Nanodiamond-Enhanced Nanofiber Separators for High-Energy Lithium-Ion Batteries

Current lithium-ion battery separators made from polyolefins such as polypropylene and polyethylene generally suffer from low porosity, low wettability, and slow ionic conductivity and tend to perform poorly against heat-triggering reactions that may cause potentially catastrophic issues, such as fire. To overcome these limitations, here we report that a porous composite membrane consisting of poly(vinylidene fluoride-co-hexafluoropropylene) nanofibers functionalized with nanodiamonds (NDs) can realize a thermally resistant, mechanically robust, and ionically conductive separator. We critically reveal the role of NDs in the polymer matrix of the membrane to improve the thermal, mechanical, crystalline, and electrochemical properties of the composites. Taking advantages of these characteristics, the ND-functionalized nanofiber separator enables high-capacity and stable cycling of lithium cells with LiNi_0.8Mn_0.1Co_0.1O₂ (NMC811) as the cathode, much superior to those using conventional polyolefin separators in otherwise identical cells.

Porous TiO2-x/C Nanofibers with Axially Aligned Tunnel Pores as Effective Sulfur Hosts for Stabilized Lithium-Sulfur Batteries

Hierarchically porous TiO_2-x/C nanofibers (NFs) with axially aligned cylindrical tunnel pore channels were synthesized as a sulfur (S) host for lithium-sulfur batteries (LSBs) by a microemulsion electrospinning method. We explored a synergistic chemical trapping reinforced by coordinatively unsaturated Ti³⁺ nuclei with oxygen deficiency (or more broadly via polar O-Ti-O units) in combination with physical trapping in both narrow pores (<5 nm) and larger ordered pore tunnels (20-100 nm) separated by thin walls to allow for a large volume of active material and rapid diffusion within the channels while effectively blocking out the diffusion of soluble lithium polysulfides. Due to this unique architecture and enhanced conductivity, the prepared materials enabled a high S loading (∼72 wt %) and significantly reduced the shuttle effect. Hence, the composite TiO_2-x/C@S cathodes exhibited a high utilization of active materials, excellent rate performance, and promising cycling stability (retention of up to ∼1010 mAh g^-1 after 150 cycles for the aerial capacity of 1.5 mAh cm^-2, with very stable performance even for the high S loading of 2.5 mg cm^-2). By designing control nanomaterials that lack either the pore tunnels or the desired chemical compositions, we elucidated the importance of the synergistic effect of both factors. This work demonstrates a successful exploration of oxide NFs with tunnel pores via a simple single-needle microemulsion electrospinning method, which should pave the way for similar nanomaterials engineering with other chemistries for improved LSB performance.

Stability of FeF3-Based Sodium-Ion Batteries in Nonflammable Ionic Liquid Electrolytes at Room and Elevated Temperatures

Iron trifluoride (FeF3), a conversion-type cathode for sodium-ion batteries (SIBs), is based on cheap and abundant Fe and provides high theoretical capacity. However, the applications of FeF3-based SIBs have been hindered by their low-capacity utilization and poor cycling stability. Herein, we report greatly enhanced performance of FeF3 in multiple types of ionic liquid (IL) electrolytes at both room temperature (RT) and elevated temperatures. The Pyr1,4FSI electrolyte demonstrated the best cycling stability with an unprecedented decay rate of only ∼0.023% per cycle after the initial stabilization and an average coulombic efficiency of ∼99.5% for over 1000 cycles at RT. The Pyr1,3FSI electrolyte demonstrated the best cycling stability with a capacity decay rate of only ∼0.25% per cycle at 60 °C. Cells using Pyr1,3FSI and EMIMFSI electrolytes also showed promising cycling stability with capacity decay rates of ∼0.039% and ∼0.030% per cycle over 1000 cycles, respectively. A protective and ionically conductive cathode electrolyte interphase (CEI) layer is formed during cycling in ILs, diminishing side reactions that commonly lead to gassing and excessive CEI growth in organic electrolytes, especially at elevated temperatures. Furthermore, the increased ionic conductivity and decreased viscosity of ILs at elevated temperatures help attain higher accessible capacity. The application of ILs sheds light on designing a protective CEI for its use in stable SIBs.

High-Temperature Oxidation of Single Carbon Nanoparticles: Dependence on the Surface Structure and Probing Real-Time Structural Evolution via Kinetics

O₂ oxidation and sublimation kinetics for >30 individual nanoparticles (NPs) of five different feedstocks (graphite, graphene oxide, carbon black, diamond, and nano-onion) were measured using single-NP mass spectrometry at temperatures (T_NP) in the 1100-2900 K range. It was found that oxidation, studied in the 1200-1600 K range, is highly sensitive to the NP surface structure, with etching efficiencies (EE_O2) varying by up to 4 orders of magnitude, whereas sublimation rates, significant only for T_NP ≥ ∼1700 K, varied by only a factor of ∼3. Its sensitivity to the NP surface structure makes O₂ etching a good real-time structure probe, which was used to follow the evolution of the NP surface structures over time as they were either etched or annealed at high T_NP. All types of carbon NPs were found to have initial EE_O2 values in the range near 10^-3 Da/O₂ collision, and all eventually evolved to become essentially inert to O₂ (EE_O2 < 10^-6 Da/O₂ collision); however, the dependence of EE_O2 on time and mass loss was very different for NPs from different feedstocks. For example, diamond NPs evolved rapidly and monotonically toward inertness, and evolution occurred in both oxidizing and inert atmospheres. In contrast, graphite NPs evolved only under oxidizing conditions and were etched with complex time dependence, with multiple waves of fast but non-monotonic etching separated by periods of near-inertness. Possible mechanisms to account for the complex etching behavior are proposed.

Iron Phosphide Confined in Carbon Nanofibers as a Free-Standing Flexible Anode for High-Performance Lithium-Ion Batteries

Iron phosphide with high specific capacity has emerged as an appealing candidate for next-generation lithium-ion battery anodes. However, iron phosphide could undergo conversion reactions and generally suffer from a rapid capacity degradation upon cycling due to its structure pulverization. Chemomechanical breakdown of iron phosphide due to its rigidity has been a challenge to fully realizing its electrochemical performance. To address this challenge, we report here on an enticing opportunity: a flexible, free-standing iron phosphide anode with Fe₂P nanoparticles confined in carbon nanofibers may overcome existing challenges. For the synthesis, we introduce a facile electrospinning strategy that enables in situ formation of Fe₂P within a carbon matrix. Such a carbon matrix can effectively minimize the structure change of Fe₂P particles and protect them from pulverization, allowing the electrodes to retain a free-standing structure after long-term cycling. The produced electrodes showed excellent electrochemical performance in lithium-ion half and full cells, as well as in flexible pouch cells. These results demonstrate the successful development of iron phosphide materials toward high capacity, light weight, and flexible energy storage.

Electrolyte melt infiltration for scalable manufacturing of inorganic all-solid-state lithium-ion batteries

All-solid-state lithium (Li) metal and lithium-ion batteries (ASSLBs) with inorganic solid-state electrolytes offer improved safety for electric vehicles and other applications. However, current inorganic ASSLB manufacturing technology suffers from high cost, excessive amounts of solid-state electrolyte and conductive additives, and low attainable volumetric energy density. Such a fabrication method involves separate fabrications of sintered ceramic solid-state electrolyte membranes and ASSLB electrodes, which are then carefully stacked and sintered together in a precisely controlled environment. Here we report a disruptive manufacturing technology that offers reduced manufacturing costs and improved volumetric energy density in all solid cells. Our approach mimics the low-cost fabrication of commercial Li-ion cells with liquid electrolytes, except that we utilize solid-state electrolytes with low melting points that are infiltrated into dense, thermally stable electrodes at moderately elevated temperatures (~300 °C or below) in a liquid state, and which then solidify during cooling. Nearly the same commercial equipment could be used for electrode and cell manufacturing, which substantially reduces a barrier for industry adoption. This energy-efficient method was used to fabricate inorganic ASSLBs with LiNi_0.33Mn_0.33Co_0.33O₂ cathodes and both Li₄Ti₅O₁₂ and graphite anodes. The promising performance characteristics of such cells open new opportunities for the accelerated adoption of ASSLBs for safer electric transportation.

Cycle stability of conversion-type iron fluoride lithium battery cathode at elevated temperatures in polymer electrolyte composites

Metal fluoride conversion cathodes offer a pathway towards developing lower-cost Li-ion batteries. Unfortunately, such cathodes suffer from extremely poor performance at elevated temperatures, which may prevent their use in large-scale energy storage applications. Here we report that replacing commonly used organic electrolytes with solid polymer electrolytes may overcome this hurdle. We demonstrate long-cycle stability for over 300 cycles at 50 °C attained in high-capacity (>450 mAh g^-1) FeF₂ cathodes. The absence of liquid solvents reduced electrolyte decomposition, while mechanical properties of the solid polymer electrolyte enhanced cathode structural stability. Our findings suggest that the formation of an elastic, thin and homogeneous cathode electrolyte interphase layer on active particles is a key for stable performance. The successful operation of metal fluorides at elevated temperatures opens a new avenue for their practical applications and future successful commercialization.

Fading Mechanisms and Voltage Hysteresis in FeF2 -NiF2 Solid Solution Cathodes for Lithium and Lithium-Ion Batteries

The rapid development of ultrahigh-capacity alloying or conversion-type anodes in rechargeable lithium (Li)-ion batteries calls for matching cathodes for next-generation energy storage devices. The high volumetric and gravimetric capacities, low cost, and abundance of iron (Fe) make conversion-type iron fluoride (FeF₂ and FeF₃ )-based cathodes extremely promising candidates for high specific energy cells. Here, the substantial boost in the capacity of FeF₂ achieved with the addition of NiF₂ is reported. A systematic study of a series of FeF₂ -NiF₂ solid solution cathodes with precisely controlled morphology and composition reveals that the presence of Ni may undesirably accelerate capacity fading. Using a powerful combination of state-of-the-art analytical techniques in combination with the density functional theory calculations, fundamental mechanisms responsible for such a behavior are uncovered. The unique insights reported in this study highlight the importance of careful selection of metals and electrolytes for optimizing electrochemical properties of metal fluoride cathodes.

Iron Phosphate Coated Flexible Carbon Nanotube Fabric as a Multifunctional Cathode for Na-Ion Batteries

Conventional slurry casted electrodes cannot stand high loads or be repeatedly flexed or bent without being fractured, which inhibits their use in flexible batteries. Carbon nanotube (CNT) fabric exhibits a paramount mechanical stability and, due to its porosity, can additionally accommodate an active material within its structure. While solution-based protocols cannot achieve conformal coatings of active materials, chemical vapor deposition (CVD) gives a unique opportunity to control and vary the thickness and homogeneity of the coating. Herein, a conformal CVD coating of amorphous iron (III) phosphate (a-FePO₄ , FP) on flexible CNT fabric and its ability to reversibly accommodate large radius Na ions is reported. The freestanding binder-free CNT@FP electrodes exhibit high-rate capabilities and exceptional cycle stabilities with 98% of retention of initial capacity after 100 cycles. Such electrodes additionally demonstrate high mechanical stability under high loads, remarkable bending characteristics, and modulus of toughness (12 MJ m^-3 ) exceeding that of Al. The presented concept of flexible CNT@FePO₄ electrodes with high load-bearing characteristics opens new perspectives toward the formation of light-weight, flexible, multifunctional Na-ion battery electrodes based on abundant materials.

Synthesis of copper oxide nanowires and nanoporous copper via environmentally friendly transformation of bulk copper-calcium alloys

In this work, we report a novel, one-step, inexpensive and environmentally friendly synthesis of Cu nanostructures by means of chemical de-alloying of bulk Cu-Ca alloys in aqueous solutions. By controlling the synthesis conditions, we tune the morphology of the nanostructured Cu from nanoporous Cu to copper oxide nanowires.

Performance Enhancement and Side Reactions in Rechargeable Nickel-Iron Batteries with Nanostructured Electrodes

We report for the first time a solution-based synthesis of strongly coupled nanoFe/multiwalled carbon nanotube (MWCNT) and nanoNiO/MWCNT nanocomposite materials for use as anodes and cathodes in rechargeable alkaline Ni-Fe batteries. The produced aqueous batteries demonstrate very high discharge capacities (800 mAh gFe(-1) at 200 mA g(-1) current density), which exceed that of commercial Ni-Fe cells by nearly 1 order of magnitude at comparable current densities. These cells also showed the lack of any "activation", typical in commercial batteries, where low initial capacity slowly increases during the initial 20-50 cycles. The use of a highly conductive MWCNT network allows for high-capacity utilization because of rapid and efficient electron transport to active metal nanoparticles in oxidized [such as Fe(OH)2 or Fe3O4] states. The flexible nature of MWCNTs accommodates significant volume changes taking place during phase transformation accompanying reduction-oxidation reactions in metal electrodes. At the same time, we report and discuss that high surface areas of active nanoparticles lead to multiple side reactions. Dissolution of Fe anodes leads to reprecipitation of significantly larger anode particles. Dissolution of Ni cathodes leads to precipitation of Ni metal on the anode, thus blocking transport of OH(-) anions. The electrolyte molarity and composition have a significant impact on the capacity utilization and cycling stability.

In situ small angle neutron scattering revealing ion sorption in microporous carbon electrical double layer capacitors

Experimental studies showed the impact of the electrolyte solvents on both the ion transport and the specific capacitance of microporous carbons. However, the related structure-property relationships remain largely unclear and the reported results are inconsistent. The details of the interactions of the charged carbon pore walls with electrolyte ions and solvent molecules at a subnanometer scale are still largely unknown. Here for the first time we utilize in situ small angle neutron scattering (SANS) to reveal the electroadsorption of organic electrolyte ions in carbon pores of different sizes. A 1 M solution of tetraethylammonium tetrafluoroborate (TEATFB) salt in deuterated acetonitrile (d-AN) was used in an activated carbon with the pore size distribution similar to that of the carbons used in commercial double layer capacitors. In spite of the incomplete wetting of the smallest carbon pores by the d-AN, we observed enhanced ion sorption in subnanometer pores under the applied potential. Such results suggest the visible impact of electrowetting phenomena counterbalancing the high energy of the carbon/electrolyte interface in small pores. This behavior may explain the characteristic butterfly wing shape of the cyclic voltammetry curve that demonstrates higher specific capacitance at higher applied potentials, when the smallest pores become more accessible to electrolyte. Our study outlines a general methodology for studying various organic salts-solvent-carbon combinations.

Sulfur-infiltrated micro- and mesoporous silicon carbide-derived carbon cathode for high-performance lithium sulfur batteries

Novel nanostructured sulfur (S)-carbide derived carbon (CDC) composites with ordered mesopores and high S content are successfully prepared for lithium sulfur batteries. The tunable pore-size distribution and high pore volume of CDC allow for an excellent electrochemical performance of the composites at high current densities. A higher electrolyte molarity is found to enhance the capacity utilization dramatically and reduce S dissolution in S-CDC composite cathodes during cycling.

Towards ultrathick battery electrodes: aligned carbon nanotube-enabled architecture

Vapor deposition techniques were utilized to synthesize very thick (∼1 mm) Li-ion battery anodes consisting of vertically aligned carbon nanotubes coated with silicon and carbon. The produced anode demonstrated ultrahigh thermal (>400 W·m(-1) ·K(-1)) and high electrical (>20 S·m(-1)) conductivities, high cycle stability, and high average capacity (>3000 mAh·g(Si) (-1)). The processes utilized allow for the conformal deposition of other materials, thus making it a promising architecture for the development of Li-ion anodes and cathodes with greatly enhanced electrical and thermal conductivities.

Chemical vapor deposition of aluminum nanowires on metal substrates for electrical energy storage applications

Metal nanowires show promise in a broad range of applications, but many synthesis techniques require complex methodologies. We have developed a method for depositing patterned aluminum nanowires (Al NWs) onto Cu, Ni, and stainless steel substrates using low-pressure decomposition of trimethylamine alane complex. The NWs exhibited an average diameter in the range from 45 to 85 nm, were crystalline, and did not contain a detectable amount of carbon impurities. Atomic layer deposition of 50 nm of vanadium oxide on the surface of Al NW allows fabrication of supercapacitor electrodes with volumetric capacitance in excess of 1400 F·cc(-3), which exceeds the capacitance of traditional activated carbon supercapacitor electrodes by more than an order of magnitude.

Toward efficient binders for Li-ion battery Si-based anodes: polyacrylic acid

Si-based Li-ion battery anodes offer specific capacity an order of magnitude beyond that of conventional graphite. However, the formation of stable Si anodes is a challenge because of significant volume changes occurring during their electrochemical alloying and dealloying with Li. Binder selection and optimization may allow significant improvements in the stability of Si-based anodes. Most studies of Si anodes have involved the use of carboxymethylcellulose (CMC) and poly(vinylidene fluoride) (PVDF) binders. Herein, we show for the first time that pure poly(acrylic acid) (PAA), possessing certain mechanical properties comparable to those of CMC but containing a higher concentration of carboxylic functional groups, may offer superior performance as a binder for Si anodes. We further show the positive impact of carbon coating on the stability of the anode. The carbon-coated Si nanopowder anodes, tested between 0.01 and 1 V vs Li/Li+ and containing as little as 15 wt % of PAA, showed excellent stability during the first hundred cycles. The results obtained open new avenues to explore a novel series of binders from the polyvinyl acids (PVA) family.

High-performance lithium-ion anodes using a hierarchical bottom-up approach

Si-based Li-ion battery anodes have recently received great attention, as they offer specific capacity an order of magnitude beyond that of conventional graphite. The applications of this transformative technology require synthesis routes capable of producing safe and easy-to-handle anode particles with low volume changes and stable performance during battery operation. Herein, we report a large-scale hierarchical bottom-up assembly route for the formation of Si on the nanoscale--containing rigid and robust spheres with irregular channels for rapid access of Li ions into the particle bulk. Large Si volume changes on Li insertion and extraction are accommodated by the particle's internal porosity. Reversible capacities over five times higher than that of the state-of-the-art anodes (1,950 mA h g(-1)) and stable performance are attained. The synthesis process is simple, low-cost, safe and broadly applicable, providing new avenues for the rational engineering of electrode materials with enhanced conductivity and power.