Scalable Production of Si Nanoparticles Directly from Low Grade Sources for Lithium-Ion Battery Anode

Reutilization of Silicon-Cutting Waste via Constructing Multilayer Si@SiO2@C Composites as Anode Materials for Li-Ion Batteries

The rapid development of the photovoltaic industry has also brought some economic losses and environmental problems due to the waste generated during silicon ingot cutting. This study introduces an effective and facile method to reutilize silicon-cutting waste by constructing a multilayer Si@SiO2@C composite for Li-ion batteries via two-step annealing. The double-layer structure of the resultant composite alleviates the severe volume changes of silicon effectively, and the surrounding slightly graphitic carbon, known for its high conductivity and mechanical strength, tightly envelops the silicon nanoflakes, facilitates ion and electron transport and maintains electrode structural integrity throughout repeated charge/discharge cycles. With an optimization of the carbon content, the initial coulombic efficiency (ICE) was improved from 53% to 84%. The refined Si@SiO2@C anode exhibits outstanding cycling stability (711.4 mAh g-1 after 500 cycles) and rate performance (973.5 mAh g-1 at 2 C). This research presents a direct and cost-efficient strategy for transforming photovoltaic silicon-cutting waste into high-energy-density lithium-ion battery (LIB) anode materials.

Engineering of Siloxanes for Stabilizing Silicon Anode Materials

Silicon (Si) is considered the most promising anode material for the next generation of lithium-ion batteries (LIBs) because of its high theoretical specific capacity and abundant reserves. However, the volume expansion of silicon in the cycling process causes the destruction of the electrode structure and irreversible capacity loss. As a result, the commercial application of silicon materials is greatly hindered. In recent years, siloxane-based organosilicon materials have been widely used in silicon anode of LIBs because of their unique structure and physical and chemical properties, and have shown excellent electrochemical properties. The comprehensive achievement of siloxanes in silicon-based LIBs can be understood better through a systematic summary, which is necessary to guide the design of electrodes and achieve better electrochemical performance. This paper systematically introduces the unique advantages of siloxane materials in electrode, surface/interface modification, binder, and electrolyte. The challenges and future directions for siloxane materials are presented to enhance their performance and expand their application in silicon-based LIBs.

High-Value Utilization of Silicon Cutting Waste and Excrementum Bombycis to Synthesize Silicon-Carbon Composites as Anode Materials for Li-Ion Batteries

Silicon-based photovoltaic technology is helpful in reducing the cost of power generation; however, it suffers from economic losses and environmental pollution caused by silicon cutting waste. Herein, a hydrothermal method accompanied by heat treatment is proposed to take full advantage of the photovoltaic silicon cutting waste and biomass excrementum bombycis to fabricate flake-like porous Si@C (FP-Si@C) composite anodes for lithium-ion batteries (LIBs). The resulting FP-Si@C composite with a meso-macroporous structure can buffer the severe volume changes and facilitate electrolyte penetration. Meanwhile, the slightly graphitic carbon with high electrical conductivity and mechanical strength tightly surrounds the Si nanoflakes, which not only contributes to the ion/electron transport but also maintains the electrode structural integrity during the repeated lithiation/delithiation process. Accordingly, the synergistic effect of the unique structure of FP-Si@C composite contributes to a high discharge specific capacity of 1322 mAh g^-1 at 0.1 A g^-1, superior cycle stability with a capacity retention of 70.8% after 100 cycles, and excellent rate performance with a reversible capacity of 406 mAh g^-1 at 1.0 A g^-1. This work provides an easy and cost-effective approach to achieving the high-value application of photovoltaic silicon cutting waste, as well as obtaining high-performance Si-based anodes for LIBs.

Flexible electrodes with high areal capacity based on electrospun fiber mats

The ever-growing portable, flexible, and wearable devices impose new requirements from power sources. In contrast to gravitational metrics, areal metrics are more reliable performance indicators of energy storage systems for portable and wearable devices. For energy storage devices with high areal metrics, a high mass loading of the active species is generally required, which imposes formidable challenges on the current electrode fabrication technology. In this regard, integrated electrodes made by electrospinning technology have attracted increasing attention due to their high controllability, excellent mechanical strength, and flexibility. In addition, electrospun electrodes avoid the use of current collectors, conductive additives, and polymer binders, which can essentially increase the content of the active species in the electrodes as well as reduce the unnecessary physically contacted interfaces. In this review, the electrospinning technology for fabricating flexible and high areal capacity electrodes is first highlighted by comparing with the typical methods for this purpose. Then, the principles of electrospinning technology and the recent progress of electrospun electrodes with high areal capacity and flexibility are elaborately discussed. Finally, we address the future perspectives for the construction of high areal capacity electrodes using electrospinning technology to meet the increasing demands of flexible energy storage systems.

Production of high-energy Li-ion batteries comprising silicon-containing anodes and insertion-type cathodes

Rechargeable Li-based battery technologies utilising silicon, silicon-based, and Si-derivative anodes coupled with high-capacity/high-voltage insertion-type cathodes have reaped significant interest from both academic and industrial sectors. This stems from their practically achievable energy density, offering a new avenue towards the mass-market adoption of electric vehicles and renewable energy sources. Nevertheless, such high-energy systems are limited by their complex chemistry and intrinsic drawbacks. From this perspective, we present the progress, current status, prevailing challenges and mitigating strategies of Li-based battery systems comprising silicon-containing anodes and insertion-type cathodes. This is accompanied by an assessment of their potential to meet the targets for evolving volume- and weight-sensitive applications such as electro-mobility.

Insight into the Formation and Stability of Solid Electrolyte Interphase for Nanostructured Silicon-Based Anode Electrodes Used in Li-Ion Batteries

Silicon-based anode fabrication with nanoscale structuration improves the energy density and life cycle of Li-ion batteries. As-synthesized silicon (Si) nanowires (NWs) or nanoparticles (NPs) directly on the current collector represent a credible alternative to conventional graphite anodes. However, the operating potentials of these electrodes are below the electrochemical stability window of all electrolytes used in commercial Li-ion systems. During the first charging phase of the cell, partial decomposition of the electrolyte takes place, which leads to the formation of a layer at the surface of the electrode, called solid electrolyte interphase (SEI). A stable and continuous SEI layer formation is a critical factor to achieve reliable lifetime stability of the battery. Once formed, the SEI acts as a passivation layer that minimizes further degradation of the electrolyte during cycling, while allowing lithium-ion diffusion with their subsequent insertion into the active material and ensuring reversible operation of the electrode. However, one of the major issues requiring deeper investigation is the assessment of the morphological extension of the SEI layer into the active material, which is one of the main parameters affecting the anode performances. In the present study, we use electron tomography with a low electron dose to retrieve three-dimensional information on the SEI layer formation and its stability around SiNWs and SiNPs. The possible mechanisms of SEI evolution could be inferred from the interpretation and analysis of the reconstructed volumes. Significant volume variations in the SiNW and an inhomogeneous distribution of the SEI layer around the NWs are observed during cycling and provide insights into the potential mechanism leading to the generally reported SiNW anode capacity fading. By contrast, analysis of the reconstructed SiNPs' volume for a sample undergoing one lithiation-delithiation cycle shows that the SEI remains homogeneously distributed around the NPs that retain their spherical morphology and points to the potential benefit of such nanoscale Si anode materials to improve their cycling lifetime.

Insights into the Li Diffusion Mechanism in Si/C Composite Anodes for Lithium-Ion Batteries

Recently, Si/C composite materials have attracted enormous research interest as the most promising candidates for the anodes of next-generation lithium-ion batteries, owing to their high energy density and mechanical buffering property. However, the fundamental mechanism of Li diffusion behavior in various Si/C composite materials remains unclear, with our understanding limited by experimental techniques and continuum modeling methodologies. Herein, the atomic behavior of Li diffusion in the Si/C composite material is studied within the framework of density functional theory. Two representative structural mixing formats, that is, simple mixture mode and core-shell mode, are modeled and compared. We discover that the carbon material increases Li diffusion in silicon from 7.75 × 10^-5 to 2.097 × 10^-4 cm²/s. The boost is about 50% more obvious in the mixture mode, while the core-shell structure shows more dependence on the atomic structures of the carbon layer. These results offer new insights into Li diffusion behavior in Si/C composites and unlock the enhancing mechanism for Li diffusion in Si/C. This understanding facilitates the modeling of batteries with composite anodes and will guide the corresponding structure designs for robust and high-energy-density batteries.

Scalable Synthesis of Porous SiFe@C Composite with Excellent Lithium Storage

Utilizing cost-effective raw materials to prepare high-performance silicon-based anode materials for lithium-ion batteries (LIBs) is both challenging and attractive. Herein, a porous SiFe@C (pSiFe@C) composite derived from low-cost ferrosilicon is prepared via a scalable three-step procedure, including ball milling, partial etching, and carbon layer coating. The pSiFe@C material integrates the advantages of the mesoporous structure, the partially retained FeSi₂ conductive phase, and a uniform carbon layer (12-16 nm), which can substantially alleviate the huge volume expansion effect in the repeated lithium-ion insertion/extraction processes, effectively stabilizing the solid-electrolyte interphase (SEI) film and markedly enhancing the overall electronic conductivity of the material. Benefiting from the rational structure, the obtained pSiFe@C hybrid material delivers a reversible capacity of 1162.1 mAh g^-1 after 200 cycles at 500 mA g^-1 , with a higher initial coulombic efficiency of 82.30 %. In addition, it shows large discharge capacities of 803.1 and 600.0 mAh g^-1 after 500 cycles at 2 and 4 A g^-1 , respectively, manifesting an excellent electrochemical lithium storage. This work provides a good prospect for the commercial production of silicon-based anode materials for LIBs with a high lithium-storage capacity.

Morphology engineering of silicon nanoparticles for better performance in Li-ion battery anodes

Amorphous silicon nanoparticles were synthesized through pyrolysis of silane gas at temperatures ranging from 575 to 675 °C. According to the used temperature and silane concentration, two distinct types of particles can be obtained: at 625 °C, spherical particles with smooth surface and a low degree of aggregation, but at a higher temperature (650 °C) and lower silane concentration, particles with extremely rough surfaces and high degree of aggregation are found. This demonstrates the importance of the synthesis temperature on the morphology of silicon particles. The two types of silicon nanoparticles were subsequently used as active materials in a lithium half cell configuration, using LiPF₆ in an alkylcarbonate-based electrolyte, in order to investigate the impact of the particles morphology on the cycling performances of silicon anode material. The difference in morphology of the particles resulted in different volume expansions, which impacts the solid electrolyte interface (SEI) formation and, as a consequence, the lifetime of the electrode. Half-cells fabricated from spherical particles demonstrated almost 70% capacity retention for over 300 cycles, while the cells made from the rough, aggregated particles showed a sharp decrease in capacity after the 20^th cycle. The cycling results underline the importance of Si particle engineering and its influence on the lifetime of Si-based materials.

High-Performance Porous Silicon/Nanosilver Anodes from Industrial Low-Grade Silicon for Lithium-Ion Batteries

Silicon (Si) has been considered as one of the most promising candidates for the next-generation lithium-ion battery (LIB) anode materials owing to its huge theoretical specific capacity of 4200 mA h g^-1. However, the practical application of Si anodes in commercial LIBs is facing challenges because of the lack of scalable and cost-effective methods to prepare Si-based anode materials with proper microstructure and competitive electrochemical performances. Herein, we report a facile and scalable method to produce multidimensional porous silicon embedded with a nanosilver particle (pSi/Ag) composite from commercially available low-cost metallurgical-grade silicon (MG-Si) powder. The unique hybrid structure contributes to fast electronic transport and relieves volume change of silicon during the charge-discharge process. The pSi/Ag composite exhibits a large initial discharge capacity (3095 mA h g^-1 at a high current of 1 A g^-1), an excellent cycling performance (1930 mA h g^-1 at 1 A g^-1 after 50 cycles), and outstanding rate capacities (up to 1778 mA h g^-1 at a higher current of 2 A g^-1). After the samples are modified by reduced graphene oxide, the capacities of the pSi/Ag@RGO composite electrode can still be maintained over 1000 mA h g^-1 after 200 cycles. This study provides a simple and effective strategy for production of high-performance anode materials.

Covalently Bonded Si-Polymer Nanocomposites Enabled by Mechanochemical Synthesis as Durable Anode Materials

Silicon is one of the most promising anode materials for lithium-ion batteries due to its high theoretical capacity and low cost. However, significant capacity fading caused by severe structural degradation during cycling limits its practical implication. To overcome this barrier, we design a covalently bonded nanocomposite of silicon and poly(vinyl alcohol) (Si-PVA) by high-energy ball-milling of a mixture of micron-sized Si and PVA. The obtained Si nanoparticles are wrapped by resilient PVA coatings that covalently bond to the Si particles. In such nanostructures, the soft PVA coatings can accommodate the volume change of the Si particles during repeated lithiation and delithiation. Simultaneously, as formed covalent bonds enhance the mechanical strength of the coatings. Due to the significantly improved structural stability, the Si-PVA composite delivers a lifespan of 100 cycles with a high capacity of 1526 mAh g^-1. In addition, a high initial Coulombic efficiency of over 86% and an average value of 99.2% in subsequent cycles can be achieved. This reactive ball-milling strategy provides a low-cost and scalable route to fabricate high-performance anode materials.

Top-Down Synthesis of Silicon/Carbon Composite Anode Materials for Lithium-Ion Batteries: Mechanical Milling and Etching

Lithium-ion batteries (LIBs) providing high energy and power densities as well as long cycle life are in high demand for various applications. Benefitting from its high theoretical specific charge capacity of ≈4200 mAh g^-1 and natural abundance, Si is nowadays considered as one of the most promising anode candidates for high-energy-density LIBs. However, its huge volume change during cycling prevents its widespread commercialization. Si/C-based electrodes, fabricated through top-down mechanical-milling technique and etching, could be particularly promising since they can adequately accommodate the Si volume expansion, buffer the mechanical stress, and ameliorate the interface/surface stability. In this Review, the current progresses in the top-down synthesis of Si/C anode materials for LIBs from inexpensive Si sources via the combination of low-cost, simple, scalable, and efficient ball-milling and etching processes are summarized. Various Si precursors as well as etching routes are highlighted in this Review. This review would be a guide for fabricating high-performance Si-based anodes.

Facile preparation of MoS2/maleic acid composite as high-performance anode for lithium ion batteries

We propose a facile one-step method to prepare a MoS₂ composite anode with excellent electrochemical performance and potential for practical applications in lithium ion batteries.

Minimized lithium trapping by isovalent isomorphism for high initial Coulombic efficiency of silicon anodes

Silicon demonstrates great potential as a next-generation lithium ion battery anode because of high capacity and elemental abundance. However, the issue of low initial Coulombic efficiency needs to be addressed to enable large-scale applications. There are mainly two mechanisms for this lithium loss in the first cycle: the formation of the solid electrolyte interphase and lithium trapping in the electrode. The former has been heavily investigated while the latter has been largely neglected. Here, through both theoretical calculation and experimental study, we demonstrate that by introducing Ge substitution in Si with fine compositional control, the energy barrier of lithium diffusion will be greatly reduced because of the lattice expansion. This effect of isovalent isomorphism significantly reduces the Li trapping by ~70% and improves the initial Coulombic efficiency to over 90%. We expect that various systems of battery materials can benefit from this mechanism for fine-tuning their electrochemical behaviors.

Largely Improved Battery Performance Using a Microsized Silicon Skeleton Caged by Polypyrrole as Anode

Various architectures with nanostructured silicon have demonstrated promising battery performance while posing a challenge in industrial production. The current ratio of silicon in graphite as anode is less than 5 wt %, which greatly limits the battery energy density. In this article, we report a scalable synthesis of a large silicon cage composite (micrometers) that is composed of a silicon skeleton and an ultrathin (<5 nm) mesoporous polypyrrole (PPy) skin via a facile wet-chemical method. The industry available, microsized AlSi alloy was used as precursor. The hollow skeleton configuration provides sufficient space to accommodate the drastic volume expansion/shrinkage upon charging/discharging, while the conductive polymer serves as a protective layer and fast channel for Li⁺/e^- transport. The battery with the microsilicon (μ-Si) cage as anode displays an excellent capacity retention upon long cycling at high charge/discharge rates and high material loadings. At 0.2 C, a specific capacity of ∼1660 mAh/g with a Coulombic efficiency (CE) of ∼99.8% and 99.4% was achieved after 500 cycles at 3 mg/cm² loading and 400 cycles at 4.4 mg/cm² loading, respectively. At 1.0 C, a capacity as high as 1149 mAh/g was retained after 500 cycles with such high silicon loading. The areal capacity of as high as 6.4 mAh/cm² with 4.4 mg/cm² loading was obtained, which ensures a high battery energy density in powering large devices such as electric vehicles.

Integration of Graphite and Silicon Anodes for the Commercialization of High-Energy Lithium-Ion Batteries

Silicon is considered a most promising anode material for overcoming the theoretical capacity limit of carbonaceous anodes. The use of nanomethods has led to significant progress being made with Si anodes to address the severe volume change during (de)lithiation. However, less progress has been made in the practical application of Si anodes in commercial lithium-ion batteries (LIBs). The drastic increase in the energy demands of diverse industries has led to the co-utilization of Si and graphite resurfacing as a commercially viable method for realizing high energy. Herein, we highlight the necessity for the co-utilization of graphite and Si for commercialization and discuss the development of graphite/Si anodes. Representative Si anodes used in graphite-blended electrodes are covered and a variety of strategies for building graphite/Si composites are organized according to their synthetic methods. The criteria for the co-utilization of graphite and Si are systematically presented. Finally, we provide suggestions for the commercialization of graphite/Si combinations.

Inorganic Gel-Derived Metallic Frameworks Enabling High-Performance Silicon Anodes

Metallic matrix materials have emerged as an ideal platform to hybridize with next-generation electrode materials such as silicon for practical applications in Li-ion batteries. However, these metallic species commonly exist in the form of isolated particles, failing to provide enough free space for silicon volume changes as well as continuous charge transport pathways. Herein, three-dimensional (3D) metallic frameworks with interconnected pore channels and conductive skeletons, have been synthesized from inorganic gel precursors as buffering/conducting matrices to boost lithium storage performance of silicon anodes. As a proof-of-concept demonstration, commercial Si particles are in situ immobilized within the Sn-Ni alloy framework via a facile gel-reduction route, and the rearrangement of Si particles during cycling increases the dispersity of Si in the Sn-Ni framework as well as their synergic effects toward lithium storage. The Si@Sn-Ni all-metallic framework manifests high structural integrity, 3D Li⁺/e^- mixed conduction pathway, and synergic effects of interfacial bonding and concurrent reaction dynamics between active Si and Sn, enabling long-term cycle life (1205 mA h g^-1 after 100 cycles at 0.5 A g^-1) and superior rate capability (653 mA h g^-1 at 10 A g^-1).

Effect of the Pillar Size on the Electrochemical Performance of Laser-Induced Silicon Micropillars as Anodes for Lithium-Ion Batteries

Silicon micropillars with tunable sizes are successfully fabricated on copper foils by using nanosecond-pulsed laser irradiation and then used as anodes for lithium-ion batteries. The size of the silicon micropillars is manipulated by using different slurry layer thicknesses ranging from a few microns to tens of microns. The effects of the pillar size on electrochemical properties are thoroughly investigated. The smaller the pillars, the better the electrochemical performance. A capacity of 1647 mAh g−1 at 0.1 C current rate is achieved in the anode with the smallest pillars, with 1215, 892, and 582 mAh g−1 at 0.2, 0.5, and 1.0 C, respectively. Although a significant difference in discharge capacity is observed in the early period of cycling among micropillars of different sizes, this discrepancy becomes smaller as a function of the cycle number. Morphological studies reveal that the expansion of micropillars occurred during long-term cycling, which finally led to the formation of island-like structures. Also, the formation of a solid electrolyte interphase film obstructs Li+ diffusion into Si for lithiation, resulting in capacity decay. This study demonstrates the importance of minimizing the pillar size and optimizing the pillar density during anode fabrication.

Towards high energy density lithium battery anodes: silicon and lithium

Silicon and lithium metal are considered as promising alternatives to state-of-the-art graphite anodes for higher energy density lithium batteries because of their high theoretical capacity. However, significant challenges such as short cycle life and low coulombic efficiency have seriously hindered their practical applications. In the past decades, various strategies have been proposed to address the major problems of Si and Li anodes. In this review, we summarize the understanding on Si and Li anodes, highlight the recent progress in the development and introduce advanced characterization techniques. We also indicate the remaining challenges of Si and Li anodes requiring more efforts for future widespread applications. We expect that this review provides an overall picture of the recent progress and inspires more efforts in the fundamental understanding and practical applications of Si and Li anodes.

Scalable Engineering of Bulk Porous Si Anodes for High Initial Efficiency and High-Areal-Capacity Lithium-Ion Batteries

Nano-Si has been long-hampered in its use for practical lithium battery anodes due to its intrinsic high surface area. To improve the Coulombic efficiency and areal mass loading, we extend the starting materials from nano-Si to photovoltaic waste Si powders (∼1.5 μm). Unique morphology design and interfacial engineering are designed to overcome the particle fracture of micrometer Si. First, we develop a Cu-assisted chemical wet-etching method to prepare micrometer-size bulk-porous Si (MBPS), which provides interconnected porous space to accommodate volume expansion. In addition, a monolithic, multicore, interacting MBPS/carbonized polyacrylonitrile (c-PAN) electrode with strong interfacial Si-N-C is designed to improve the interparticle electrical conductivity during volume expansion and shrinkage. Furthermore, intermediate Si nanocrystals are well-maintained during the lithiation of MBPS, which facilitates the reversibility of lithiation-delithiation process. As a result, the MBPS/c-PAN electrodes exhibit a reversible specific capacity of 2126 mAh g^-1 with a high initial Coulombic efficiency of 92%. Moreover, even after increasing the capacity loading to 3.4 mAh cm^-2, the well-designed electrode shows a capacity retention of 94% in the first 50 cycles at a current density of 0.2 A g^-1 with deep lithiation and delithiation processes between 0.005 and 2.5 V.

Nanocomposite of Si/C Anode Material Prepared by Hybrid Process of High-Energy Mechanical Milling and Carbonization for Li-Ion Secondary Batteries

Si/C nanocomposite was successfully prepared by a scalable approach through high-energy mechanical milling and carbonization process. The crystalline structure of the milled powders was studied using X-ray diffraction (XRD) and transmission electron microscopy (TEM). Morphology of the milled powders was investigated by Field-emission scanning electron microscopy (FE-SEM). The effects of milling time on crystalline size, crystal structure and microstructure, and the electrochemical properties of the nanocomposite powders were studied. The nanocomposite showed high reversible capacity of ~1658 mAh/g with an initial cycle coulombic efficiency of ~77.5%. The significant improvement in cyclability and the discharge capacity was mainly ascribed to the silicon particle size reduction and carbon layer formation over silicon for good electronic conductivity. As the prepared nanocomposite Si/C electrode exhibits remarkable electrochemical performance, it is potentially applied as a high capacity anode material in the lithium-ion secondary batteries.

Scalable Fabrication of Nanostructured Tin Oxide Anodes for High-Energy Lithium-Ion Batteries

Although tin and tin oxides have been considered very promising anode materials for future high-energy lithium-ion batteries due to high theoretical capacity and low cost, the development of commercial anodes falls short of expectations. This is due to several challenging issues related to a massive volume expansion during operation. Nanostructured electrodes can accommodate the volume expansion but typically suffer from cumbersome synthesis routes and associated problems regarding scalability and cost efficiency, preventing their commercialization. Herein, a facile, easily scalable, and highly cost-efficient fabrication route is proposed based on electroplating and subsequent electrolytic oxidation of tin, resulting in additive-free tin oxide anodes for lithium-ion batteries. The electrodes prepared accordingly exhibit excellent performance in terms of gravimetric and volumetric capacity as well as promising cycle life and rate capability, making them suitable for future high-energy lithium-ion batteries.

Hierarchical Carbon-Coated Ball-Milled Silicon: Synthesis and Applications in Free-Standing Electrodes and High-Voltage Full Lithium-Ion Batteries

Lithium-ion batteries have been regarded as one of the most promising energy storage devices, and development of low-cost batteries with high energy density is highly desired so that the cost per watt-hour ($/Wh) can be minimized. In this work, we report using ball-milled low-cost silicon (Si) as the starting material and subsequent carbon coating to produce low-cost hierarchical carbon-coated (HCC) Si. The obtained particles prepared from different Si sources all show excellent cycling performance of over 1000 mAh/g after 1000 cycles. Interestingly, we observed in situ formation of porous Si, and it is well confined in the carbon shell based on postcycling characterization of the hierarchical carbon-coated metallurgical Si (HCC-M-Si) particles. In addition, lightweight and free-standing electrodes consisting of the HCC-M-Si particles and carbon nanofibers were fabricated, which achieved 1015 mAh/g after 100 cycles based on the total mass of the electrodes. Compared with conventional electrodes, the lightweight and free-standing electrodes significantly improve the energy density by 745%. Furthermore, LiCoO₂ and LiNi_0.5Mn_1.5O₄ cathodes were used to pair up with the HCC-M-Si anode to fabricate full cells. With LiNi_0.5Mn_1.5O₄ as cathode, an energy density up to 547 Wh/kg was achieved by the high-voltage full cell. After 100 cycles, the full cell with a LiNi_0.5Mn_1.5O₄ cathode delivers 46% more energy density than that of the full cell with a LiCoO₂ cathode. The systematic investigation on low-cost Si anodes together with their applications in lightweight free-standing electrodes and high-voltage full cells will shed light on the development of high-energy Si-based lithium-ion batteries for real applications.

Sustainable Interfaces between Si Anodes and Garnet Electrolytes for Room-Temperature Solid-State Batteries

Solid-state batteries (SSBs) have seen a resurgence of research interests in recent years for their potential to offer high energy density and excellent safety far beyond current commercialized lithium-ion batteries. The compatibility of Si anodes and Ta-doped Li₇La₃Zr₂O₁₂ (Li_6.4La₃Zr_1.4Ta_0.6O₁₂, LLZTO) solid electrolytes and the stability of the Si anode have been investigated. It is found that Si layer anodes thinner than 180 nm can maintain good contact with the LLZTO plate electrolytes, leading the Li/LLZTO/Si cells to exhibit excellent cycling performance with a capacity retention over 85% after 100 cycles. As the Si layer thickness is increased to larger than 300 nm, the capacity retention of Li/LLZTO/Si cells becomes 77% after 100 cycles. When the thickness is close to 900 nm, the cells can cycle only for a limited number of times because of the destructive volume change at the interfaces. Because of the sustainable Si/LLZTO interfaces with the Si layer anodes with a thickness of 180 nm, full cells with the LiFePO₄ cathodes show discharge capacities of 120 mA h g^-1 for LiFePO₄ and 2200 mA h g^-1 for the Si anodes at room temperature. They cycle 100 times with a capacity retention of 72%. These results indicate that the combination between the Si anodes and the garnet electrolytes is a promising strategy for constructing high-performance SSBs.

Two-Dimensional Porous Sandwich-Like C/Si-Graphene-Si/C Nanosheets for Superior Lithium Storage

A novel two-dimensional porous sandwich-like Si/carbon nanosheet is designed and successfully fabricated as an anode for superior lithium storage, where a porous Si nanofilm grows on the two sides of reduced graphene oxide (rGO) and is then coated with a carbon layer (denoted as C/Si-rGO-Si/C). The coexistence of micropores and mesopores in C/Si-rGO-Si/C nanosheets offers a rapid Li⁺ diffusion rate, and the porous Si provides a short pathway for electric transportation. Meanwhile, the coated carbon layer not only can promote to form a stable SEI layer, but also can improve the electric conductivity of nanoscale Si coupled with rGO. Thus, the unique nanostructures offer the resultant C/Si-rGO-Si/C electrode with high reversible capacity (1187 mA h g^-1 after 200 cycles at 0.2 A g^-1), excellent cycle stability (894 mA h g^-1 after 1000 cycles at 1 A g^-1), and high rate capability (694 mA h g^-1 at 5 A g^-1, 447 mA h g^-1 at 10 A g^-1).

Fabrication of a Nondegradable Si@SiO x /n-Carbon Crystallite Composite Anode for Lithium-Ion Batteries

A Si-based anode maintaining its high electrochemical performance with cycles was prepared for the nondegradable lithium-ion battery. Nanoscaled Si particles were mechanochemically coupled with approximately 3 nm thick oxide layer and n-carbon (nanoscaled carbon) crystallites to overcome silicon's inherent problems of poor electronic conductivity and severe volume change during lithiation and delithiation cycling. The oxide layer of SiO _x was chemically formed via a controlled oxygen environment during the process; meanwhile, the n-carbon crystallites were obtained by mechanical fragmentation from ∼70 μm sized multilayered graphene powders with a low degree of agglomeration. The Si-based composite anode, processed by the above-mentioned mechanochemical coupling, maintained a superior discharge capacity of 1767 mA h/g through 100 cycles with a Coulombic efficiency exceeding 98% at a current density of 100 mA/g. According to our current study, the coupling of the Si particles with oxide layer and n-carbon crystallites was found to be a significantly efficient way to prevent the performance degradation of the Si-based anode.

Red Phosphorus Nanodots on Reduced Graphene Oxide as a Flexible and Ultra-Fast Anode for Sodium-Ion Batteries

Sodium-ion batteries offer an attractive option for potential low cost and large scale energy storage due to the earth abundance of sodium. Red phosphorus is considered as a high capacity anode for sodium-ion batteries with a theoretical capacity of 2596 mAh/g. However, similar to silicon in lithium-ion batteries, several limitations, such as large volume expansion upon sodiation/desodiation and low electronic conductance, have severely limited the performance of red phosphorus anodes. In order to address the above challenges, we have developed a method to deposit red phosphorus nanodots densely and uniformly onto reduced graphene oxide sheets (P@RGO) to minimize the sodium ion diffusion length and the sodiation/desodiation stresses, and the RGO network also serves as electron pathway and creates free space to accommodate the volume variation of phosphorus particles. The resulted P@RGO flexible anode achieved 1165.4, 510.6, and 135.3 mAh/g specific charge capacity at 159.4, 31878.9, and 47818.3 mA/g charge/discharge current density in rate capability test, and a 914 mAh/g capacity after 300 deep cycles in cycling stability test at 1593.9 mA/g current density, which marks a significant performance improvement for red phosphorus anodes for sodium-ion chemistry and flexible power sources for wearable electronics.

Scalable Production of the Silicon-Tin Yin-Yang Hybrid Structure with Graphene Coating for High Performance Lithium-Ion Battery Anodes

Alloy anodes possessed of high theoretical capacity show great potential for next-generation advanced lithium-ion battery. Even though huge volume change during lithium insertion and extraction leads to severe problems, such as pulverization and an unstable solid-electrolyte interphase (SEI), various nanostructures including nanoparticles, nanowires, and porous networks can address related challenges to improve electrochemical performance. However, the complex and expensive fabrication process hinders the widespread application of nanostructured alloy anodes, which generate an urgent demand of low-cost and scalable processes to fabricate building blocks with fine controls of size, morphology, and porosity. Here, we demonstrate a scalable and low-cost process to produce a porous yin-yang hybrid composite anode with graphene coating through high energy ball-milling and selective chemical etching. With void space to buffer the expansion, the produced functional electrodes demonstrate stable cycling performance of 910 mAh g^-1 over 600 cycles at a rate of 0.5C for Si-graphene "yin" particles and 750 mAh g^-1 over 300 cycles at 0.2C for Sn-graphene "yang" particles. Therefore, we open up a new approach to fabricate alloy anode materials at low-cost, low-energy consumption, and large scale. This type of porous silicon or tin composite with graphene coating can also potentially play a significant role in thermoelectrics and optoelectronics applications.

A Well-Defined Silicon Nanocone-Carbon Structure for Demonstrating Exclusive Influences of Carbon Coating on Silicon Anode of Lithium-Ion Batteries

Nanotechnology and carbon coating have been applied to silicon anodes to achieve excellent lithium-ion batteries, but the exclusive influence of carbon coating on solid-electrolyte interphase (SEI) formation is difficult to exhibit distinctly because of the impurity and morphological irregularity of most nanostructured anodes. Here, we design a silicon nanocone-carbon (SNC-C) composite structure as a model anode to demonstrate the significant influences of carbon coating on SEI formation and electrochemical performance, unaffectedly as a result of pure electrode component and distinctly due to regular nanocone morphology. As demonstrated by morphological and elemental analysis, compared to the SNC electrode, the SNC-C electrode maintains a thinner SEI layer (∼10 nm) and more stable structure during cycling as well as longer cycle life (>725 cycles), higher Coulombic efficiency (>99%), and lower electrode polarization. This well-defined structure clearly shows the interface stability attributed to carbon coating and is promising in fundamental research of the silicon anode.

5L-Scale Magnesio-Milling Reduction of Nanostructured SiO2 for High Capacity Silicon Anodes in Lithium-Ion Batteries

Nanostructured silicon (Si) is useful in many applications and has typically been synthesized by bottom-up colloid-based solution processes or top-down gas phase reactions at high temperatures. These methods, however, suffer from toxic precursors, low yields, and impractical processing conditions (i.e., high pressure). The magnesiothermic reduction of silicon oxide (SiO₂) has also been introduced as an alternative method. Here, we demonstrate the reduction of SiO₂ by a simple milling process using a lab-scale planetary-ball mill and industry-scale attrition-mill. Moreover, an ignition point where the reduction begins was consistently observed for the milling processes, which could be used to accurately monitor and control the reaction. The complete conversion of rice husk SiO₂ to high purity Si was demonstrated, taking advantage of the rice husk's uniform nanoporosity and global availability, using a 5L-scale attrition-mill. The resulting porous Si showed excellent performance as a Li-ion battery anode, retaining 82.8% of the initial capacity of 1466 mAh g^-1 after 200 cycles.

Precise Perforation and Scalable Production of Si Particles from Low-Grade Sources for High-Performance Lithium Ion Battery Anodes

Alloy anodes, particularly silicon, have been intensively pursued as one of the most promising anode materials for the next generation lithium-ion battery primarily because of high specific capacity (>4000 mAh/g) and elemental abundance. In the past decade, various nanostructures with porosity or void space designs have been demonstrated to be effective to accommodate large volume expansion (∼300%) and to provide stable solid electrolyte interphase (SEI) during electrochemical cycling. However, how to produce these building blocks with precise morphology control at large scale and low cost remains a challenge. In addition, most of nanostructured silicon suffers from poor Coulombic efficiency due to a large surface area and Li ion trapping at the surface coating. Here we demonstrate a unique nanoperforation process, combining modified ball milling, annealing, and acid treating, to produce porous Si with precise and continuous porosity control (from 17% to 70%), directly from low cost metallurgical silicon source (99% purity, ∼ $1/kg). The produced porous Si coated with graphene by simple ball milling can deliver a reversible specific capacity of 1250 mAh/g over 1000 cycles at the rate of 1C, with Coulombic efficiency of first cycle over 89.5%. The porous networks also provide efficient ion and electron pathways and therefore enable excellent rate performance of 880 mAh/g at the rate of 5C. Being able to produce particles with precise porosity control through scalable processes from low-grade materials, it is expected that this nanoperforation may play a role in the next generation lithium ion battery anodes, as well as many other potential applications such as optoelectronics and thermoelectrics.

Rapid, in Situ Synthesis of High Capacity Battery Anodes through High Temperature Radiation-Based Thermal Shock

High capacity battery electrodes require nanosized components to avoid pulverization associated with volume changes during the charge-discharge process. Additionally, these nanosized electrodes need an electronically conductive matrix to facilitate electron transport. Here, for the first time, we report a rapid thermal shock process using high-temperature radiative heating to fabricate a conductive reduced graphene oxide (RGO) composite with silicon nanoparticles. Silicon (Si) particles on the order of a few micrometers are initially embedded in the RGO host and in situ transformed into 10-15 nm nanoparticles in less than a minute through radiative heating. The as-prepared composites of ultrafine Si nanoparticles embedded in a RGO matrix show great performance as a Li-ion battery (LIB) anode. The in situ nanoparticle synthesis method can also be adopted for other high capacity battery anode materials including tin (Sn) and aluminum (Al). This method for synthesizing high capacity anodes in a RGO matrix can be envisioned for roll-to-roll nanomanufacturing due to the ease and scalability of this high-temperature radiative heating process.

Hydrogenation Driven Conductive Na2Ti3O7 Nanoarrays as Robust Binder-Free Anodes for Sodium-Ion Batteries

We present a general and rational approach to fabricate highly accessible and affordable sodium-ion battery anodes by engineering three-dimensional hydrogenated Na2Ti3O7 nanoarrays supported on flexible Ti substrates. The hydrogenated Na2Ti3O7 nanoarrays exhibit desirable properties for sodium storage, such as high surface area, high electrical conductivity, and Na(+) diffusivity. The as-obtained nanoarrays demonstrate remarkably stable and robust Na-storage performance when tested as binder-free anodes for sodium-ion battery. They can afford a high reversible (desodiation) capacity of 227 mAh g(-1) and retain a capacity of 65 mAh g(-1) over 10,000 continuous cycles at a high rate of 35 C. Therefore, through this synergy of array architecture and hydrogenation, it is possible to engineer numerous anodes that can reversibly store Na(+) ions in a fast and stable manner.

A Deep Reduction and Partial Oxidation Strategy for Fabrication of Mesoporous Si Anode for Lithium Ion Batteries

A deep reduction and partial oxidation strategy to convert low-cost SiO2 into mesoporous Si anode with the yield higher than 90% is provided. This strategy has advantage in efficient mesoporous silicon production and in situ formation of several nanometers SiO2 layer on the surface of silicon particles. Thus, the resulted silicon anode provides extremely high reversible capacity of 1772 mAh g(-1), superior cycling stability with more than 873 mAh g(-1) at 1.8 A g(-1) after 1400 cycles (corresponding to the capacity decay rate of 0.035% per cycle), and good rate capability (∼710 mAh g(-1) at 18A g(-1)). These promising results suggest that such strategy for mesoporous Si anode can be potentially commercialized for high energy Li-ion batteries.

Towards cost-effective silicon anodes using conductive polyaniline-encapsulated silicon micropowders

To overcome the remaining issues of nanostructured Si anode, we investigated the feasibility towards practically viable Si anode by combining low-cost material precursors with facile and scalable processes.