Electrophoretic Deposition for Lithium-Ion Battery Electrode Manufacture

In Situ Electrophoretic Decorated Cactus-Type Metallic-Phase MoS2 on CaMn2O4 Nanofibers for Binder-Free Next-Generation LIBs

Ternary manganese-based oxides, such as CaMn2O4 (CMO) nanofibers fabricated via the electrospinning technique, have the potential to offer higher reversible capacity through conversion reactions in comparison to that of carbon-based anodes. However, its poor electrical conductivity hinders its usage in lithium-ion batteries (LIBs). Hence, to mitigate this issue, controlled single-step in situ decoration of highly conducting metallic-phase MoS2@CMO nanofibers has been achieved for the first time via the electrophoretic deposition (EPD) technique and utilized as a binder-free nanocomposite anode for LIBs. Further, the composition of MoS2@CMO nanofibers has also been optimized to attain better electronic and ionic conductivity. The morphological investigation revealed that the flakes of MoS2 nanoflowers are successfully and uniformly decorated over the CMO nanofibers' surface, forming a cactus-type morphology. As a binder-free nanocomposite LIB anode, CMOMS-7 (7 wt % MoS2@CMO) demonstrates a specific capacity of 674 mA h g-1 after 60 cycles at 50 mA g-1 and maintains a capacity of 454 mA h g-1 even after 300 cycles at 1000 mA g-1. Further, the good rate performance (102 mA h g-1 at 5000 mA g-1) of CMOMS-7 can be ascribed to the enhanced electrical conductivity provided by the metallic-phase MoS2. Moreover, the feasibility of CMOMS-7 is thoroughly investigated by using a full Li-ion cell incorporating a binder-free cathode of LiNi0.3Mn0.3Co0.3O2 (NMC). This configuration showcases an impressive energy density of 154 Wh kg-1. Thus, the hierarchical and aligned structure of CMO nanofibers combined with highly conductive MoS2 nanoflowers facilitates charge transportation within the composite electrodes. This synergistic effect significantly enhances the energy density of the conversion-based nanocomposites, making them highly promising anodes for advanced LIBs.

Development of an Electrophoretic Deposition Method for the In Situ Fabrication of Ultra-Thin Composite-Polymer Electrolytes for Solid-State Lithium-Metal Batteries

All-solid-state lithium-metal batteries offer higher energy density and safety than lithium-ion batteries, but their practical applications have been pushed back by the sluggish Li+ transport, unstable electrolyte/electrode interface, and/or difficult processing of their solid-state electrolytes. Li+ -conducting composite polymer electrolytes (CPEs) consisting of sub-micron particles of an oxide solid-state electrolyte (OSSE) dispersed in a solid, flexible polymer electrolyte (SPE) have shown promises to alleviate the low Li+ conductivity of SPE, and the high rigidity and large interfacial impedance of OSSEs. Solution casting has been by far the most widely used procedure for the preparation of CPEs in research laboratories; however, this method imposes several drawbacks including particle aggregation and settlement during a long-term solvent evaporation step, excessive use of organic solvents, slow production time, and mechanical issues associated with handling of ultra-thin films of CPEs (<50 µm). To address these challenges, an electrophoretic deposition (EPD) method is developed to in situ deposit ultra-thin CPEs on lithium-iron-phosphate (LFP) cathodes within just a few minutes. EPD-prepared CPEs have shown better electrochemical performance in the lithium-metal battery than those CPEs prepared by solution casting due to a better dispersion of OSSE within the SPE matrix and improved CPE contact with LFP cathodes.

All-Electrochemical Nanofabrication of Stacked Ternary Metal Sulfide/Graphene Electrodes for High-Performance Alkaline Batteries

Energy-storage materials can be assembled directly on the electrodes of a battery using electrochemical methods, this allowing sequential deposition, high structural control, and low cost. Here, a two-step approach combining electrophoretic deposition (EPD) and cathodic electrodeposition (CED) is demonstrated to fabricate multilayer hierarchical electrodes of reduced graphene oxide (rGO) and mixed transition metal sulfides (NiCoMnS_x ). The process is performed directly on conductive electrodes applying a small electric bias to electro-deposit rGO and NiCoMnS_x in alternated cycles, yielding an ideal porous network and a continuous path for transport of ions and electrons. A fully rechargeable alkaline battery (RAB) assembled with such electrodes gives maximum energy density of 97.2 Wh kg^-1 and maximum power density of 3.1 kW kg^-1 , calculated on the total mass of active materials, and outstanding cycling stability (retention 72% after 7000 charge/discharge cycles at 10 A g^-1 ). When the total electrode mass of the cell is considered, the authors achieve an unprecedented gravimetric energy density of 68.5 Wh kg^-1 , sevenfold higher than that of typical commercial supercapacitors, higher than that of Ni/Cd or lead-acid Batteries and similar to Ni-MH Batteries. The approach can be used to assemble multilayer composite structures on arbitrary electrode shapes.

Valorisation of CO2 into Value-Added Products via Microbial Electrosynthesis (MES) and Electro-Fermentation Technology

Microbial electrocatalysis reckons on microbes as catalysts for reactions occurring at electrodes. Microbial fuel cells and microbial electrolysis cells are well-known in this context; both prefer the oxidation of organic and inorganic matter for producing electricity. Notably, the synthesis of high energy-density chemicals (fuels) or their precursors by microorganisms using bio-cathode to yield electrical energy is called Microbial Electrosynthesis (MES), giving an exceptionally appealing novel way for producing beneficial products from electricity and wastewater. This review accentuates the concept, importance and opportunities of MES, as an emerging discipline at the nexus of microbiology and electrochemistry. Production of organic compounds from MES is considered as an effective technique for the generation of various beneficial reduced end-products (like acetate and butyrate) as well as in reducing the load of CO2 from the atmosphere to mitigate the harmful effect of greenhouse gases in global warming. Although MES is still an emerging technology, this method is not thoroughly known. The authors have focused on MES, as it is the next transformative, viable alternative technology to decrease the repercussions of surplus carbon dioxide in the environment along with conserving energy.

Practical aspects of electrophoretic deposition to produce commercially viable supercapacitor energy storage electrodes

Electrophoretic deposition (EPD) is a highly convenient and demonstrated industrial operation for the manufacture of surface coatings. Recent years are seeing increasing evidence in using this technique to produce energy storage electrodes (notably for lithium-ion batteries, solid-state devices, supercapacitors, and flow batteries), but their advancement for industrialisation remains unclear. Using activated carbon (AC) as an exemplary supercapacitor material, this study reports the practical aspects of porous energy storage electrodes produced by the EPD technique. Practical electrodes with commercially viable parameters are shown, specifically high density active material (in excess of 9.8 mg cm^-2) and very thick coating layer (about 168 μm). Research investigations including colloidal electrolyte formulations, electrode deposition parameters and cell performance testing are reported. Materials and electrode properties were studied by various charactersisation tools. Prototype A7 sized pouch cells were assembled and tested to show evidence of practical EPD electrodes in a commercial cell format. Electrochemical performance of EPD over slurry casting is presented. In short, this research shows the successful production of practical EPD electrodes for electrochemical energy storage, which is directly relevant for scale-up industrial adoption and can be applied as a platform electrode manufacturing technology for any battery and supercapacitor materials.