Low-Tortuosity Thick Electrodes with Active Materials Gradient Design for Enhanced Energy Storage

Fabrication of Soft-Hard Heterostructure Porous Carbon with Enhanced Performance for High Mass-Loading Aqueous Supercapacitors

With the increasing attention to energy and environmental issues, the high value-added utilization of biomass and pitch to functional carbon materials has become an important topic in science and technology. In this work, the soft-hard heterostructure porous carbon (NRP-HPC) is prepared by bio-template method, in which biomass and pitch are used as hard carbon and soft carbon precursors, respectively. The prepared NRP-HPC-4 shows high specific surface area (2293 m2 g-1), suitable pore size distribution, good conductivity (0.25 Ω cm-1), and strong wettability. The synergistic effect of soft carbon and hard carbon ensures the composite material exhibiting excellent electrochemical performance for high mass loading (12.0 mg cm-2) aqueous supercapacitor, i.e., high specific capacitance (304.69 F g-1 at 0.1 A g-1), high area capacitance (3.67 F cm-2 at 0.1 A g-1), high volumetric specific capacitance (202.74 F cm-3 at 0.1 A g-1), low open-circuit voltage attenuation rate (21.04 mV h-1), good voltage retention (79.12%), and excellent cyclic stability (92.04% capacitance retention and 100% coulombic efficiency after 20 000 cycles). The composite technology of soft carbon and hard carbon not only ensures the prepared porous carbon electrode materials with enhanced electrochemical performance, but also realizes the high value-added coupling utilization of biomass and pitch.

Enhancing Electrode Performance through Triple Distribution Modulation of Active Material, Conductive Agent, and Porosity

The increasing demand for large-scale energy storage propels the development of lithium-ion batteries with high energy and high power density. Low tortuosity electrodes with aligned straight channels have proved to be effective in building such batteries. However, manufacturing such low tortuosity electrodes in large scale remains extremely challenging. In contrast, high-performance electrodes with customized gradients of materials and porosity are possible to be made by industrial roll-to-roll coating process. Yet, the desired design of gradients combining materials and porosity is unclear for high-performance gradient electrodes. Here, triple gradient LiFePO4 electrodes (TGE) are fabricated featuring distribution modulation of active material, conductive agent, and porosity by combining suction filtration with the phase inversion method. The effects and mechanism of active material, conductive agent, and porosity distribution on electrode performance are analyzed by experiments. It is found that the electrode with a gradual increase of active material content from current collector to separator coupled with the distribution of conductive agent and porosity in the opposite direction, demonstrates the best rate capability, the fastest electrochemical reaction kinetics, and the highest utilization of active material. This work provides valuable insights into the design of gradient electrodes with high performance and high potential in application.

Efficient Ion Percolating Network for High-Performance All-Solid-State Cathodes

All-solid-state lithium batteries (ASSLBs) face critical challenges of low cathode loading and poor rate performances, which handicaps their energy/power densities. The widely-accepted aim of high ionic conductivity and low interfacial resistance seems insufficient to overcome these challenges. Here, it is revealed that an efficient ion percolating network in the cathode exerts a more critical influence on the electrochemical performance of ASSLBs. By constructing vertical alignment of Li0.35La0.55TiO3 nanowires (LLTO NWs) in solid-state cathode through magnetic manipulation, the ionic conductivity of the cathode increases twice compared with the cathode consisted of randomly distributed LLTO NWs. The all-solid-state LiFePO4/Li cells using poly(ethylene oxide) as the electrolyte is able to deliver high capacities of 151 mAh g-1 (2 C) and 100 mAh g-1 (5 C) at 60 °C, and a room-temperature capacity of 108 mAh g-1 can be achieved at a charging rate of 2 C. Furthermore, the cell can reach a high areal capacity of 3 mAh cm-2 even with a practical LFP loading of 20 mg cm-2. The universality of this strategy is also presented showing the demonstration in LiNi0.8Co0.1Mn0.1O2 cathodes. This work offers new pathways for designing ASSLBs with improved energy/power densities.

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.

Woven fabric-based separators with low tortuosity for sodium-ion batteries

In order to achieve high-performance and stable sodium-ion batteries, numerous attempts have been made to construct continuous ion transport pathways, in which a separator is one of the key components that affects the battery performance. In this study, a novel low-tortuosity woven fabric separator is fabricated by combining a weaving technique with a cellulose-solution method, followed by an infusion of a TEMPO-oxidized bacterial cellulose slurry into woven fabric substrates. The macropores in the fabric combine with the micropores in the oxidized bacterial cellulose to form a separator with a suitable pore structure and low tortuosity, forming a continuous sodium ion transport channel within the sodium-ion battery and effectively enhancing ion transport dynamics. The results show that, compared with a commercial polypropylene separator, the TEMPO-oxidized bacterial cellulose-woven fabric separator has a special weaving structure and lower tortuosity (0.77), as well as significant advantages in tensile strength (3.07 MPa), ionic conductivity (1.15 mS c), ionic transfer number (0.75), thermal stability, and electrochemical stability. This novel and simple preparation method provides new possibilities for achieving high-performance separators of sodium-ion batteries through rational structural design by textile technology.

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.

Orthogonal-Channel, Low-Tortuosity Carbon Nanotube Platforms for High-Performance Li-O2 Batteries

Aerogels and foams are promising electrode materials owing to their lightweight, high porosity, and large surface area for creating abundant active/catalytic sites. Tailoring their porous structure is essential toward maximum electrode performance yet remains challenging in the field. Here, by modifying a pristine carbon nanotube (CNT) sponge with random internal distribution, we present a CNT platform consisting of regular, orthogonally intercrossed through-channels centered at a suitable lateral size (around 5 μm), with low tortuosity and enhanced electrochemical kinetics under predefined compression. Our CNT platforms, grafted by bifunctional transitional metal hydroxide catalyst, overcome considerable challenges of both long cycle life and high rates simultaneously, serving as Li-O2 cathodes and achieving lifetime of 500 cycles at 0.5 mA cm-2 (275 cycles even at 1 mA cm-2) and also displaying high areal capacity (27 mA h cm-2), which are superior to most of the recently reported porous electrodes based on various materials. The mechanism involving fast triple-phase transport and reversible discharge product deposition, enabled by catalyst-loaded orthogonal channels, has been disclosed. Such structure-tailored robust CNT platforms could find many applications in electrochemical catalysis and energy storage systems.

Minimal Architecture Lithium Batteries: Toward High Energy Density Storage Solutions

The coupling of thick and dense cathodes with anode-free lithium metal configuration is a promising path to enable the next generation of high energy density solid-state batteries. In this work, LiCoO₂ (30 µm)/LiPON/Ti is considered as a model system to study the correlation between fundamental electrode properties and cell electrochemical performance, and a physical model is proposed to understand the governing phenomena. The first cycle loss is demonstrated to be constant and independent of both cathode thickness and anode configuration, and only ascribed to the diffusion coefficient's abrupt fall at high lithium contents. Subsequent cycles achieve close to 100% coulombic efficiency. The examination of the effect of cathode thickness demonstrate a nearly linear correlation with areal specific capacity for sub-100 µm LiCoO₂ and 0.1 mA cm^-2 current density. These findings bring new insights to better understand the energy density limiting factors and to suggest potential optimization approaches.

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.

Vertically assembled nanosheet networks for high-density thick battery electrodes

As one of the prevailing energy storage systems, lithium-ion batteries (LIBs) have become an essential pillar in electric vehicles (EVs) during the past decade, contributing significantly to a carbon-neutral future. However, the complete transition to electric vehicles requires LIBs with yet higher energy and power densities. Here, we propose an effective methodology via controlled nanosheet self-assembly to prepare low-tortuosity yet high-density and high-toughness thick electrodes. By introducing a delicate densification in a three-dimensionally interconnected nanosheet network to maintain its vertical architecture, facile electron and ion transports are enabled despite their high packing density. This dense and thick electrode is capable of delivering a high volumetric capacity >1,600 mAh cm^-3, with an areal capacity up to 32 mAh cm^-2, which is among the best reported in the literature. The high-performance electrodes with superior mechanical and electrochemical properties demonstrated in this work provide a potentially universal methodology in designing advanced battery electrodes with versatile anisotropic properties.

Smart Manufacturing Processes of Low-Tortuous Structures for High-Rate Electrochemical Energy Storage Devices

To maximize the performance of energy storage systems more effectively, modern batteries/supercapacitors not only require high energy density but also need to be fully recharged within a short time or capable of high-power discharge for electric vehicles and power applications. Thus, how to improve the rate capability of batteries or supercapacitors is a very important direction of research and engineering. Making low-tortuous structures is an efficient means to boost power density without replacing materials or sacrificing energy density. In recent years, numerous manufacturing methods have been developed to prepare low-tortuous configurations for fast ion transportation, leading to impressive high-rate electrochemical performance. This review paper summarizes several smart manufacturing processes for making well-aligned 3D microstructures for batteries and supercapacitors. These techniques can also be adopted in other advanced fields that require sophisticated structural control to achieve superior properties.

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.

A Figure of Merit for Fast-Charging Li-ion Battery Materials

Rate capability is characterized necessarily in almost all battery-related reports, while there is no universal metric for quantitative comparison. Here, we proposed the characteristic time of diffusion, which mainly combines the effects of diffusion coefficients and geometric sizes, as an easy-to-use figure of merit (FOM) to standardize the comparison of fast-charging battery materials. It offers an indicator to rank the rate capabilities of different battery materials and suggests two general methods to improve the rate capability: decreasing the geometric sizes or increasing the diffusion coefficients. Based on this FOM, more comprehensive FOMs for quantifying the rate capabilities of battery materials are expected by incorporating other processes (interfacial reaction, migration) into the current diffusion-dominated electrochemical model. Combined with Peukert's empirical law, it may characterize rate capabilities of batteries in the future.