Gradient Architecture Design in Scalable Porous Battery Electrodes

Progress and perspectives on iron-based electrode materials for alkali metal-ion batteries: a critical review

Iron-based materials with significant physicochemical properties, including high theoretical capacity, low cost and mechanical and thermal stability, have attracted research attention as electrode materials for alkali metal-ion batteries (AMIBs). However, practical implementation of some iron-based materials is impeded by their poor conductivity, large volume change, and irreversible phase transition during electrochemical reactions. In this review we critically assess advances in the chemical synthesis and structural design, together with modification strategies, of iron-based compounds for AMIBs, to obviate these issues. We assess and categorize structural and compositional regulation and its effects on the working mechanisms and electrochemical performances of AMIBs. We establish insight into their applications and determine practical challenges in their development. We provide perspectives on future directions and likely outcomes. We conclude that for boosted electrochemical performance there is a need for better design of structures and compositions to increase ionic/electronic conductivity and the contact area between active materials and electrolytes and to obviate the large volume change and low conductivity. Findings will be of interest and benefit to researchers and manufacturers for sustainable development of advanced rechargeable ion batteries using iron-based electrode materials.

Design of Thick Electrodes with Vertical Channels for Aqueous Batteries: Experimental and Numerical Analysis

Developing thick electrodes with high-area loadings is a direct method for boosting the energy density. However, this approach also leads to a proportional increase in the resistance to charge transport. Optimizing the microstructure of the electrode can effectively enhance the charge transport kinetics in thick electrodes. Herein, a low-tortuosity nickel electrode with vertical channels (VC-Ni) is fabricated using a phase inversion method. A high-loading VC-Ni electrode (26.7 mg cm-2) delivers a superior specific capacity of 134.0 mAh g-1 at a 5 C rate, significantly outperforming the conventional nickel electrode (Con-Ni). Numerical simulations reveal the fast transport kinetics within the vertical channel electrodes. For the thick electrode, the VC-Ni electrode shows a substantially lower concentration gradient of OH- and H+ compared to the Con-Ni electrode. Notably, beyond a critical loading of 26.5 mg cm-2, the specific capacity initially increases with volume fraction, peaking at 50%, and then diminishes. The specific capacity increases as the channel size decreases, but the tendency to increase gradually decreases. The highest specific capacity is achieved with an inverted trapezoidal channel shape, characterized by larger pores near the separator and smaller pores near the current collector. This work is of guidance for the design of thick electrodes for high-performance aqueous batteries.

Emerging Multiscale Porous Anodes toward Fast Charging Lithium-Ion Batteries

With the accelerated penetration of the global electric vehicle market, the demand for fast charging lithium-ion batteries (LIBs) that enable improvement of user driving efficiency and user experience is becoming increasingly significant. Robust ion/electron transport paths throughout the electrode have played a pivotal role in the progress of fast charging LIBs. Yet traditional graphite anodes lack fast ion transport channels, which suffer extremely elevated overpotential at ultrafast power outputs, resulting in lithium dendrite growth, capacity decay, and safety issues. In recent years, emergent multiscale porous anodes dedicated to building efficient ion transport channels on multiple scales offer opportunities for fast charging anodes. This review survey covers the recent advances of the emerging multiscale porous anodes for fast charging LIBs. It starts by clarifying how pore parameters such as porosity, tortuosity, and gradient affect the fast charging ability from an electrochemical kinetic perspective. We then present an overview of efforts to implement multiscale porous anodes at both material and electrode levels in diverse types of anode materials. Moreover, we critically evaluate the essential merits and limitations of several quintessential fast charging porous anodes from a practical viewpoint. Finally, we highlight the challenges and future prospects of multiscale porous fast charging anode design associated with materials and electrodes as well as crucial issues faced by the battery and management level.

Scalable Fast-Charging Aligned Battery Electrodes Enabled by Bidirectional Freeze-Casting

Over the past few years, lithium-ion batteries have been extensively adopted in electric transportation. Meanwhile, the energy density of lithium-ion battery packs has been significantly improved, thanks to the development of materials science and packing technology. Despite recent progress in electric vehicle cruise ranges, the increase in battery charging rates remains a pivotal problem in electrodes with commercial-level mass loadings. Herein, we develop a scalable strategy that incorporates bidirectional freeze-casting into the conventional tape-casting method to fabricate energy-dense, fast-charging battery electrodes with aligned structures. The vertically lamellar architectures in bidirectional freeze-cast electrodes can be roll-to-roll calendered, forming the tilted yet aligned channels. These channels enable directional pathways for efficient lithium-ion transport in electrolyte-filled pores and thus realize fast-charging capabilities. In this work, we not only provide a simple yet controllable approach for building the aligned electrode architectures for fast charging but also highlight the significance of scalability in electrode fabrication considerations.

Dual Porosity-Enhanced Antireflection Coatings with Continuous Gradient

The incorporation of porous structures into films and coatings can transform their properties for applications in optics, separation, electronics, and energy generation and storage. Packing nanoparticles (NPs) is a versatile approach for fabricating nanoporous films with a tunable structure and properties. The mechanical fragility of NP packing-based films and coatings, however, significantly impedes their widespread utilization. Although infiltrating a polymer into the interstices of these NP packings has been shown to enhance their mechanical durability, this method completely eliminates the porosity of the structures, compromising their properties and functionality. This study presents a new approach to fabricate highly loaded porous nanocomposite films with a gradient in the refractive index by infiltrating subsaturating amounts of poly(methyl methacrylate) (PMMA) into disordered packings of hollow silica NPs. We demonstrate that dual porosity is a critical feature that enhances their antireflection (AR) and mechanical properties. The hollow cores of NPs prevent a substantial increase in the refractive index of the resulting films. Moreover, the interparticle voids allow for mechanical reinforcement to occur when the NP packings are infiltrated with PMMA, making them even more suitable for AR coatings. The refractive index and gradient across the nanocomposites can be tailored by adjusting the amount of PMMA infiltrated into the NP packing, the shape of hollow NPs, and the annealing time. The nanocomposite coatings with a continuous gradient in refractive index exhibit excellent AR properties and enhanced mechanical durability. Combined with the unique structural tunability afforded by the dual porosity, this approach provides a scalable and effective way to create robust and graded nanoporous structures for various applications.

Two-Dimensional Siloxene Nanosheets: Impact of Morphology and Purity on Electrochemistry

Two-dimensional (2D) siloxene (Si₆O₃H₆) has shown promise as a negative electrode material for Li-ion batteries due to its high gravimetric capacity and superior mechanical properties under (de)lithiation compared to bulk Si. In this work, we prepare purified siloxene nanosheets through the removal of bulk Si contaminants, use ultrasonication to control the lateral size and thickness of the nanosheets, and probe the effects of the resulting morphology and purity on the electrochemistry. The thin siloxene nanosheets formed after 4 h of ultrasonication deliver an average capacity of 810 mA h/g under a 1000 mA/g rate over 200 cycles with a capacity retention of 76%. Interestingly, the purified siloxene shows lower initial capacity but superior capacity retention over extended cycling. The 2D morphology benefit is illustrated where the parent siloxene nanosheet morphology and structure were largely maintained based on operando optoelectrochemistry, in situ Raman, ex situ scanning electron microscopy, and ex situ transmission electron microscopy. Furthermore, the purified siloxene-based electrode free from crystalline Si impurity experiences the least expansion upon (de)lithiation as visualized by cross-section electron microscopy of samples recovered post-cycling.

Less is more: a perspective on thinning lithium metal towards high-energy-density rechargeable lithium batteries

Lithium (Li) metal, owing to its high specific capacity and low redox potential as a Li⁺ ion source in rechargeable lithium batteries, shows impressive prospects for electrochemical energy storage. However, engineering Li metal into thin foils has historically remained difficult, owing to its stickiness and fragility upon mechanical rolling. Consequently, using thick Li in battery systems betrays the original target for achieving higher energy density, results in material waste, and creates illusions on evaluating modification strategies for taming the highly reactive Li metal anode. Being apprehensive of this, in the tutorial review, we illustrate the argument of applying thin Li (<50 μm, preferably ≤30 μm) to achieve more realistic and advanced battery systems. A brief overview of Li is sketched first to help understand its role in batteries. Then, the reasons for pursuing thin Li are critically analyzed. Next, seminal technologies enabling the fabrication of thin Li are summarized and compared, which calls for the participation of experts from mechanical engineering, metallurgy, electrochemistry, and other fields. Subsequently, the possible applications of thin Li in batteries are presented. With the deployment of thin Li, there are new challenges and opportunities to encounter and an outlook is afforded thereof. Holy-grail Li metal anodes, combined with the subtraction operation in thickness and compatible modification strategies, would bring about a truly great leap forward in electrochemical energy storage.

Gradient design of imprinted anode for stable Zn-ion batteries

Achieving long-term stable zinc anodes at high currents/capacities remains a great challenge for practical rechargeable zinc-ion batteries. Herein, we report an imprinted gradient zinc electrode that integrates gradient conductivity and hydrophilicity for long-term dendrite-free zinc-ion batteries. The gradient design not only effectively prohibits side reactions between the electrolyte and the zinc anode, but also synergistically optimizes electric field distribution, zinc ion flux and local current density, which induces preferentially deposited zinc in the bottom of the microchannels and suppresses dendrite growth even under high current densities/capacities. As a result, the imprinted gradient zinc anode can be stably cycled for 200 h at a high current density/capacity of 10 mA cm^-2/10 mAh cm^-2, with a high cumulative capacity of 1000 mAh cm^-2, which outperforms the none-gradient counterparts and bare zinc. The imprinted gradient design can be easily scaled up, and a high-performance large-area pouch cell (4*5 cm²) is also demonstrated.

Stable Zn Anodes with Triple Gradients

Aqueous zinc-ion batteries are highly desirable for sustainable energy storage, but the undesired Zn dendrites growth severely shortens the cycle life. Herein, a triple-gradient electrode that simultaneously integrates gradient conductivity, zincophilicity, and porosity is facilely constructed for a dendrite-free Zn anode. The simple mechanical rolling-induced triple-gradient design effectively optimizes the electric field distribution, Zn²⁺ ion flux, and Zn deposition paths in the Zn anode, thus synergistically achieving a bottom-up deposition behavior for Zn metals and preventing the short circuit from top dendrite growth. As a result, the electrode with triple gradients delivers a low overpotential of 35 mV and operates steadily over 400 h at 5 mA cm^-2 /2.5 mAh cm^-2 and 250 h at 10 mA cm^-2 /1 mAh cm^-2 , far surpassing the non-gradient, single-gradient and dual-gradient counterparts. The well-tunable materials and structures with the facile fabrication method of the triple-gradient strategy will bring inspiration for high-performance energy storage devices.

Chemistry-mechanics-geometry coupling in positive electrode materials: a scale-bridging perspective for mitigating degradation in lithium-ion batteries through materials design

Despite their rapid emergence as the dominant paradigm for electrochemical energy storage, the full promise of lithium-ion batteries is yet to be fully realized, partly because of challenges in adequately resolving common degradation mechanisms. Positive electrodes of Li-ion batteries store ions in interstitial sites based on redox reactions throughout their interior volume. However, variations in the local concentration of inserted Li-ions and inhomogeneous intercalation-induced structural transformations beget substantial stress. Such stress can accumulate and ultimately engender substantial delamination and transgranular/intergranular fracture in typically brittle oxide materials upon continuous electrochemical cycling. This perspective highlights the coupling between electrochemistry, mechanics, and geometry spanning key electrochemical processes: surface reaction, solid-state diffusion, and phase nucleation/transformation in intercalating positive electrodes. In particular, we highlight recent findings on tunable material design parameters that can be used to modulate the kinetics and thermodynamics of intercalation phenomena, spanning the range from atomistic and crystallographic materials design principles (based on alloying, polymorphism, and pre-intercalation) to emergent mesoscale structuring of electrode architectures (through control of crystallite dimensions and geometry, curvature, and external strain). This framework enables intercalation chemistry design principles to be mapped to degradation phenomena based on consideration of mechanics coupling across decades of length scales. Scale-bridging characterization and modeling, along with materials design, holds promise for deciphering mechanistic understanding, modulating multiphysics couplings, and devising actionable strategies to substantially modify intercalation phase diagrams in a manner that unlocks greater useable capacity and enables alleviation of chemo-mechanical degradation mechanisms.

Gradient Design for High-Energy and High-Power Batteries

Charge transport is a key process that dominates battery performance, and the microstructures of the cathode, anode, and electrolyte play a central role in guiding ion and/or electron transport inside the battery. Rational design of key battery components with varying microstructure along the charge-transport direction to realize optimal local charge-transport dynamics can compensate for reaction polarization, which accelerates electrochemical reaction kinetics. Here, the principles of charge-transport mechanisms and their decisive role in battery performance are presented, followed by a discussion of the correlation between charge-transport regulation and battery microstructure design. The design strategies of the gradient cathodes, lithium-metal anodes, and solid-state electrolytes are summarized. Future directions and perspectives of gradient design are provided at the end to enable practically accessible high-energy and high-power-density batteries.