Chemical Evolution in Silicon-Graphite Composite Anodes Investigated by Vibrational Spectroscopy

Innovative Solutions for High-Performance Silicon Anodes in Lithium-Ion Batteries: Overcoming Challenges and Real-World Applications

Silicon (Si) has emerged as a potent anode material for lithium-ion batteries (LIBs), but faces challenges like low electrical conductivity and significant volume changes during lithiation/delithiation, leading to material pulverization and capacity degradation. Recent research on nanostructured Si aims to mitigate volume expansion and enhance electrochemical performance, yet still grapples with issues like pulverization, unstable solid electrolyte interface (SEI) growth, and interparticle resistance. This review delves into innovative strategies for optimizing Si anodes' electrochemical performance via structural engineering, focusing on the synthesis of Si/C composites, engineering multidimensional nanostructures, and applying non-carbonaceous coatings. Forming a stable SEI is vital to prevent electrolyte decomposition and enhance Li+ transport, thereby stabilizing the Si anode interface and boosting cycling Coulombic efficiency. We also examine groundbreaking advancements such as self-healing polymers and advanced prelithiation methods to improve initial Coulombic efficiency and combat capacity loss. Our review uniquely provides a detailed examination of these strategies in real-world applications, moving beyond theoretical discussions. It offers a critical analysis of these approaches in terms of performance enhancement, scalability, and commercial feasibility. In conclusion, this review presents a comprehensive view and a forward-looking perspective on designing robust, high-performance Si-based anodes the next generation of LIBs.

Unlocking High-Current Performance in Silicon Anode: Synergistic Phosphorus Doping and Nitrogen-Doped Carbon Encapsulation to Enhance Lithium Diffusivity

The silicon (Si) offers enormous theoretical capacity as a lithium-ion battery (LIB) anode. However, the low charge mobility in Si particles hinders its application for high current loading. In this study, ball-milled phosphorus-doped Si nanoparticles encapsulated with nitrogen-doped carbon (P-Si@N-C) are employed as an anode for LIBs. P-doped Si nanoparticles are first obtained via ball-milling and calcination of Si with phosphoric acid. N-doped carbon encapsulation is then introduced via carbonization of the surfactant-assisted polymerization of pyrrole monomer on P-doped Si. While P dopant is required to support the stability at high current density, the encapsulation of Si particles with N-doped carbon is influential in enhancing the overall Li+ diffusivity of the Si anode. The combined approaches improve the anode's Li+ diffusivity up to tenfold compared to the untreated anode. It leads to exceptional anode stability at a high current, retaining 87 % of its initial capacity under a large current rate of 4000 mA g-1. The full-cell comprising P-Si@N-C anode and LiFePO4 cathode demonstrates 94 % capacity retention of its initial capacity after 100 cycles at 1 C. This study explores the effective strategies to improve Li+ diffusivity for high-rate Si-based anode.

Sputtered Silicon-Coated Graphite Electrodes as High Cycling Stability and Improved Kinetics Anodes for Lithium Ion Batteries

Amorphous Si thin films with different thicknesses were deposited on synthetic graphite electrodes by using a simple and scalable one-step physical vapor deposition (PVD) method. The specific capacities and rate capabilities of the produced electrodes were investigated. X-ray diffraction, scanning electron microscopy, Raman spectroscopy, profilometry, cyclic voltammetry, galvanostatic techniques, and in situ Raman spectroscopy were used to investigate their physicochemical and electrochemical properties. Our results demonstrated that the produced Si films covered the bare graphite electrodes completely and uniformly. Si-coated graphite, Si@G, with an optimal thickness of 1 μm exhibited good stability, with an initial discharge capacity of 628.7 mAhg-1, a capacity retention of 96.2%, and a columbic efficiency (CE) higher than 99% at C/3. A discharge capacity of 250 mAh g-1 was attained at a high current rate of 3C, which was over 2.5 times that of a bare graphite electrode, thanks to the high activated surface area (1.5 times that of pristine graphite) and reduced resistance during cycling.

Electrochemical Properties of Laser-Printed Multilayer Anodes for Lithium-Ion Batteries

New electrode architectures promise huge potential for improving batteries' electrochemical properties, such as power density, energy density, and lifetime. In this work, the use of laser-induced forward transfer (LIFT) was employed and evaluated as a tool for the development of advanced electrode architectures. For this purpose, it was first confirmed that the printing process has no effect on the transferred battery material by comparing the electrochemical performance of the printed anodes with state-of-the-art coated ones. For this, polyvinylidene fluoride (PVDF) was used as a binder and n-methyl-2-pyrrolidone (NMP) as a solvent, which is reported to be printable. Subsequently, multilayer electrodes with flake-like and spherical graphite particles were printed to test if a combination of their electrochemical related properties can be realized with measured specific capacities ranging from 321 mAh·g-1 to 351 mAh·g-1. Further, a multilayer anode design with a silicon-rich intermediate layer was printed and electrochemically characterized. The initial specific capacity was found to be 745 mAh·g-1. The presented results show that the LIFT technology offers the possibility to generate alternative electrode designs, promoting research in the optimization of 3D battery systems.

Functionalized Silicon Particles for Enhanced Half- and Full-Cell Cycling of Si-Based Li-Ion Batteries

Vinylene carbonate (VC) and polyethylene oxide (PEO) have been investigated as functional agents that mimic the solid electrolyte interphase (SEI) chemistry of silicon (Si). VC and PEO are known to contribute to the stability of Si-based lithium-ion batteries as an electrolyte additive and as a SEI component, respectively. In this work, covalent surface functionalization was achieved via a facile route, which involves ball-milling the Si particles with sacrificial VC and PEO. Thermogravimetric analysis (TGA), X-ray photoelectron spectroscopy (XPS), and magic angle spinning nuclear magnetic resonance (MAS NMR) spectroscopy indicate that the additives are strongly bound to Si. In particular, MAS NMR shows Si-R or Si-O-R groups, which confirm functionalization of the Si after milling in VC or PEO. Particle size analysis by dynamic light scattering reveals that the additives facilitate particle size reduction and that the functionalized particles result in more stable dispersions based on zeta potential measurements. Raman mapping of the electrodes fabricated from the VC and PEO-coated active material with a polyacrylic acid (PAA) binder reveals a more homogenous distribution of Si and the carbon conductive additive compared to the electrodes prepared from the neat Si. Furthermore, the VC-milled Si strikingly exhibited the highest capacity in both half- and full-cell configurations, with more than 200 mAh g^-1 measured capacity compared to the neat Si in the half-cell format. This is linked to an improved electrode processing based on the Raman and zeta potential measurements as well as a thinner SEI (with more organic components for the functionalized Si relative to the neat Si) based on XPS analysis of the cycled electrodes. The effect of binder was also investigated by comparing PAA with P84 (polyimide type), where an increased capacity is observed in the latter case.

Recent Progress in Silicon-Based Materials for Performance-Enhanced Lithium-Ion Batteries

Silicon (Si) has been considered to be one of the most promising anode materials for high energy density lithium-ion batteries (LIBs) due to its high theoretical capacity, low discharge platform, abundant raw materials and environmental friendliness. However, the large volume changes, unstable solid electrolyte interphase (SEI) formation during cycling and intrinsic low conductivity of Si hinder its practical applications. Various modification strategies have been widely developed to enhance the lithium storage properties of Si-based anodes, including cycling stability and rate capabilities. In this review, recent modification methods to suppress structural collapse and electric conductivity are summarized in terms of structural design, oxide complexing and Si alloys, etc. Moreover, other performance enhancement factors, such as pre-lithiation, surface engineering and binders are briefly discussed. The mechanisms behind the performance enhancement of various Si-based composites characterized by in/ex situ techniques are also reviewed. Finally, we briefly highlight the existing challenges and future development prospects of Si-based anode materials.

Wrapping silicon microparticles by using well-dispersed single-walled carbon nanotubes for the preparation of high-performance lithium-ion battery anode

Silicon microparticles (SiMPs) show considerable promise as an anode material in high-performance lithium-ion batteries (LIBs) because of their low-cost starting material and high capacity. The failure issues associated with the intrinsically low conductivity and significant volume expansion of Si have largely been resolved by designing silicon/carbon composites using carbon nanotubes (CNTs). The CNTs are important in terms of stress dissipation and the conductive network in Si/CNT composites. Here, we synthesized a SiMP/2D CNT sheet wrapping composite (SiMP/CNT wrapping) via a facile freeze-drying method with the use of highly dispersed single-walled CNTs. In this work, the well-dispersed CNTs are easily mixed with Si, resulting in effective CNT wrapping on the SiMP surface. During freeze-drying, the CNTs are self-assembled into a segregated 2D CNT sheet morphology via van der Waals interactions. The resulting CNT wrapping shows a unique wide range of conductive networks and mesh-like CNT sheets with void spaces. The SiMP/CNT wrapping 9 : 1 electrode exhibits good rate and cycle performance. The first charge/discharge capacity of SiMP/CNT wrapping 9 : 1 is 3160.7 mA h g^-1/3469.1 mA h g^-1 at 0.1 A g^-1 with superior initial coulombic efficiency of 91.11%. After cycling, the SiMP/CNT wrapping electrode shows good structural integrity with preserved electrical conductivity. The superior electrochemical performance of the SiMP/CNT wrapping composite can be explained by an extensive conductive CNT network on the SiMPs and facile lithium-ion diffusion via mesh-like CNT wrapping.

Understanding the Capacity Decay of Si/NMC622 Li-Ion Batteries Cycled in Superconcentrated Ionic Liquid Electrolytes: A New Perspective

Silicon-containing Li-ion batteries have been the focus of many energy storage research efforts because of the promise of high energy density. Depending on the system, silicon generally demonstrates stable performance in half-cells, which is often attributed to the unlimited lithium supply from the lithium (Li) metal counter electrode. Here, the electrochemical performance of silicon with a high voltage NMC622 cathode was investigated in superconcentrated phosphonium-based ionic liquid (IL) electrolytes. As a matter of fact, there is very limited work and understanding of the full cell cycling of silicon in such a new class of electrolytes. The electrochemical behavior of silicon in the various IL electrolytes shows a gradual and steeper capacity decay, compared to what we previously reported in half-cells. This behavior is linked to a different evolution of the silicon morphology upon cycling, and the characterization of cycled electrodes points toward mechanical reasons, complete disconnection of part of the electrode, or internal mechanical stress, due to silicon and Li metal volume variation upon cycling, to explain the progressive capacity fading in full cell configuration. An extremely stable solid electrolyte interphase (SEI) in the full Li-ion cells can be seen from a combination of qualitative and quantitative information from transmission electron microscopy, X-ray photoelectron spectroscopy, electrochemical impedance spectroscopy, and magic angle spinning nuclear magnetic resonance. Our findings provide a new perspective to full cell interpretation regarding capacity fading, which is oftentimes linked almost exclusively to the loss of Li inventory but also more broadly, and provide new insights into the impact of the evolution of silicon morphology on the electrochemical behavior.

High Initial Coulombic Efficiency of SiO Enabled by Controlling SiO2 Matrix Crystallization

SiO is a promising anode material for practical Li-ion batteries because it can achieve a much higher capacity than graphite and a better capacity retention than Si. However, SiO suffers from poor initial Coulombic efficiency (ICE). Here, we report on a fundamentally different approach to increase the low ICE of SiO while achieving high capacity and long-term cycle stability compared to previous approaches such as electrochemical/chemical pre-lithiation processes. To enhance the ICE, the long-range/short-range orders of amorphous SiO₂ in SiO are increased by the chemical reaction of a small amount of LiOH·H₂O even at a much lower temperature (900 °C) than the reported. The increased crystallization of SiO₂ substantially reduces the irreversible electrochemical reaction of SiO. As a result, the Li-added SiO shows substantially increased ICE, ∼82.7%, which is one of the highest values. Furthermore, we demonstrate that controlling the crystallization of SiO can enable us to achieve high ICE, high reversible capacity, and superior capacity retention (∼100% at 1C rate for 100 cycles) in SiO simultaneously. The understanding and findings will pave the way to design high-capacity SiO with high ICE and long-term stability for practical high energy density Li batteries.

Chemical Interplay of Silicon and Graphite in a Composite Electrode in SEI Formation

We investigated the effect of the Si/graphite weight ratio in half-cells on the solid electrolyte interphase (SEI) layer's chemistry. The nominal concentrations of active materials were (wt % Si/wt % Gr) 15/73, 30/58, 60/28, and 80/0. The electrolyte in the cells consisted of either 1.2 M LiPF₆ in ethylene carbonate/ethyl methyl carbonate (3:7 by wt) or 1.2 M LiPF₆ in ethylene carbonate:ethyl methyl carbonate (3:7 by wt) + 10 wt % fluoroethylene carbonate. These coin cells were cycled five times at the C/10 rate. As expected, the addition of silicon to the electrode significantly increased the measured capacity. Examination of the aged composite material showed that the electrolyte influenced the concentration of chemical environments on the surface. Depth profiling revealed that these concentrations of surface environments changed with sputtering time. A statistics-of-mixtures model was used to deconvolute how silicon and graphite interacted during the formation of these species and how the interaction changed with depth.

Direct Measure of Electrode Spatial Heterogeneity: Influence of Processing Conditions on Anode Architecture and Performance

In this work, the spatial (in)homogeneity of aqueous processed silicon electrodes using standard poly(acrylic acid)-based binders and slurry preparation conditions is demonstrated. X-ray nanotomography shows segregation of materials into submicron-thick layers depending on the mixing method and starting binder molecular weights. Using a dispersant, or in situ production of dispersant from the cleavage of the binder into smaller molecular weight species, increases the resulting lateral homogeneity while drastically decreasing the vertical homogeneity as a result of sedimentation and separation due to gravitational forces. This data explains some of the variability in the literature with respect to silicon electrode performance and demonstrates two potential ways to improve slurry-based electrode fabrications.

Three-Dimensional Mapping of Resistivity and Microstructure of Composite Electrodes for Lithium-Ion Batteries

Nanoparticle silicon-graphite composite electrodes are a viable way to advance the cycle life and energy density of lithium-ion batteries. However, characterization of composite electrode architectures is complicated by the heterogeneous mixture of electrode components and nanoscale diameter of particles, which falls beneath the lateral and depth resolution of most laboratory-based instruments. In this work, we report an original laboratory-based scanning probe microscopy approach to investigate composite electrode microstructures with nanometer-scale resolution via contrast in the electronic properties of electrode components. Applying this technique to silicon-based composite anodes demonstrates that graphite, SiO_x nanoparticles, carbon black, and LiPAA binder are all readily distinguished by their intrinsic electronic properties, with measured electronic resistivity closely matching their known material properties. Resolution is demonstrated by identification of individual nanoparticles as small as ∼20 nm. This technique presents future utility in multiscale characterization to better understand particle dispersion, localized lithiation, and degradation processes in composite electrodes for lithium-ion batteries.

Capacity Loss Mechanism of the Li4Ti5O12 Microsphere Anode of Lithium-Ion Batteries at High Temperature and Rate Cycling Conditions

Li₄Ti₅O₁₂ (LTO) as the anode of lithium (Li) ion batteries has high interfacial side reactivity with the electrolyte, which leads to severe gassing behavior and poor cycling stability. Herein, the capacity loss mechanism of the high-tap density LTO microsphere anode under different temperatures (25, 45, and 60 °C) and charge/discharge rates (1 and 5 C) is systematically investigated. The capacity retentions of the LTO/Li cell after 500 cycles at 1 C are 95.6, 90.0, and 87.1% under three temperatures, which drop to 91.9, 58.3, and 20.9% when cycling at 5 C, respectively. Results show that the high temperature and rate almost do not damage the structure of LTO, but greatly affect the thickness and components of the solid electrolyte interface (SEI), and consequently reduce the performance of the LTO/Li cells. An SEI mainly consisting of inorganic species forms on LTO after 500 cycles at 1 C, while organic compounds are observed after 500 cycles at 5 C. The capacity of cycled LTO cannot recover again because of the thick SEI although using new Li metal anodes, separators, and electrolytes. This work demonstrates that it is of great significance for LTO to construct a stable SEI for achieving excellent cycling performance at a high rate and temperature.

Full-Cell Cycling of a Self-Supporting Aluminum Foil Anode with a Phosphate Conversion Coating

Aluminum foil is a promising candidate anode material for lithium-ion batteries (LIBs), due to its high theoretical capacity, low lithiation voltage, and abundance. However, as a matter of fact, it has been a great challenge to make Al foil cycle in full cells at industrially acceptable areal capacities of 2-4 mAh/cm² for commercial 18650 LIBs and some high-power LIBs. In this study, we defined the concepts of electrochemical true contact area (ECA) (areas with perfect electrolyte/electrode contact) and electrochemical noncontact area (ENA) (referred to regions without electrolyte spread on) for the metal foil anode. An initial ECA/ENA partition would cause severe inhomogeneity of the alloying reaction, cause localized electrode pulverization, and exacerbate ECA/ENA inequality even more. Through a phosphate conversion coating on aluminum foil, we killed two birds with one stone: first, the Al foil with a phosphate conversion coating has improved wettability (characterized by the contact angle that decreased from 35.2 to 15.9°) and favors the elimination of ENA, thus guaranteeing uniform electrochemical contact; also, the coating functions as an artificial solid electrolyte interface, which stabilizes the fragile naturally formed solid electrolyte interface and a "steady-state" electrolyte/electrode interface. Therefore, when pairing the phosphated Al foil anode against a commercial LiFePO₄ (LFP) cathode (with ∼2.65 mAh/cm²), it can cycle 120 times without Li excess and stabilizes at 1.27 mAh/cm².