Current significance and future perspective of 3D-printed bio-based polymers for applications in energy conversion and storage system

The increasing global population has led to a surge in energy demand and the production of environmentally harmful products, highlighting the urgent need for renewable and clean energy sources. In this context, sustainable and eco-friendly energy production strategies have been explored to mitigate the adverse effects of fossil fuel consumption to the environment. Additionally, efficient energy storage devices with a long lifespan are also crucial. Tailoring the components of energy conversion and storage devices can improve overall performance. Three-dimensional (3D) printing provides the flexibility to create and optimize geometrical structure in order to obtain preferable features to elevate energy conversion yield and storage capacitance. It also serves the potential for rapid and cost-efficient manufacturing. Besides that, bio-based polymers with potential mechanical and rheological properties have been exploited as material feedstocks for 3D printing. The use of these polymers promoted carbon neutrality and environmentally benign processes. In this perspective, this review provides an overview of various 3D printing techniques and processing parameters for bio-based polymers applicable for energy-relevant applications. It also explores the advances and current significance on the integration of 3D-printed bio-based polymers in several energy conversion and storage components from the recently published studies. Finally, the future perspective is elaborated for the development of bio-based polymers via 3D printing techniques as powerful tools for clean energy supplies towards the sustainable development goals (SDGs) with respect to environmental protection and green energy conversion.

3D printing of hierarchically micro/nanostructured electrodes for high-performance rechargeable batteries

3D printing, also known as additive manufacturing, is capable of fabricating 3D hierarchical micro/nanostructures by depositing a layer-upon-layer of precursor materials and solvent-based inks under the assistance of computer-aided design (CAD) files. 3D printing has been employed to construct 3D hierarchically micro/nanostructured electrodes for rechargeable batteries, endowing them with high specific surface areas, short ion transport lengths, and high mass loading. This review summarizes the advantages and limitations of various 3D printing methods and presents the recent developments of 3D-printed electrodes in rechargeable batteries, such as lithium-ion batteries, sodium-ion batteries, and lithium-sulfur batteries. Furthermore, the challenges and perspectives of the 3D printing technique for electrodes and rechargeable batteries are put forward. This review will provide new insight into the 3D printing of hierarchically micro/nanostructured electrodes in rechargeable batteries and promote the development of 3D printed electrodes and batteries in the future.

3D-Printed Thermoplastic Polyurethane Electrodes for Customizable, Flexible Lithium-Ion Batteries with an Ultra-Long Lifetime

3D printing technology has demonstrated great potential in fabricating flexible and customizable high-performance batteries, which are highly desired in the forthcoming intelligent and ubiquitous energy era. However, a significant performance gap, especially in cycling stability, still exists between the 3D-printed and conventional electrodes, seriously limiting the practical applications of 3D-printed batteries. Here, for the first time, a series of thermoplastic polyurethane (TPU)-based 3D-printed electrodes is developed via fused deposition modeling for flexible and customizable high-performance lithium-ion batteries. The TPU-based electrode filaments in kilogram order are prepared via a facile extrusion method. As a result, the electrodes are well-printed with high dimensional accuracy, flexibility, and mechanical stability. Notably, 3D-printed TPU-LFP electrodes exhibit a capacity retention of 100% after 300 cycles at 1C, which is among the best cycling performance of all the reported 3D-printed electrodes. Such excellent performance is associated with the superb stress cushioning properties of the TPU-based electrodes that can accommodate the volume change during the cycling and thus significantly prevent the collapse of 3D-printed electrode structures. The findings not only provide a new avenue to achieve customizable and flexible batteries but also guide a promising way to erase the performance gap between 3D-printed and conventional lithium-ion batteries.

A stable filamentous coaxial microelectrode for Li-ion batteries: a case of olivine LiFePO4

By using a facile spray drying method, we fabricated a stable filamentous coaxial microelectrode of olivine LiFePO4, which delivers an excellent electrochemical performance in Li-ion batteries. Due to its simple structure, the microelectrode is a perfect model to study electrochemical reactions, even through in situ electrochemical measurements.

Structural Design of Lithium–Sulfur Batteries: From Fundamental Research to Practical Application

Abstract

Lithium–sulfur (Li–S) batteries have been considered as one of the most promising energy storage devices that have the potential to deliver energy densities that supersede that of state-of-the-art lithium ion batteries. Due to their high theoretical energy density and cost-effectiveness, Li–S batteries have received great attention and have made great progress in the last few years. However, the insurmountable gap between fundamental research and practical application is still a major stumbling block that has hindered the commercialization of Li–S batteries. This review provides insight from an engineering point of view to discuss the reasonable structural design and parameters for the application of Li–S batteries. Firstly, a systematic analysis of various parameters (sulfur loading, electrolyte/sulfur (E/S) ratio, discharge capacity, discharge voltage, Li excess percentage, sulfur content, etc.) that influence the gravimetric energy density, volumetric energy density and cost is investigated. Through comparing and analyzing the statistical information collected from recent Li–S publications to find the shortcomings of Li–S technology, we supply potential strategies aimed at addressing the major issues that are still needed to be overcome. Finally, potential future directions and prospects in the engineering of Li–S batteries are discussed.

Graphical Abstract

Free-Standing Porous Carbon Nanofiber/Carbon Nanotube Film as Sulfur Immobilizer with High Areal Capacity for Lithium-Sulfur Battery

Low sulfur utilization and poor cycle life of the sulfur cathode with high sulfur loadings remain a great challenge for lithium-sulfur (Li-S) battery. Herein, the free-standing carbon film consisting of porous carbon nanofibers (PCNFs) and carbon nanotubes (CNTs) is successfully fabricated by the electrospinning technology. The PCNF/CNT film with three-dimensional and interconnected structure is promising for the uniformity of the high-loading sulfur, good penetration of the electrolyte, and reliable accommodation of volumetric expansion of the sulfur cathode. In addition, the abundant N/O-doped elements in PCNF/CNT film are helpful to chemically trap soluble polysulfides in the charge-discharge processes. Consequently, the obtained monolayer S/PCNF/CNT film as the cathode shows high specific capacity, excellent cycle stability, and rate stability with the sulfur loading of 3.9 mg cm^-2. Moreover, the high areal capacity of 13.5 mA h cm^-2 is obtained for the cathode by stacking three S/PCNF/CNT layers with the high sulfur loading of 12 mg cm^-2. The stacking-layered cathode with high sulfur loading provides excellent cycle stability, which is beneficial to fabricate high-energy-density Li-S battery in future.

A review of flexible lithium–sulfur and analogous alkali metal–chalcogen rechargeable batteries

This review summarizes recent progress in flexible Li–S and analogous alkali metal–chalcogen batteries, including flexible chalcogen cathodes, flexible alkali metal anodes, flexible solid-state electrolytes, and flexible battery prototypes.