for the fabrication of graphene-based hosts with large areal capacity and high-rate capability for Li metal batteries.

3D Printing Manufacturing of Lithium Batteries: Prospects and Challenges toward Practical Applications

The manufacturing and assembly of components within cells have a direct impact on the sample performance. Conventional processes restrict the shapes, dimensions, and structures of the commercially available batteries. 3D printing, a novel manufacturing process for precision and practicality, is expected to revolutionize the lithium battery industry owing to its advantages of customization, mechanization, and intelligence. This technique can be used to effectively construct intricate 3D structures that enhance the designability, integrity, and electrochemical performance of both liquid- and solid-state lithium batteries. In this study, an overview of the development of 3D printing technologies is provided and their suitability for comparison with conventional printing processes is assessed. Various 3D printing technologies applicable to lithium-ion batteries have been systematically introduced, especially more practical composite printing technologies. The practicality, limitations, and optimization of 3D printing are discussed dialectically for various battery modules, including electrodes, electrolytes, and functional architectures. In addition, all-printed batteries are emphatically introduced. Finally, the prospects and challenges of 3D printing in the battery industry are evaluated.

Deeply Reconstructed Hierarchical Ni-Co Microwire for Flexible Ni-Zn Microbattery with Excellent Comprehensive Performance

The rise of flexible electronics calls for efficient microbatteries (MBs) with requirements in energy/power density, stability, and flexibility simultaneously. However, the ever-reported flexible MBs only display progress around certain aspects of energy loading, reaction rate, and electrochemical stability, and it remains challenging to develop a micro-power source with excellent comprehensive performance. Herein, a reconstructed hierarchical Ni-Co alloy microwire is designed to construct flexible Ni-Zn MB. Notably, the interwoven microwires network is directly formed during the synthesis process, and can be utilized as a potential microelectrode which well avoids the toxic additives and the tedious traditional powder process, thus greatly simplifying the manufacture of MB. Meanwhile, the hierarchical alloy microwire is composed of spiny nanostructures and highly active alloy sites, which contributes to deep reconstruction (≈100 nm). Benefiting from the dense self-assembled structure, the fabricated Ni-Zn MB obtained high volumetric/areal energy density (419.7 mWh cm-3 , 1.3 mWh cm-2 ), and ultrahigh rate performance extending the power density to 109.4 W cm-3 (328.3 mW cm-2 ). More surprisingly, the MB assembled by this inherently flexible microwire network is extremely resistant to bending/twisting. Therefore, this novel concept of excellent comprehensive micro-power source will greatly hold great implications for next-generation flexible electronics.

Fundamental Understanding of Nonaqueous and Hybrid Na-CO2 Batteries: Challenges and Perspectives

Alkali metal-CO₂ batteries, which combine CO₂ recycling with energy conversion and storage, are a promising way to address the energy crisis and global warming. Unfortunately, the limited cycle life, poor reversibility, and low energy efficiency of these batteries have hindered their commercialization. Li-CO₂ battery systems have been intensively researched in these aspects over the past few years, however, the exploration of Na-CO₂ batteries is still in its infancy. To improve the development of Na-CO₂ batteries, one must have a full picture of the chemistry and electrochemistry controlling the operation of Na-CO₂ batteries and a full understanding of the correlation between cell configurations and functionality therein. Here, recent advances in CO₂ chemical and electrochemical mechanisms on nonaqueous Na-CO₂ batteries and hybrid Na-CO₂ batteries (including O₂ -involved Na-O₂ /CO₂ batteries) are reviewed in-depth and comprehensively. Following this, the primary issues and challenges in various battery components are identified, and the design strategies for the interfacial structure of Na anodes, electrolyte properties, and cathode materials are explored, along with the correlations between cell configurations, functional materials, and comprehensive performances are established. Finally, the prospects and directions for rationally constructing Na-CO₂ battery materials are foreseen.

Advanced Three-Dimensional Microelectrode Architecture Design for High-Performance On-Chip Micro-Supercapacitors

The rapid development of miniaturized electronic devices has greatly stimulated the endless pursuit of high-performance on-chip micro-supercapacitors (MSCs) delivering both high energy and power densities. To this end, an advanced three-dimensional (3D) microelectrode architecture design offers enormous opportunities due to high mass loading of active materials, large specific surface areas, fast ion diffusion kinetics, and short electron transport pathways. In this review, we summarize the recent advances in the rational design of 3D architectured microelectrodes including 3D dense microelectrodes, 3D nanoporous microelectrodes, and 3D macroporous microelectrodes. Furthermore, the emergent microfabrication strategies are discussed in detail in terms of charge storage mechanisms and structure-performance correlation for on-chip MSCs. Finally, we conclude with a perspective on future opportunities and challenges in this thriving field.

New Metal-Plastic Hybrid Additive Manufacturing for Precise Fabrication of Arbitrary Metal Patterns on External and Even Internal Surfaces of 3D Plastic Structures

Constructing precise metal patterns on complex three-dimensional (3D) plastic parts allows the fabrication of functional devices for advanced applications. However, it is currently expensive and requires complex processes. This study demonstrates a process for the fabrication of 3D metal-plastic composite structures with arbitrarily complex shapes. A light-cured resin is modified to prepare the active precursor allowing subsequent electroless plating (ELP). A multimaterial digital light processing 3D printer was newly developed to fabricate the parts containing regions made of either standard resin or active precursor nested within each other. Selective 3D ELP processing of such parts provided various metal-plastic composite parts having complicated hollow structures with specific topological relationships with the resolution of 40 μm. Using this technique, 3D devices that cannot be manufactured by traditional methods are possible, and metal patterns can be produced inside plastic parts as a means of further miniaturizing electronics. The proposed method can also generate metal coatings exhibiting improved adhesion of metal to substrate. Finally, several sensors composed of different functional materials and specific metal patterns were designed and fabricated. The present results demonstrate the viability of the proposed method and suggest potential applications in the fields of 3D electronics, wearable devices, and sensors.

Microsupercapacitive Stone Module for Natural Energy Storage

Increasing accessibility of energy storage platforms through user interface is significant in realizing autonomous power supply systems because they can be expanded in multidimensional directions to enable pervasive and customized energy storage systems (ESSs) for portable and miniaturized electronics. Herein, we implemented a high-performance asymmetric microsupercapacitor (MSC) on a natural stone surface, which represents a class of omnipresent, low-cost, ecofriendly, and recyclable energy storage interface for sustainable and conveniently accessible ESSs. Highly conductive and porous Cu electrodes were robustly fabricated on a rough marble substrate via explosive reduction-sintering of cost-effective CuO nanoparticles by using instantaneous, inexpensive, and simple laser-material interaction (LMI) technology. Faradaic Fe₃O₄ and capacitive Mn₃O₄ were sequentially electroplated on the surface of the porous Cu interdigitated electrodes to demonstrate hybrid MSC with a high-potential window and specific area. Despite the irregular geometry of the stone interface, the laser-induced MSC module produced high areal energy density and power density (6.55 μWh cm^-2 and 1.2 mW cm^-2, respectively) without the use of complex integrated circuit fabrication methods, such as photolithography, vacuum deposition, or chemical etching. The fabricated MSC stone cells were successfully scaled up via serial or parallel connections to achieve the concept of a scalable energy storage wall applicable as a three-dimensional energy station inside or outside a whole-building interface. The excellent durability of the MSC wall was confirmed by harsh-impact tests, and it was attributed to the robustness of the LMI-derived Cu current collectors and electroplated MSC metal oxides. Furthermore, a natural stone substrate with high mechanical toughness could be recycled by grinding the MSC conductors and active layers, thus considerably reducing the environmental pollutants and helping to realize green electronics.

Perspective on Micro-Supercapacitors

The rapid development of portable, wearable, and implantable electronic devices greatly stimulated the urgent demand for modern society for multifunctional and miniaturized electrochemical energy storage devices and their integrated microsystems. This article reviews material design and manufacturing technology in different micro-supercapacitors (MSCs) along with devices integrate to achieve the targets of their various applications in recent years. Finally, We also critically prospect the future development directions and challenges of MSCs.