In Situ Fabrication of Hierarchical CuO@CoNi-LDH Composite Structures for High-Performance Supercapacitors

Layered double hydroxide (LDH) materials, despite their high theoretical capacity, exhibit significant performance degradation with increasing load due to their low conductivity. Simultaneously achieving both high capacity and high rate performance is challenging. Herein, we fabricated vertically aligned CuO nanowires in situ on the copper foam (CF) substrate by alkali-etching combined with the annealing process. Using this as a skeleton, electrochemical deposition technology was used to grow the amorphous α-phase CoNi-LDH nanosheets on its surface. Thanks to the high specific surface area of the CuO skeleton, ultrahigh loading (̃16.36 mg cm-2) was obtained in the fabricated CF/CuO@CoNi-LDH electrode with the cactus-like hierarchical structure, which enhanced the charge transfer and ion diffusion dynamics. The CF/CuO@CoNi-LDH electrode achieved a good combination of high areal capacitance (33.5 F cm-2) and high rate performance (61% capacitance retention as the current density increases 50 times). The assembled asymmetric supercapacitor device demonstrated a maximum potential window of 0-1.6 V and an energy density of 1.7 mWh cm-2 at a power density of 4 mW cm-2. This work provides a feasible strategy for the design and fabrication of high-mass-loading LDH composites for electrochemical energy storage applications.

Chlorination Design for Highly Stable Electrolyte toward High Mass Loading and Long Cycle Life Sodium-Based Dual-Ion Battery

Sodium-based dual ion batteries (SDIBs) have garnered significant attention as novel energy storage devices offering the advantages of high-voltage and low-cost. Nonetheless, conventional electrolytes exhibit low resistance to oxidation and poor compatibility with electrode materials, resulting in rapid battery failure. In this study, for the first time, a chlorination design of electrolytes for SDIB, is proposed. Using ethyl methyl carbonate (EMC) as a representative, chlorine (Cl)-substituted EMC not only demonstrates increased oxidative stability ascribed to the electron-withdrawing characteristics of chlorine atom, electrolyte compatibility with both the cathode and anode is also greatly improved by forming Cl-containing interface layers. Consequently, a discharge capacity of 104.6 mAh g-1 within a voltage range of 3.0-5.0 V is achieved for Na||graphite SDIB that employs a high graphite cathode mass loading of 5.0 mg cm-2, along with almost no capacity decay after 900 cycles. Notably, the Na||graphite SDIB can be revived for an additional 900 cycles through the replacement of a fresh Na anode. As the mass loading of graphite cathode increased to 10 mg cm-2, Na||graphite SDIB is still capable of sustaining over 700 times with ≈100% capacity retention. These results mark the best outcome among reported SDIBs. This study corroborates the effectiveness of chlorination design in developing high-voltage electrolytes and attaining enduring cycle stability of Na-based energy storage devices.

Ti─O─C Bonding at 2D Heterointerfaces of 3D Composites for Fast Sodium Ion Storage at High Mass Loading Level

3D composite electrodes have shown extraordinary promise as high mass loading electrode materials for sodium ion batteries (SIBs). However, they usually show poor rate performance due to the sluggish Na+ kinetics at the heterointerfaces of the composites. Here, a 3D MXene-reduced holey graphene oxide (MXene-RHGO) composite electrode with Ti─O─C bonding at 2D heterointerfaces of MXene and RHGO is developed. Density functional theory (DFT) calculations reveal the built-in electric fields (BIEFs) are enhanced by the formation of bridged interfacial Ti─O─C bonding, that lead to not only faster diffusion of Na+ at the heterointerfaces but also faster adsorption and migration of Na+ on the MXene surfaces. As a result, the 3D composite electrodes show impressive properties for fast Na+ storage. Under high current density of 10 mA cm-2, the 3D MXene-RHGO composite electrodes with high mass loading of 10 mg cm-2 achieve a strikingly high and stable areal capacity of 3 mAh cm-2, which is same as commercial LIBs and greatly exceeds that of most reported SIBs electrode materials. The work shows that rationally designed bonding at the heterointerfaces represents an effective strategy for promoting high mass loading 3D composites electrode materials forward toward practical SIBs applications.

Endogenous Interfacial Mo-C/N-Mo-S Bonding Regulates the Active Mo Sites for Maximized Li+ Storage Areal Capacity

Active sites, mass loading, and Li-ion diffusion coefficient are the benchmarks for boosting the areal capacity and storage capability of electrode materials for lithium-ion batteries. However, simultaneously modulating these criteria to achieve high areal capacity in LIBs remains challenging. Herein, MoS2 is considered as a suitable electroactive host material for reversible Li-ion storage and establish an endogenous multi-heterojunction strategy with interfacial Mo-C/N-Mo-S coordination bonding that enables the concurrent regulation of these benchmarks. This strategy involves architecting 3D integrated conductive nanostructured frameworks composed of Mo2 C-MoN@MoS2 on carbon cloth (denoted as C/MMMS) and refining the sluggish kinetics in the MoS2 -based anodes. Benefiting from the rich hetero-interface active sites, optimized Li adsorption energy, and low diffusion barrier, C/MMMS reaches a mass loading of 12.11 mg cm-2 and showcases high areal capacity and remarkable rate capability of 9.6 mAh cm-2 @0.4 mA cm-2 and 2.7 mAh cm-2 @6.0 mA cm-2 , respectively, alongside excellent stability after 500 electrochemical cycles. Moreover, this work not only affirms the outstanding performance of the optimized C/MMMS as an anode material for supercapacitors, underscoring its bifunctionality but also offers valuable insight into developing endogenous transition metal compound electrodes with high mass loading for the next-generation high areal capacity energy storage devices.

A Ternary (P, Se, S) Covalent Inorganic Framework as a Shuttle Effect-Free Cathode for Li-S Batteries

Developing new cathode materials to avoid shuttle effect of Li-S batteries at source is crucial for practical high-energy applications, which, however, remains a great challenge. Herein, a new class of sulfur-containing ternary covalent inorganic framework (CIF), P4 Se6 S40 , is explored, by simply comelting powders of P, S, and Se. The P4 Se6 S40 CIF with open framework enables all active sites available during electrochemical reactions, giving a high capacity delivery. Moreover, introducing Se atoms can improve intrinsic electronic conductivity of S chains yet without remarkably compromising the capacity because Se is also electrochemical active to lithium storage. More importantly, Se atoms in S-Se chains can serve as a heteroatom barrier to block the bonding of S atoms around, effectively avoiding the formation of long-chain polysulfides during cycling. Besides, stable Li3 PS4 with a tetrahedral configuration formed after lithiation works as not only a good ionic conductor to promote Li ion diffusion, but a three-dimensional spatial barrier and chemical anchor to suppress the dissolution and diffusion of lithium polysulfides (LiPS), further inhibiting the shuttle effect. Consequently, the P4 Se6 S40 cathode delivers high capacity and excellent capacity retention with even a high loading of 10.5 mg cm-2 which far surpasses the requirement for commercial applications.

Small Things Make a Big Difference: Conductive Cross-Linking Sodium Alginate@MXene Binder Enables High-Volumetric-Capacity and High-Mass-Loading Li-S Battery

Binders are crucial for maintaining the integrity of an electrode, and there is a growing need for integrating multiple desirable properties into the binder for high-energy batteries, yet significant challenges remain. Here, we successfully synthesized a new binder by cross-linking sodium alginate (SA) with MXene materials (Ti3C2Tx). Besides the improved adhesion and mechanical properties, the integrated SA@Ti3C2Tx binder demonstrates much improved electronic conductivity, which enables ruling out the fluffy conductive additive from the electrode component with enhanced volumetric capacity. When SA@Ti3C2Tx is used to fabricate sulfur (S) cathodes, the conductive-additive-free electrode demonstrates extremely high capacity (1422 mAh cm-3/24.5 mAh cm-2) under an S loading of 17.2 mg cm-2 for Li-S batteries. Impressively, the SA@Ti3C2Tx binder shows remarkable feasibility in other battery systems such as Na-S and LiFePO4 batteries. The proposed strategy of constructing a cross-linking conductive binder opens new possibilities for designing high-mass-loading electrodes with high volumetric capacity.

Hierarchical 3D Electrode Design with High Mass Loading Enabling High-Energy-Density Flexible Lithium-Ion Batteries

Flexible lithium-ion batteries (LIBs) have attracted significant attention owing to their ever-increasing use in flexible and wearable electronic devices. However, the practical application of flexible LIBs in devices has been plagued by the challenge of simultaneously achieving high energy density and high flexibility. Herein, a hierarchical 3D electrode (H3DE) is introduced with high mass loading that can construct highly flexible LIBs with ultrahigh energy density. The H3DE features a bicontinuous structure and the active materials along with conductive agents are uniformly distributed on the 3D framework regardless of the active material type. The bicontinuous electrode/electrolyte integration enables a rapid ion/electron transport, thereby improving the redox kinetics and lowering the internal cell resistance. Moreover, the H3DE exhibits exceptional structural integrity and flexibility during repeated mechanical deformations. Benefiting from the remarkable physicochemical properties, pouch-type flexible LIBs using H3DE demonstrate stable cycling under various bending states, achieving a record-high energy density (438.6 Wh kg-1 and 20.4 mWh cm-2 ), and areal capacity (5.6 mAh cm-2 ), outperforming all previously reported flexible LIBs. This study provides a feasible solution for the preparation of high-energy-density flexible LIBs for various energy storage devices.

Dual-Ion Co-intercalation Mechanism on a Na2V6O16·3H2O Cathode with a Commercial-Level Mass Loading for Aqueous Zinc-Ion Batteries with High Areal Capacity

A proton (H⁺) and zinc ion (Zn²⁺) co-insertion model is put forward in this study to elucidate the capacity origin of an aqueous zinc ion battery (ZIB) based on a heavily loaded (∼15 mg cm^-2) cathode, which consists of Na₂V₆O₁₆·3H₂O (NVO) embedded particularly in the macropores of activated carbon cloth (ACC), coupled with a highly stable Zn/In anode. The confinement effect of these porous channels not only prevents the detachment of NVO from ACC but also well mitigates its volume change resulting from H⁺ and Zn²⁺ co-intercalation, which collectively render the stability of NVO/ACC markedly enhanced. Moreover, the bicontinuous structure of NVO/ACC, as a result of the self-interlacing of intrapore NVO, which is first engineered into the nanobelts, and their interlocking with the carbon fibers of ACC, simultaneously giving rise to a solid and a holey framework, is favorable to the electron and ion transport throughout the entire electrode. The synergistic effect of such facile charge transfer kinetics and the high packing density of NVO in the cathode endows ZIBs with not only a good rate performance but also an exceptional areal capacity amounting to 4.6 mAh cm^-2, far surpassing those reported for additional vanadium-based counterparts reported in the literature.

3D Asymmetric Bilayer Garnet-Hybridized High-Energy-Density Lithium-Sulfur Batteries

Lithium garnet Li₇La₃Zr₂O₁₂ (LLZO), with high ionic conductivity and chemical stability against a Li metal anode, is considered one of the most promising solid electrolytes for lithium-sulfur batteries. However, an infinite charge time resulting in low capacity has been observed in Li-S cells using Ta-doped LLZO (Ta-LLZO) as a solid electrolyte. It was observed that this cell failure is correlated with lanthanum segregation to the surface of Ta-LLZO that reacts with a sulfur cathode. We demonstrated this correlation by using lanthanum excess and lanthanum deficient Ta-LLZO as the solid electrolyte in Li-S cells. To resolve this challenge, we physically separated the sulfur cathode and LLZO using a poly(ethylene oxide) (PEO)-based buffer interlayer. With a thin bilayer of LLZO and the stabilized sulfur cathode/LLZO interface, the hybridized Li-S batteries achieved a high initial discharge capacity of 1307 mA h/g corresponding to an energy density of 639 W h/L and 134 W h/kg under a high current density of 0.2 mA/cm² at room temperature without any indication of a polysulfide shuttle. By simply reducing the LLZO dense layer thickness to 10 μm as we have demonstrated before, a significantly higher energy density of 1308 W h/L and 257 W h/kg is achievable. X-ray diffraction and X-ray photoelectron spectroscopy indicate that the PEO-based interlayer, which physically separates the sulfur cathode and LLZO, is both chemically and electrochemically stable with LLZO. In addition, the PEO-based interlayer can adapt to the stress/strain associated with sulfur volume expansion during lithiation.

Interface Engineering of Aqueous Zinc/Manganese Dioxide Batteries with High Areal Capacity and Energy Density

Commercialization of aqueous batteries is mainly hampered by their low energy density, owing to the low mass loading of active cathode materials. In this work, a MnO₂ cathode structure (MnO₂ /CTF) is designed to modify the MnO₂ /collector interface for enhanced ion transportation properties. Such a cathode can achieve ultrahigh mass loading of MnO₂ , large areal capacity, and high energy density, with excellent cycling stability and rate performance. Specifically, a 0.15 mm thick MnO₂ /CTF cathode can realize a mass loading of 20 mg cm^-2 with almost 100% electrochemical conversion of MnO₂ , providing the maximum areal capacity of 12.08 mA h cm^-2 and energy density of 191 W h kg^-1 for Zn-MnO₂ /CTF batteries when considering both cathode and anode. Besides the conventional low energy demonstrations, such a Zn-MnO₂ /CTF battery is capable of realistic applications, such as mobile phones in our daily life, which is a promising alternative for wearable electronics.

Dense T-Nb2O5/Carbon Microspheres for Ultrafast-(Dis)charge and High-Loading Lithium-Ion Batteries

Orthorhombic niobium pentoxide (T-Nb2O5) is regarded as a potential anode material for lithium-ion batteries (LIBs) due to ultrafast charge/discharge and high safety. However, the poor electronic conductivity and low mass loading of nanostructured T-Nb2O5 limit its practical application in LIBs. Herein, we design and construct dense microspheres consisting of nanostructured T-Nb2O5 embedded in amorphous N-doped carbon (Nb2O5@NC) via a facile method to achieve fast ionic and electronic transport as well as a high mass loading. The dense micro-sized particles with an interconnected carbon network avoid the low mass loading and volumetric energy density of conventional nanostructures. Interconnected pores in the range of a few nanometers are also formed in the Nb2O5@NC microspheres. Notably, at a high mass loading of 12.8 mg cm-2, Nb2O5@NC can achieve a high specific capacity of 171.5 mAh g-1 and an areal capacity of 2.05 mAh cm-2, showing its high lithium storage capacity. The intercalation reaction mechanism with a small volume change during cycling at both crystal lattice and microsphere levels is confirmed by in situ X-ray diffraction and in situ high-resolution transmission electron microscopy. The elegant structure and the electrochemical reaction mechanism disclosed in the work is important for designing ultrafast-(dis)charge electrode materials.

All-Carbon Monolithic Composites from Carbon Foam and Hierarchical Porous Carbon for Energy Storage

We designed high-volumetric-energy-density supercapacitors from monolithic composites composed of self-standing carbon foam (CF) as the conducting matrix and embedded hierarchically organized porous carbon (PICK) as the active material. Using multiprobe scanning tunneling microscopy at selected areas, we were able to disentangle morphology-dependent contributions of the heterogeneous composite to the overall conductivity. Adding PICK is found to enhance the conductivity of the monoliths by providing additional links for the CF network, enabling high and stable performance. The resulting all-carbon CF-PICK composites were used as self-standing electrodes for symmetric supercapacitors without the need for a binder, additional conducting additive, metals as a current collector, or casting/drying steps. Supercapacitors achieved a capacitance of 181 F g^-1 based on the entire mass of the monolithic electrode as well as an outstanding rate capability. Our symmetrical supercapacitors also delivered a record volumetric energy density of 19.4 mW h cm^-3 when using aqueous electrolytes. Excellent cycling stability with almost quantitative retention of capacitance was found after 10,000 cycles in 6.0 M KOH as the electrolyte. Furthermore, charge-discharge testing at different currents demonstrated the fast charge-discharge capability of this material system that meets the requirements for practical applications.

Low-Temperature High-Areal-Capacity Rechargeable Potassium-Metal Batteries

High mass loading and high areal capacity are key metrics for commercial batteries, which are usually limited by the large charge-transfer impedance in thick electrodes. This can be kinetically deteriorated under low temperatures, and the realization of high-areal-capacity batteries in cold climates remains challenging. Herein, a low-temperature high-areal-capacity rechargeable potassium-tellurium (K-Te) battery is successfully fabricated by knocking down the kinetic barriers in the cathode and pairing it with stable anode. Specifically, the in situ electrochemical self-reconstruction of amorphous Cu_1.4 Te in a thick electrode is realized simply by coating micro-sized Te on the Cu collector, significantly improving its ionic conductivity. Meanwhile, the optimized electrolyte enables fast ion transportation and a stable K-metal anode at a large current density and areal capacity. Consequently, this K-Te battery achieves a high areal capacity of 1.25 mAh cm^-2 at -40 °C, which greatly exceeds those of most reported works. This work highlights the significance of electrode design and electrolyte engineering for high areal capacity at low temperatures, and represents a critical step toward practical applications of low-temperature batteries.

Wood-Derived High-Mass-Loading MnO2 Composite Carbon Electrode Enabling High Energy Density and High-Rate Supercapacitor

The simple design of a high-energy-density device with high-mass-loading electrode has attracted much attention but is challenging. Manganese oxide (MnO₂ ) with its low cost and excellent electrochemical performance shows high potential for practical application in this regard. Hence, the high-mass-loading of the MnO₂ electrode with wood-derived carbon (WC) as the current collector is reported through a convenient hydrothermal reaction for high-energy-density devices. Benefiting from the high-mass-loading of the MnO₂ electrode (WC@MnO₂ -20, ≈14.1 mg cm^-2 ) and abundant active sites on the surface of the WC hierarchically porous structure, the WC@MnO₂ -20 electrode shows remarkable high-rate performance of areal/specific capacitance ≈1.56 F cm^-2 /45 F g^-1 , compared to the WC electrode even at the high density of 20 mA cm^-2 . Furthermore, the obtained symmetric supercapacitor exhibits high areal/specific capacitances of 3.62 F cm^-2 and 87 F g^-1 at 1.0 mA cm^-2 and high energy densities of 0.502 mWh cm^-2 /12.2 Wh kg^-1 with capacitance retention of 75.2% after 10 000 long-term cycles at 20 mA cm^-2 . This result sheds light on a feasible design strategy for high-energy-density supercapacitors with the appropriate mass loading of active materials and low-tortuosity structural design while also encouraging further investigation into electrochemical storage.

Interface Engineering on Cellulose-Based Flexible Electrode Enables High Mass Loading Wearable Supercapacitor with Ultrahigh Capacitance and Energy Density

For practical energy storage devices, a bottleneck is to retain decent integrated performances while increasing the mass loading of active materials to the commercial level, which highlights an urgent need for novel electrode structure design strategies. Here, an active nitrogen-doped carbon interface with "high conductivity, high porosity, and high electrolyte affinity" on a flexible cellulose electrode surface is engineered to accommodate 1D active materials. The high conductivity of interface favors fast electron transport, while its high porosity and high electrolyte affinity properties benefit ion migration. As a result, the flexible anode accommodated by carbon nanotubes achieves an ultrahigh capacitance of 9501 mF cm^-2 (315.6 F g^-1 ) at a high mass loading of 30.1 mg cm^-2 , and the flexible cathode accommodated by polypyrrole nanotubes realizes a remarkably high capacitance of 6212 mF cm^-2 (248 F g^-1 , 25 mg cm^-2 ). The assembled flexible quasi-solid-state asymmetric supercapacitor delivers a maximum energy density of 1.42 mWh cm^-2 (2.2 V, 2105 mF cm^-2 ), representing the highest value among all reported flexible supercapacitors. This versatile design concept provides a new way to prepare high performance flexible energy storage devices.

3D Printed Template-Assisted Assembly of Additive-Free Ti3C2Tx MXene Microlattices with Customized Structures toward High Areal Capacitance

Ti₃C₂T_x MXene is a promising material for electrodes in microsupercapacitors. Recent efforts have been made to fabricate MXene electrodes with designed structures using 3D printing to promote electrolyte permeation and ion diffusion. However, challenges remain in structural design diversity due to the strict ink rheology requirement and limited structure choices caused by existing extrusion-based 3D printing. Herein, additive-free 3D architected MXene aerogels are fabricated via a 3D printed template-assisted method that combines 3D printed hollow template and cation-induced gelation process. This method allows the use of MXene ink with a wide range of concentrations (5 to 150 mg mL^-1) to produce MXene aerogels with high structural freedom, fine feature size (>50 μm), and controllable density (3 to 140 mg cm^-3). Through structure optimization, the 3D MXene aerogel shows high areal capacitance of 7.5 F cm^-2 at 0.5 mA cm^-2 with a high mass loading of 54.1 mg cm^-2. It also exhibits an ultrahigh areal energy density of 0.38 mWh cm^-2 at a power density of 0.66 mW cm^-2.

High Mass Loading Asymmetric Micro-supercapacitors with Ultrahigh Areal Energy and Power Density

High mass loading asymmetric micro-supercapacitors (MSCs) are key components for the development of high-performance energy and power supply systems. Here, a concept for achieving high mass loading electrodes is presented and applied to high mass loading micro-supercapacitors with ultrahigh areal energy and power density. The positive electrode is made from porous carbon with birnessite coverage and multiwalled carbon nanotubes (CNTs) as conducting additives (PIC-CNTs-MnO₂). The negative electrode is prepared from hierarchically porous active carbon mixed with CNTs (PICK-CNTs). Both positive and negative electrode materials are tailored to ensure a high content of macro- and mesopores. MSCs with an optimized mass loading of 13.9 mg·cm^-2 (maximum: 23.6 mg·cm^-2) provide an ultrahigh areal capacitance of 1.13 F·cm^-2 (volumetric capacitance: 22.6 F·cm^-3), an outstanding energy of 627.8 μWh·cm^-2, and a maximum power density of 64 mW·cm^-2. About 85% of the initial capacitance remained after 5000 cycles. Moreover, shunt and tandem device testing confirmed a high uniformity of these MSCs, meeting the requirements of adjustable output currents and voltages in microchips.

Dense Silicon Nanowire Networks Grown on a Stainless-Steel Fiber Cloth: A Flexible and Robust Anode for Lithium-Ion Batteries

Silicon nanowires (Si NWs) are a promising anode material for lithium-ion batteries (LIBs) due to their high specific capacity. Achieving adequate mass loadings for binder-free Si NWs is restricted by low surface area, mechanically unstable and poorly conductive current collectors (CCs), as well as complicated/expensive fabrication routes. Herein, a tunable mass loading and dense Si NW growth on a conductive, flexible, fire-resistant, and mechanically robust interwoven stainless-steel fiber cloth (SSFC) using a simple glassware setup is reported. The SSFC CC facilitates dense growth of Si NWs where its open structure allows a buffer space for expansion/contraction during Li-cycling. The Si NWs@SSFC anode displays a stable performance for 500 cycles with an average Coulombic efficiency of >99.5%. Galvanostatic cycling of the Si NWs@SSFC anode with a mass loading of 1.32 mg cm^-2 achieves a stable areal capacity of ≈2 mAh cm^-2 at 0.2 C after 200 cycles. Si NWs@SSFC anodes with different mass loadings are characterized before and after cycling by scanning and transmission electron microscopy to examine the effects of Li-cycling on the morphology. Notably, this approach allows the large-scale fabrication of robust and flexible binder-free Si NWs@SSFC architectures, making it viable for practical applications in high energy density LIBs.

High-Performance Aqueous Zinc Batteries Based on Organic/Organic Cathodes Integrating Multiredox Centers

Organic cathode materials with redox-active sites and flexible structure are promising for developing aqueous zinc ion batteries with high capacity and large output power. However, the energy storage of most organic hosts relies on the coordination/incoordination reaction between Zn²⁺ /H⁺ and a single functional group, which result in inferior capacity, low discharge platform, and structural instability. Here, the lead is taken in in situ electrodepositing stable poly(1,5-naphthalenediamine, 1,5-NAPD) as interlayer and excellent conductive poly(para-aminophenol, pAP) skin onto nanoporous carbon in sequence for the structural optimization of organic/organic cathodes, designated as C@multi-layer polymer. In situ analyses, electrochemical measurements, and theoretical calculation prove that both CO and CN active groups can act as a strong electron donor as well as Zn²⁺ host during the discharging process. Benefiting from the synergistic effect of the double organic layers, C@multi-layer polymer delivers high capacity, long lifespan, and excellent capacity reservation even at large discharge current and commercial mass loading (>10 mg cm^-2 ). Introducing multiredox centers into one organic composites will provide new insights into designing advanced Zn-organic batteries.

High mass loading NiCo-OH nanothorns coated CuO nanowire arrays for high-capacity nickel-zinc battery

The rational design of cathode materials with core-shell heterostructures is significant to develop a Ni//Zn battery with both high gravimetric and areal energy density under high mass loading. In this work, the NiCo-OH nanothorns with a mass loading of 11.6 mg cm^-2were coated on CuO nanowire arrays via a chemical bath deposition method. Thanks to the construction of 3D core-shell nanowire arrays and appropriate cobalt doping, as-fabricated Ni//Zn battery based on the NiCo-OH as cathode achieved the maximum specific capacity of 383 mAh g^-1at 5 mA cm^-2with high energy density of 649 Wh kg^-1at 0.73 kW kg^-1, indicating good energy storage performance in Ni//Zn battery.

Commercialization-Driven Electrodes Design for Lithium Batteries: Basic Guidance, Opportunities, and Perspectives

Current lithium-ion battery technology is approaching the theoretical energy density limitation, which is challenged by the increasing requirements of ever-growing energy storage market of electric vehicles, hybrid electric vehicles, and portable electronic devices. Although great progresses are made on tailoring the electrode materials from methodology to mechanism to meet the practical demands, sluggish mass transport, and charge transfer dynamics are the main bottlenecks when increasing the areal/volumetric loading multiple times to commercial level. Thus, this review presents the state-of-the-art developments on rational design of the commercialization-driven electrodes for lithium batteries. First, the basic guidance and challenges (such as electrode mechanical instability, sluggish charge diffusion, deteriorated performance, and safety concerns) on constructing the industry-required high mass loading electrodes toward commercialization are discussed. Second, the corresponding design strategies on cathode/anode electrode materials with high mass loading are proposed to overcome these challenges without compromising energy density and cycling durability, including electrode architecture, integrated configuration, interface engineering, mechanical compression, and Li metal protection. Finally, the future trends and perspectives on commercialization-driven electrodes are offered. These design principles and potential strategies are also promising to be applied in other energy storage and conversion systems, such as supercapacitors, and other metal-ion batteries.

Mechanical Stirring Synthesis of 1D Electrode Materials and Designing of Pyramid/Inverted Pyramid Interlocking for Highly Flexible and Foldable Li-Ion Batteries with High Mass Loading

Flexible and foldable Li-ion batteries (LIBs) are presently attracting immense research interest for their potential use in wearable electronics but are still limited to electrodes with very small mass loading, low bending/folding endurance, and poor electrochemical stability during repeated bending and folding movements. Moreover, one-dimensional (1D) structured electrode materials have shown excellent electrochemical performance but are still restricted by the high cost and complicated fabrication process. Here, we present a very simple yet novel approach for fabricating extra-long Li₄Ti₅O₁₂ (LTO) and LiCoO₂ (LCO) nanofiber precursors by directly stirring the reagents in an atmospheric vessel. In addition, we present multilayer pyramid/inverted pyramid interlocking inside the LTO and LCO nanofiber films as well as between films and current collectors, which can create strengthened interfacial bonding like a zipper and tangentially disperse the strains generated during folding through the pyramidal planes and edges, leading to the realization of thick-film electrodes with outstanding electrochemical stability during folding movements. The foldable LIBs that are assembled with LTO and LCO nanofiber electrodes at a practical level of mass loading (14.9-19.4 mg cm^-2) can maintain 102% of the initial capacity after 15 000 times of fully folding (180°) motions.

Tailoring Pore Structures of 3D Printed Cellular High-Loading Cathodes for Advanced Rechargeable Zinc-Ion Batteries

Developing high-loading cathodes with superior electrochemical performance is desirable but challenging in aqueous zinc-ion batteries (ZIBs) for commercialization. Advanced 3D printing of cellular and hierarchical porous cathodes with high mass loading for superior ZIBs is explored here. To obtain a high-performance 3D printable ink, a composite material of iron vanadate and reduced holey graphene oxide is synthesized as the ink component. A cellular cathode with hierarchical porous architecture for aqueous ZIBs is then designed and fabricated by 3D printing for the first time. The unique structures of 3D printed composite cathode provide interpenetrating transmission paths as well as channels for electrons and ions. 3D printed cathodes with high mass loading over 10 mg cm^-2 exhibit a high specific capacity of 344.8 mAh g^-1 at 0.1 A g^-1 and deliver outstanding cycling stability over 650 cycles at 2 A g^-1 . In addition, the printing strategy enables the ease increase in mass loading up to 24.4 mg cm^-2 , where a remarkably high areal capacity of 7.04 mAh cm^-2 is reached. The superior electrochemical performance paves the new way to design the state-of-the-art cathodes for ZIBs.

Electrocatalytic NiCo2O4 Nanofiber Arrays on Carbon Cloth for Flexible and High-Loading Lithium-Sulfur Batteries

Lithium-sulfur batteries have ultrahigh theoretical energy densities, which makes them one of the most promising next-generation energy storage systems. However, it is still difficult to achieve large-scale commercialization because of the severe lithium polysulfide (LiPS) shuttle effect and low sulfur loading. Here, we report a flexible lithium-sulfur battery of a high sulfur loading with the assistance of NiCo₂O₄ nanofiber array grown carbon cloth. The NiCo₂O₄ nanofibers are ideal electrocatalysts for accelerating LiPS conversion kinetics through strong chemical interactions. Therefore, the composite cathode delivers a high specific capacity of 1280 mAh g^-1 at 0.2 C with a sulfur loading of 3.5 mg cm^-2, and it can maintain a high specific capacity of 660 mAh g^-1 after 200 cycles, showing a good cycle stability. The "layer-by-layer" stacking strategy enables the Li-S battery with a high S loading of ∼9.0 mg cm^-2 to deliver a high areal capacity of 8.9 mAh cm^-2.

Water-Based Dual-Cross-Linked Polymer Binders for High-Energy-Density Lithium-Sulfur Batteries

High-mass-loading electrodes with long-term stability have long been a great challenge for lithium-sulfur batteries (LSBs), since the conventional binders are unable to cope with the shuttling of lithium polysulfides and the structural damage in an electrode. Here, a novel water-based polymer, polyphosphate acid cross-linked chitosan ethylamide carbamide (PACEC), is developed as a binder to construct high-energy-density sulfur cathode and flexible LSBs. With a dual-cross-linked network, the PACEC shows excellent affinity with lithium polysulfides to relieve the shuttle effect and robust mechanical properties to stabilize the electrode. The sulfur cathode based on PACEC demonstrates a high sulfur loading of 14.8 mg cm^-2, the areal initial capacity of 17.5 mAh cm^-2, and Coulombic efficiency of 99.3%, while the amount of electrolyte is strictly limited to 6 μL mg^-1. More importantly, a robust pouch cell with an area of 6 cm² and only 177% oversized lithium can successfully integrate the energy density of 6.5 mAh cm^-2 with the cycling retention per cycle of 99.74% during 270 cycles and flexibility at a curvature of 3 mm. This study provides inspirations for the design of eco-friendly polymer binders and paving new ways for the development of LSBs.

Two-Dimensional Materials for High-Energy Solid-State Asymmetric Pseudocapacitors with High Mass Loadings

A porous nanostructure and high mass loading are crucial for a pseudocapacitor to achieve a good electrochemical performance. Although pseudocapacitive materials, such as MnO₂ and MoS₂ , with record capacitances close to their theoretical values have been realized, the achieved capacitances are possible only when the electrode mass loading is less than 1 mg cm^-2 . Increasing the mass loading affects the capacitance as electron conduction and ion diffusion become sluggish. Achieving fast ion and electron transport at high mass loadings through all active sites remains a challenge for high-mass-loading electrodes. In this study, 2D MnO₂ nanosheets supported on carbon fibers (MnO₂ @CF) as well as MoS₂ @CF with high mass loadings (6.6 and 7.2 mg cm^-2 , respectively) were used in a high-energy pseudocapacitor. These hierarchical 2D nanosheets yielded outstanding areal capacitances of 1187 and 495 mF cm^-2 at high current densities with excellent cycling stabilities. A pliable pseudocapacitive solid-state asymmetric supercapacitor was designed using MnO₂ @CF and MoS₂ @CF as the positive and negative electrodes, respectively, with a high mass loading of 14.2 mg cm^-2 . The assembled solid-state asymmetric cell had an energy density of 2.305 mWh cm^-3 at a power density of 50 mW cm^-3 and a capacitance retention of 92.25 % over 11 000 cycles and a very small diffusion resistance (1.72 Ω s^-1/2 ). Thus, it is superior to most state-of-the-art reported pseudocapacitors. The rationally designed nanostructured electrodes with high mass loading are likely to open up new opportunities for the development of a supercapacitor device capable of supplying higher energy and power.

Natural Polymers as Green Binders for High-Loading Supercapacitor Electrodes

The state-of-the-art aqueous binder for supercapacitors is carboxymethyl cellulose (CMC). However, it limits the mass loading of the coatings owing to shrinkage upon drying. In this work, natural polymers, that is, guar gum (GG), wheat starch (WS), and potato starch (PS), were studied as alternatives. The flexibility and adhesion of the resulting coatings and electrochemical performance was tested. The combination of 75:25 (w/w) ratio PS/GG showed a promising performance. Electrodes were characterized by SEM, thermal, adhesion, and bending tests. Their electrochemical properties were determined by cyclic voltammetry, electrochemical impedance spectroscopy, and cycling experiments. The PS/GG mixture conformed well to criteria for industrial production, enabling mass loadings higher than CMC (7.0 mg cm^-2 ) while granting the same specific capacitance (26 F g^-1 ) and power performance (20 F g^-1 at 10 A g^-1 ). Including the mass of the current collector, this represents a +45 % increase in specific energy at the electrode level.

Scalable Solution Processing MoS2 Powders with Liquid Crystalline Graphene Oxide for Flexible Freestanding Films with High Areal Lithium Storage Capacity

Freestanding flexible electrodes with high areal mass loading are required for the development of flexible high-performance lithium-ion batteries (LIBs). Currently they face the challenge of low mass loading due to the limited concentrations attainable in processable dispersions. Here, we report a simple low-temperature hydrothermal route to fabricate flexible layered molybdenum disulfide (MoS₂)/reduced graphene oxide (MSG) films offering high areal capacity and good lithium storage performance. This is achieved using a self-assembly process facilitated by the use of liquid crystalline graphene oxide (LCGO) and commercial MoS₂ powders at a low temperature of 70 °C. The amphiphilic properties of ultralarge LCGO nanosheets facilitates the processability of large-size MoS₂ powders, which is otherwise nondispersible in water. The resultant film with an areal mass of 8.2 mg cm^-2 delivers a high areal capacity of 5.80 mAh cm^-2 (706 mAh g^-1) at 0.1 A g^-1. This simple method can be adapted to similar nondispersible commercial battery materials for films fabrication or production of more complicated constructs via advanced fabrication technologies.

In Situ Intercalation of Bismuth into 3D Reduced Graphene Oxide Scaffolds for High Capacity and Long Cycle-Life Energy Storage

Metal anodes, such as zinc and bismuth have been regarded as ideal materials for aqueous batteries due to high gravimetrical capacity, high abundance, low toxicity, and intrinsic safety. However, their translation into practical applications are hindered by the low mass loading (≈1 mg cm^-2 ) of active materials. Here, the multiscale integrated structural engineering of 3D scaffold and active material, i.e., bismuth is in situ intercalated in reduced graphene oxide (rGO) wall of network, are reported. Tailoring the rapid charge transport on rGO 3D network and facile access to nano- and microscale bismuth, the rGO/Bi hybrid anode shows high utilization efficiency of 91.4% at effective high load density of ≈40 mg cm^-2 , high areal capacity of 3.51 mAh cm^-2 at the current density of 2 mA cm^-2 and high reversibility of >10 000 cycles. The resulting Ni-Bi full battery exhibits high areal capacity of 3.13 mAh cm^-2 at the current density of 2 mA cm^-2 , far outperforming the other counterpart batteries. It represents a general and efficient strategy in enhancing the battery performance by designing hierarchically networked structure.

Building Carbon-Based Versatile Scaffolds on the Electrode Surface to Boost Capacitive Performance for Fiber Pseudocapacitors

In order to fabricate high performance fiber pseudocapacitors, the trade-off between high mass loading and high utilization efficiency of pseudocapacitive materials should be carefully addressed. Here, a solution that is to construct a carbon-based versatile scaffold is reported for loading pseudocapacitive materials on carbonaceous fibers. The scaffold can be easily built by conformally coating commercial pen ink on the fibers without any destruction to the fiber skeleton. Due to the high electrical conductivity and abundant macropore structure, it can provide sufficient loading room and a high ion/electron conductive network for pseudocapacitive materials. Therefore, their loading mass and utilization efficiency can be increased simultaneously, and thus the as-designed fibrous electrode displays a high areal capacitance of 649 mF cm^-2 (or 122 mF cm^-1 based on length), which is higher than most of the reported fiber pseudocapacitors. The simple and low-cost strategy opens up a new way to prepare high performance portable/wearable energy storage devices.

A Lithium-Sulfur Battery using a 2D Current Collector Architecture with a Large-Sized Sulfur Host Operated under High Areal Loading and Low E/S Ratio

While backless freestanding 3D electrode architectures for batteries with high loading sulfur have flourished in the recent years, the more traditional and industrially turnkey 2D architecture has not received the same amount of attention. This work reports a spray-dried sulfur composite with large intrinsic internal pores, ensuring adequate local electrolyte availability. This material offers good performance with a electrolyte content of 7 µL mg^-1 at high areal loadings (5-8 mg cm^-2 ), while also offering the first reported 2.8 µL mg^-1 (8 mg cm^-2 ) to enter into the second plateau of discharge and continue to operate for 20 cycles. Moreover, evidence is provided that the high-frequency semicircle (i.e., interfacial resistance) is mainly responsible for the often observed bypassing of the second plateau in lean electrolyte discharges.

A Pseudolayered MoS2 as Li-Ion Intercalation Host with Enhanced Rate Capability and Durability

As a popular strategy, interlayer expansion significantly improves the Li-ion diffusion kinetics in the MoS₂ host, while the large interlayer spacing weakens the van der Waals force between MoS₂ monolayers, thus harming its structural stability. Here, an oxygen-incorporated MoS₂ (O-MoS₂ )/graphene composite as a self-supported intercalation host of Li-ion is prepared. The composite delivers a specific capacity of 80 mAh g^-1 in only 36 s at a mass loading of 1 mg cm^-2 , and it can be cycled 3000 times (over 91% capacity retention) with a 5 mg cm^-2 loading at 2 A g^-1 . The O-MoS₂ exhibits a dominant 1T phase with an expanded layer spacing of 10.15 Å, leading to better Li-ion intercalation kinetics compared with pristine MoS₂ . Furthermore, ex situ X-ray diffraction tests indicate that O-MoS₂ sustains a stable structure in cycling compared with the gradual collapse of pristine MoS₂ , which suffers from excessive lattice breathing. Density functional theory calculations suggest that the MoO_x (OH)_y pillars in O-MoS₂ interlayers not only expand the layer spacing, but also tense the MoS₂ layers to avoid exfoliation in cycling. Therefore, the O-MoS₂ shows a pseudolayered structure, leading to remarkable durability besides the outstanding rate capability as a Li-ion intercalation host.

Efficient Capacitive Deionization Using Natural Basswood-Derived, Freestanding, Hierarchically Porous Carbon Electrodes

Carbon electrodes are of great importance in constructing high-performance capacitive deionization (CDI) devices. However, the use of conventional carbon electrodes for CDI is limited because of their poor mechanical stability and low mass loading. Herein, we report a binder-free, freestanding, robust, and ultrathick carbon electrode derived from a wood carbon framework (WCF) for CDI applications. The WCF inherits the unique structure of natural basswood, containing straightly aligned channels interconnected with highly ordered, open, and hierarchical pores. A CDI device based on thick WCF electrodes (1200 μm, equal to a mass loading of 50 mg cm^-2) exhibits a remarkable areal salt adsorption capacity (SAC) of 0.3 mg cm^-2, a high volumetric SAC of 2.4 mg cm^-3, and a competitive gravimetric SAC of 5.7 mg g^-1. Also, the good mechanical strength and water tolerance of the WCF electrodes improve the cycling stability of the CDI device. Finite element simulations of ion transport behavior indicate that the unique structure of the WCF substantially facilitates ion transport within the ultrathick CDI electrodes. This work provides a viable route to the rational design of freestanding and ultrathick electrodes for CDI applications and offers insights into the structure-performance relationship of CDI electrodes.

High Mass Loading MnO2 with Hierarchical Nanostructures for Supercapacitors

Metal oxides have attracted renewed interest as promising electrode materials for high energy density supercapacitors. However, the electrochemical performance of metal oxide materials deteriorates significantly with the increase of mass loading due to their moderate electronic and ionic conductivities. This limits their practical energy. Herein, we perform a morphology and phase-controlled electrodeposition of MnO₂ with ultrahigh mass loading of 10 mg cm^-2 on a carbon cloth substrate to achieve high overall capacitance without sacrificing the electrochemical performance. Under optimum conditions, a hierarchical nanostructured architecture was constructed by interconnection of primary two-dimensional ε-MnO₂ nanosheets and secondary one-dimensional α-MnO₂ nanorod arrays. The specific hetero-nanostructures ensure facile ionic and electric transport in the entire electrode and maintain the structure stability during cycling. The hierarchically structured MnO₂ electrode with high mass loading yields an outstanding areal capacitance of 3.04 F cm^-2 (or a specific capacitance of 304 F g^-1) at 3 mA cm^-2 and an excellent rate capability comparable to those of low mass loading MnO₂ electrodes. Finally, the aqueous and all-solid asymmetric supercapacitors (ASCs) assembled with our MnO₂ cathode exhibit extremely high volumetric energy densities (8.3 mWh cm^-3 at the power density of 0.28 W cm^-3 for aqueous ASC and 8.0 mWh cm^-3 at 0.65 W cm^-3 for all-solid ASC), superior to most state-of-the-art supercapacitors.

Directly Formed Alucone on Lithium Metal for High-Performance Li Batteries and Li-S Batteries with High Sulfur Mass Loading

Lithium metal is considered the "holy grail" of next-generation battery anodes. However, severe parasitic reactions at the lithium-electrolyte interface deplete the liquid electrolyte and the uncontrolled formation of high surface area and dendritic lithium during cycling causes rapid capacity fading and battery failure. Engineering a dendrite-free lithium metal anode is therefore critical for the development of long-life batteries using lithium anodes. In this study, we deposit a conformal, organic/inorganic hybrid coating, for the first time, directly on lithium metal using molecular layer deposition (MLD) to alleviate these problems. This hybrid organic/inorganic film with high cross-linking structure can stabilize lithium against dendrite growth and minimize side reactions, as indicated by scanning electron microscopy. We discovered that the alucone coating yielded several times longer cycle life at high current rates compared to the uncoated lithium and achieved a steady Coulombic efficiency of 99.5%, demonstrating that the highly cross-linking structured material with great mechanical properties and good flexibility can effectively suppress dendrite formation. The protected Li was further evaluated in lithium-sulfur (Li-S) batteries with a high sulfur mass loading of ∼5 mg/cm². After 140 cycles at a high current rate of ∼1 mA/cm², alucone-coated Li-S batteries delivered a capacity of 657.7 mAh/g, 39.5% better than that of a bare lithium-sulfur battery. These findings suggest that flexible coating with high cross-linking structure by MLD is effective to enable lithium protection and offers a very promising avenue for improved performance in the real applications of Li-S batteries.

Folding Graphene Film Yields High Areal Energy Storage in Lithium-Ion Batteries

We show that a high energy density can be achieved in a practical manner with freestanding electrodes without using conductive carbon, binders, and current collectors. We made and used a folded graphene composite electrode designed for a high areal capacity anode. The traditional thick graphene composite electrode, such as made by filtering graphene oxide to create a thin film and reducing it such as through chemical or thermal methods, has sluggish reaction kinetics. Instead, we have made and tested a thin composite film electrode that was folded several times using a water-assisted method; it provides a continuous electron transport path in the fold regions and introduces more channels between the folded layers, which significantly enhances the electron/ion transport kinetics. A fold electrode consisting of SnO₂/graphene with high areal loading of 5 mg cm^-2 has a high areal capacity of 4.15 mAh cm^-2, well above commercial graphite anodes (2.50-3.50 mAh cm^-2), while the thickness is maintained as low as ∼20 μm. The fold electrode shows stable cycling over 500 cycles at 1.70 mA cm^-2 and improved rate capability compared to thick electrodes with the same mass loading but without folds. A full cell of fold electrode coupled with LiCoO₂ cathode was assembled and delivered an areal capacity of 2.84 mAh cm^-2 after 300 cycles. This folding strategy can be extended to other electrode materials and rechargeable batteries.

Suppressing Polysulfide Dissolution via Cohesive Forces by Interwoven Carbon Nanofibers for High-Areal-Capacity Lithium-Sulfur Batteries

Nanostructural design renders several breakthroughs for the construction of high-performance materials and devices including energy-storage systems. Although attempts made toward electrode engineering have improved the existing drawbacks, nanoengineering is still hindered by some issues. To achieve practical applications of lithium-sulfur (Li-S) batteries, it is difficult to attain a high areal capacity with stable cycling. Physical encapsulation via nanostructural design not only can resolve the issue of lithium polysulfide dissolution during the electrochemical cycling, but also can offer significant contact resistance, which in turn can decrease the kinetics, particularly at a high sulfur loading. Thus, we demonstrate an electrospun carbon nanofiber (CNF) matrix for a sulfur cathode. This simple design enables a high mass loading of 10.5 mg cm^-2 with a high specific capacity and stable cycling. The CNF-sulfur complex can deliver a high areal capacity of greater than 7 mAh cm^-2, which is related to the excellent electrical conductivity of one-dimensional species. Moreover, we have observed that the reacted sulfur species have adhered well to the junction of the CNF network with specific wetting angles, which are induced by the cohesive force between the narrow gaps in the matrix that trapped the viscous polysulfides during cycling. The results of this study open new avenues for the design of high-areal-capacity Li-S batteries.

An Asymmetric Supercapacitor with Both Ultra-High Gravimetric and Volumetric Energy Density Based on 3D Ni(OH)2/MnO2@Carbon Nanotube and Activated Polyaniline-Derived Carbon

Development of a supercapacitor device with both high gravimetric and volumetric energy density is one of the most important requirements for their practical application in energy storage/conversion systems. Currently, improvement of the gravimetric/volumetric energy density of a supercapacitor is restricted by the insufficient utilization of positive materials at high loading density and the inferior capacitive behavior of negative electrodes. To solve these problems, we elaborately designed and prepared a 3D core-shell structured Ni(OH)₂/MnO₂@carbon nanotube (CNT) composite via a facile solvothermal process by using the thermal chemical vapor deposition grown-CNTs as support. Owing to the superiorities of core-shell architecture in improving the service efficiency of pseudocapacitive materials at high loading density, the prepared Ni(OH)₂/MnO₂@CNT electrode demonstrated a high capacitance value of 2648 F g^-1 (1 A g^-1) at a high loading density of 6.52 mg cm^-2. Coupled with high-performance activated polyaniline-derived carbon (APDC, 400 F g^-1 at 1 A g^-1), the assembled Ni(OH)₂/MnO₂@CNT//APDC asymmetric device delivered both high gravimetric and volumetric energy density (126.4 Wh kg^-1 and 10.9 mWh cm^-3, respectively), together with superb rate performance and cycling lifetime. Moreover, we demonstrate an effective approach for building a high-performance supercapacitor with high gravimetric/volumetric energy density.