Epitaxial Welding of Carbon Nanotube Networks for Aqueous Battery Current Collectors

Ultrafast-Loaded Nickel Sulfide on Vertical Graphene Enabled by Joule Heating for Enhanced Lithium Metal Batteries

The design and fabrication of a lithiophilic skeleton are highly important for constructing advanced Li metal anodes. In this work, a new lithiophilic skeleton is reported by planting metal sulfides (e.g., Ni3S2) on vertical graphene (VG) via a facile ultrafast Joule heating (UJH) method, which facilitates the homogeneous distribution of lithiophilic sites on carbon cloth (CC) supported VG substrate with firm bonding. Ni3S2 nanoparticles are homogeneously anchored on the optimized skeleton as CC/VG@Ni3S2, which ensures high conductivity and uniform deposition of Li metal with non-dendrites. By means of systematic electrochemical characterizations, the symmetric cells coupled with CC/VG@Ni3S2 deliver a steady long-term cycle within 14 mV overpotential for 1800 h (900 cycles) at 1 mA cm-2 and 1 mAh cm-2. Meanwhile, the designed CC/VG@Ni3S2-Li||LFP full cell shows notable electrochemical performance with a capacity retention of 92.44% at 0.5 C after 500 cycles and exceptional rate performance. This novel synthesis strategy for metal sulfides on hierarchical carbon-based materials sheds new light on the development of high-performance lithium metal batteries (LMBs).

Aluminum corrosion-passivation regulation prolongs aqueous batteries life

Aluminum current collectors are widely used in nonaqueous batteries owing to their cost-effectiveness, lightweightness, and ease of fabrication. However, they are excluded from aqueous batteries due to their severe corrosion in aqueous solutions. Here, we propose hydrolyzation-type anodic additives to form a robust passivation layer to suppress corrosion. These additives dramatically lower the corrosion current density of aluminum by nearly three orders of magnitude to ~10-6 A cm-2. In addition, realizing that electrochemical corrosion accompanies anode prelithiation, we propose a prototype of self-prolonging aqueous Li-ion batteries (Al ||LiMn2O4 ||TiO2), whose capacity retention rises from 49.5% to 70.1% after 200 cycles. A sacrificial aluminum electrode where electrochemical corrosion is utilized is introduced as an electron supplement to prolong the cycling life of aqueous batteries. Our work addresses the short-life issue of aqueous batteries resulting from the corrosion of the current collector and lithium loss from side reactions.

Toward High-Energy-Density Aqueous Lithium-Ion Batteries Using Silver Nanowires as Current Collectors

The lack of suitable lightweight current collectors is one of the primary obstacles preventing the energy density of aqueous lithium-ion batteries (ALIBs) from becoming competitive. Using silver nanowire (AgNW) films as current collectors and a molecular crowding electrolyte, we herein report the fabrication of ALIBs with relatively good energy densities. In the 2 m LiTFSI-94% PEG-6% H₂O solution, the AgNW films with a sheet resistance of less than 1.0 ohm/square exhibited an electrochemical stability window as broad as 3.8 V. The LiMn₂O₄//Li₄Ti₅O₁₂ ALIBs using AgNW films as the current collectors demonstrated an initial energy density of 70 Wh/kg weighed by the total mass of the cathode and anode, which retained 89.1% after 50 cycles.

Direct-Chemical Vapor Deposition-Enabled Graphene for Emerging Energy Storage: Versatility, Essentiality, and Possibility

The direct chemical vapor deposition (CVD) technique has stimulated an enormous scientific and industrial interest to enable the conformal growth of graphene over multifarious substrates, which readily bypasses tedious transfer procedure and empowers innovative materials paradigm. Compared to the prevailing graphene materials (i.e., reduced graphene oxide and liquid-phase exfoliated graphene), the direct-CVD-enabled graphene harnesses appealing structural advantages and physicochemical properties, accordingly playing a pivotal role in the realm of electrochemical energy storage. Despite conspicuous progress achieved in this frontier, a comprehensive overview is still lacking by far and the synthesis-structure-property-application nexus of direct-CVD-enabled graphene remains elusive. In this topical review, rather than simply compiling the state-of-the-art advancements, the versatile roles of direct-CVD-enabled graphene are itemized as (i) modificator, (ii) cultivator, (iii) defender, and (iv) decider. Furthermore, essential effects on the performance optimization are elucidated, with an emphasis on fundamental properties and underlying mechanisms. At the end, perspectives with respect to the material production and device fabrication are sketched, aiming to navigate the future development of direct-CVD-enabled graphene en-route toward pragmatic energy applications and beyond.

Epitaxial Electrocrystallization of Magnesium via Synergy of Magnesiophilic Interface, Lattice Matching, and Electrostatic Confinement

Rechargeable magnesium batteries are particularly advantageous for renewable energy storage systems. However, the inhomogeneous Mg electrodeposits greatly shorten their cycle life under practical conditions. Herein, the epitaxial electrocrystallization of Mg on a three-dimensional magnesiophilic host is implemented via the synergy of a magnesiophilic interface, lattice matching, and electrostatic confinement effects. The vertically aligned nickel hydroxide nanosheet arrays grown on carbon cloth (abbreviated as "Ni(OH)₂@CC") have been delicately designed, which satisfy the essential prerequisite of a low lattice geometrical misfit with Mg (about 2.8%) to realize epitaxial electrocrystallization. Simultaneously, the ionic crystal nature of Ni(OH)₂ displays a periodic and hillock-like electrostatic potential field over its exposed facets, which can precisely capture and confine the reduced Mg⁰ species onto the local electron-enriched sites at the atomic level. The Ni(OH)₂@CC substrate undergoes sequential Mg-ion intercalation, underpotential deposition, and electrocrystallization processes, during which the uniform, lamellar Mg electrodeposits with a locked crystallographic orientation are formed. Under practical conditions (10 mA cm^-2 and 10 mAh cm^-2), the Ni(OH)₂@CC substrate exhibits stable Mg stripping/plating cycle performances over 600 h, 2 orders of magnitude longer than those of the pristine copper foil and carbon cloth substrates.

Recent Trends in Carbon Nanotube Electrodes for Flexible Supercapacitors: A Review of Smart Energy Storage Device Assembly and Performance

In order to upgrade existing electronic technology, we need simultaneously to advance power supply devices to match emerging requirements. Owing to the rapidly growing wearable and portable electronics markets, the demand to develop flexible energy storage devices is among the top priorities for humankind. Flexible supercapacitors (FSCs) have attracted tremendous attention, owing to their unrivaled electrochemical performances, long cyclability and mechanical flexibility. Carbon nanotubes (CNTs), long recognized for their mechanical toughness, with an elastic strain limit of up to 20%, are regarded as potential candidates for FSC electrodes. Along with excellent mechanical properties, high electrical conductivity, and large surface area, their assemblage adaptability from one-dimensional fibers to two-dimensional films to three-dimensional sponges makes CNTs attractive. In this review, we have summarized various assemblies of CNT structures, and their involvement in various device configurations of FSCs. Furthermore, to present a clear scenario of recent developments, we discuss the electrochemical performance of fabricated flexible devices of different CNT structures and their composites, including additional properties such as compressibility and stretchability. Additionally, the drawbacks and benefits of the study and further potential scopes are distinctly emphasized for future researchers.

Flexible Strain-Sensitive Silicone-CNT Sensor for Human Motion Detection

This article describes the manufacturing technology of biocompatible flexible strain-sensitive sensor based on Ecoflex silicone and multi-walled carbon nanotubes (MWCNT). The sensor demonstrates resistive behavior. Structural, electrical, and mechanical characteristics are compared. It is shown that laser radiation significantly reduces the resistance of the material. Through laser radiation, electrically conductive networks of MWCNT are formed in a silicone matrix. The developed sensor demonstrates highly sensitive characteristics: gauge factor at 100% elongation −4.9, gauge factor at 90° bending −0.9%/deg, stretchability up to 725%, tensile strength 0.7 MPa, modulus of elasticity at 100% 46 kPa, and the temperature coefficient of resistance in the range of 30–40 °C is −2 × 10⁻³. There is a linear sensor response (with 1 ms response time) with a low hysteresis of ≤3%. An electronic unit for reading and processing sensor signals based on the ATXMEGA8E5-AU microcontroller has been developed. The unit was set to operate the sensor in the range of electrical resistance 5–150 kOhm. The Bluetooth module made it possible to transfer the received data to a personal computer. Currently, in the field of wearable technologies and health monitoring, a vital need is the development of flexible sensors attached to the human body to track various indicators. By integrating the sensor with the joints of the human hand, effective movement sensing has been demonstrated.

Hydrophobic, flexible electromagnetic interference shielding films derived from hydrolysate of waste leather scraps

With the rapid development of wireless telecommunication technologies, it is of fundamental and technological significance to design and engineer high-performance shielding materials against electromagnetic interference (EMI). Herein, a three-step procedure is developed to produce hydrophobic, flexible nanofiber films for EMI shielding and pressure sensing based on hydrolysate of waste leather scraps (HWLS): (i) electrospinning preparation of HWLS/polyacrylonitrile (PAN) nanofiber films, (ii) adsorption of silver nanowires (AgNWs) onto HWLS/PAN nanofiber films, and (iii) coating of HWLS/PAN/AgNWs nanofiber films with polydimethylsiloxane (PDMS). Scanning electron microscopy studies show that AgNWs are interweaved with HWLS/PAN nanofibers to form a conductive network, exhibiting an electrical conductivity of 10⁵ S m^-1 and shielding efficiency of 65 dB for a 150 μm-thick HWLS/PAN/AgNWs film. The HWLS/PAN/AgNWs/PDMS film displays an even better electromagnetic shielding efficiency of 80 dB and a water contact angle of 132.5°. Results from this study highlight the unique potential of leather solid wastes for the production of high-performance, environmentally friendly, and low-cost EMI shielding materials.

Electrically Conductive Networks from Hybrids of Carbon Nanotubes and Graphene Created by Laser Radiation

A technology for the formation of electrically conductive nanostructures from single-walled carbon nanotubes (SWCNT), multi-walled carbon nanotubes (MWCNT), and their hybrids with reduced graphene oxide (rGO) on Si substrate has been developed. Under the action of single pulses of laser irradiation, nanowelding of SWCNT and MWCNT nanotubes with graphene sheets was obtained. Dependences of electromagnetic wave absorption by films of short and long nanotubes with subnanometer and nanometer diameters on wavelength are calculated. It was determined from dependences that absorption maxima of various types of nanotubes are in the wavelength region of about 266 nm. It was found that contact between nanotube and graphene was formed in time up to 400 fs. Formation of networks of SWCNT/MWCNT and their hybrids with rGO at threshold energy densities of 0.3/0.5 J/cm² is shown. With an increase in energy density above the threshold value, formation of amorphous carbon nanoinclusions on the surface of nanotubes was demonstrated. For all films, except the MWCNT film, an increase in defectiveness after laser irradiation was obtained, which is associated with appearance of C–C bonds with neighboring nanotubes or graphene sheets. CNTs played the role of bridges connecting graphene sheets. Laser-synthesized hybrid nanostructures demonstrated the highest hardness compared to pure nanotubes. Maximum hardness (52.7 GPa) was obtained for MWCNT/rGO topology. Regularity of an increase in electrical conductivity of nanostructures after laser irradiation has been established for films made of all nanomaterials. Hybrid structures of nanotubes and graphene sheets have the highest electrical conductivity compared to networks of pure nanotubes. Maximum electrical conductivity was obtained for MWCNT/rGO hybrid structure (~22.6 kS/m). Networks of nanotubes and CNT/rGO hybrids can be used to form strong electrically conductive interconnections in nanoelectronics, as well as to create components for flexible electronics and bioelectronics, including intelligent wearable devices (IWDs).

Scalable 18,650 aqueous-based supercapacitors using hydrophobicity concept of anti-corrosion graphite passivation layer

Scalable aqueous-based supercapacitors are ideal as future energy storage technologies due to their great safety, low cost, and environmental friendliness. However, the corrosion of metal current collectors e.g., aluminium (Al) foil in aqueous solutions limits their practical applications. In this work, we demonstrate a low-cost, scalable, and simple method to prepare an anti-corrosion current collector using a concept of hydrophobicity by coating the hydrophobic graphite passivation layer on the Al foil via a roll-to-roll coating technology at the semi-automation scale of production pilot plant of 18,650 cylindrical supercapacitor cells. All qualities of materials, electrodes, and production process are therefore in the quality control as the same level of commercial supercapacitors. In addition, the effects of the graphite coating layer have been fundamentally evaluated. We have found that the graphite-coated layer can improve the interfacial contact without air void space between the activated carbon active material layer and the Al foil current collector. Importantly, it can suppress the corrosion and the formation of resistive oxide film resulting in better rate capability and excellent cycling stability without capacitance loss after long cycling. The scalable supercapacitor prototypes here in this work may pave the way to practical 18,650 supercapacitors for sustainable energy storage systems in the future.

Rational Design and Engineering of One-Dimensional Hollow Nanostructures for Efficient Electrochemical Energy Storage

The unique structural characteristics of one-dimensional (1D) hollow nanostructures result in intriguing physicochemical properties and wide applications, especially for electrochemical energy storage applications. In this Minireview, we give an overview of recent developments in the rational design and engineering of various kinds of 1D hollow nanostructures with well-designed architectures, structural/compositional complexity, controllable morphologies, and enhanced electrochemical properties for different kinds of electrochemical energy storage applications (i.e. lithium-ion batteries, sodium-ion batteries, lithium-sulfur batteries, lithium-selenium sulfur batteries, lithium metal anodes, metal-air batteries, supercapacitors). We conclude with prospects on some critical challenges and possible future research directions in this field. It is anticipated that further innovative studies on the structural and compositional design of functional 1D nanostructured electrodes for energy storage applications will be stimulated.

Carbon nanotubes for flexible batteries: recent progress and future perspective

Flexible batteries, which maintain their functions potently under various mechanical deformations, attract increasing interest due to potential applications in emerging portable and wearable electronics. Significant efforts have been devoted to material synthesis and structural designs to realize the mechanical flexibility of various batteries. Carbon nanotubes (CNTs) have a unique one-dimensional (1D) nanostructure and are convenient to further assemble into diverse macroscopic structures, such as 1D fibers, 2D films and 3D sponges/aerogels. Due to their outstanding mechanical and electrical properties, CNTs and CNT-based hybrid materials are superior building blocks for different components in flexible batteries. This review summarizes recent progress on the application of CNTs in developing flexible batteries, from closed-system to open-system batteries, with a focus on different structural designs of CNT-based material systems and their roles in various batteries. We also provide perspectives on the challenges and future research directions for realizing practical applications of CNT-based flexible batteries.

Ultrathin Densified Carbon Nanotube Film with "Metal-like" Conductivity, Superior Mechanical Strength, and Ultrahigh Electromagnetic Interference Shielding Effectiveness

Flexible and lightweight high-performance electromagnetic interference shielding materials with minimal thickness, excellent mechanical properties, and outstanding reliability are highly desired in the field of fifth-generation (5G) communication, yet remain extremely challenging to manufacture. Herein, we prepared an ultrathin densified carbon nanotube (CNT) film with superior mechanical properties and ultrahigh shielding effectiveness. Upon complete removal of impurities in pristine CNT film, charge separation in individual CNTs induced by polar molecules leads to strong CNT-CNT attraction and film densification, which significantly improve the electrical conductivity, shielding performance, and mechanical strength. The tensile strength is up to 822 ± 21 MPa, meanwhile the electrical conductivity is as high as 902,712 S/m, and the density is only 1.39 g cm^-3. Notably, the shielding effectiveness is over 51 dB with a thickness of merely 1.85 μm in the broad frequency range of 4-18 GHz, and it reaches to ∼82 dB at 6.36 μm and ∼101 dB at 14.7 μm, respectively. Further, such CNT film exhibits excellent reliability after an extended period in strong acid/alkali, high temperature, and high humidity. It demonstrates the best overall performance among representative shielding materials by far, representing a critical breakthrough in the preparation of shielding film toward applications in wearable electronics and 5G communication.

Carbon Nanotube Reinforced Strong Carbon Matrix Composites

As an excellent candidate for lightweight structural materials and nonmetal electrical conductors, carbon nanotube reinforced carbon matrix (CNT/C) composites have potential use in technologies employed in aerospace, military, and defense endeavors, where the combinations of light weight, high strength, and excellent conductivity are required. Both polymer infiltration pyrolysis (PIP) and chemical vapor infiltration (CVI) methods have been widely studied for CNT/C composite fabrications with diverse focuses and various modifications. Progress has been reported to optimize the performance of CNT/C composites from broad aspects, including matrix densification, CNT alignment, microstructure control, and interface engineering, etc. Recent approaches, such as using resistance heating for PIP or CVI, contribute to the development of CNT/C composites. To deliver a timely and up-to-date overview of CNT/C composites, we have reviewed the most recent trends in fabrication processes, summarized the mechanical reinforcement mechanism, and discussed the electrical and thermal properties, as well as relevant case studies for high-temperature applications. Conclusions and perspectives addressing future routes for performance optimization are also presented. Hence, this review serves as a rundown of recent advances in CNT/C composites and will be a valuable resource to aid future developments in this field.

Rapid Nanowelding of Carbon Coatings onto Glass Fibers by Electrothermal Shock

With the rapid development of nanomanufacturing, scaling up of nanomaterials requires advanced manufacturing technology to composite nanomaterials with disparate materials (ceramics, metals, and polymers) to achieve hybrid properties and coupling performances for practical applications. Attempts to assemble nanomaterials onto macroscopic materials are often accompanied by the loss of exceptional nanoscale properties during the fabrication process, which is mainly due to the poor contacts between carbon nanomaterials and macroscopic bulk materials. In this work, we proposed a novel cross-scale manufacturing concept to process disparate materials in different length scales and successfully demonstrated an electrothermal shock approach to process the nanoscale material (e.g., carbon nanotubes) and macroscale (e.g., glass fiber) with good bonding and excellent mechanical property for emerging applications. The excellent performance and potentially lower cost of the electrothermal shock technology offers a continuous, ultrafast, energy-efficient, and roll-to-roll process as a promising heating solution for cross-scale manufacturing.

Downscaling of sample entropy of nanofluids by carbon allotropes: A thermal lens study

The work reported in this paper is the first attempt to delineate the molecular or particle dynamics from the thermal lens signal of carbon allotropic nanofluids (CANs), employing time series and fractal analyses. The nanofluids of multi-walled carbon nanotubes and graphene are prepared in base fluid, coconut oil, at low volume fraction and are subjected to thermal lens study. We have studied the thermal diffusivity and refractive index variations of the medium by analyzing the thermal lens (TL) signal. By segmenting the TL signal, the complex dynamics involved during its evolution is investigated through the phase portrait, fractal dimension, Hurst exponent, and sample entropy using time series and fractal analyses. The study also explains how the increase of the photothermal energy turns a system into stochastic and anti-persistent. The sample entropy (S) and refractive index analyses of the TL signal by segmenting into five regions reveal the evolution of S with the increase of enthalpy. The lowering of S in CAN along with its thermal diffusivity (50%-57% below) as a result of heat-trapping suggests the technique of downscaling sample entropy of the base fluid using carbon allotropes and thereby opening a novel method of improving the efficiency of thermal systems.

Graphene foil as a current collector for NCM material-based cathodes

When used as a current collector, aluminum foil (AF) is vulnerable to local anodic corrosion during the charge/discharge process, which can lead to the deterioration of lithium-ion batteries (LIBs). Herein, a graphene foil (GF) with high electrical conductivity (∼5800 S cm^-1) and low mass density (1.80 g cm^-3) was prepared by reduction of graphene oxide foil with ultra-high temperature (2800 °C) annealing, and it exhibited significantly anodic corrosion resistance when serving as a current collector. Moreover, a LiNi_0.5Co_0.2Mn_0.3O₂ (NCM523) cathode using GF as a current collector (NCM523/GF) demonstrated a gravimetric capacity of 137.3 mAh g^-1 at 0.5 C based on the mass of the whole electrode consisting of the active material, carbon black, binder, and the current collector, which is 44.5% higher than that of the NCM523/AF electrode. Furthermore, the NCM523/GF electrode retains higher capacity at relatively faster rates, from 0.1 C to 5.0 C. Therefore, GF, a lightweight corrosion-resistant current collector, is expected to replace the current commercial metal current collectors in LIBs and to achieve high energy-density batteries.

Fast and efficient electrical–thermal responses of functional nanoparticle decorated nanocarbon aerogels

We report multifunctional nanoparticle/nanocarbon hybrid aerogels for effective and energy-efficient regeneration of exhausted functional nanoparticles.

Fly-through synthesis of nanoparticles on textile and paper substrates

The fast and efficient synthesis of nanoparticles on flexible and lightweight substrates is increasingly critical for various medical and wearable applications. However, conventional high temperature (high-T) processes for nanoparticle synthesis are intrinsically incompatible with temperature-sensitive substrates, including textiles and paper (i.e. low-T substrates). In this work, we report a non-contact, 'fly-through' method to synthesize nanoparticles on low-T substrates by rapid radiative heating under short timescales. As a demonstration, textile substrates loaded with platinum (Pt) salt precursor are rapidly heated and quenched as they move across a 2000 K heating source at a continuous production speed of 0.5 cm s-1. The rapid radiative heating method induces the thermal decomposition of various precursor salts and nanoparticle formation, while the short duration ensures negligible change to the respective low-T substrate along with greatly improved production efficiency. The reported method can be generally applied to the synthesis of metal nanoparticles (e.g. gold and ruthenium) on various low-T substrates (e.g. paper). The non-contact and continuous 'fly-through' synthesis offers a robust and efficient way to synthesize supported nanoparticles on flexible and lightweight substrates. It is also promising for ultrafast and roll-to-roll manufacturing to enable viable applications.