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Mitigating the Impact of Thermal Binder Removal for Direct Li-Ion Battery Recycling
Li-ion battery recycling will become critical to the management of end-of-life batteries from electric vehicles. Currently, it is a challenge to create a profitable recycling process, which is made more difficult by the reduction in cathode cobalt content. Maintenance of the cathode structure throughout the recycling process can yield increased revenues that may make recycling profitable. This method will require careful removal of the PVDF binder and carbon black, which can be achieved through thermal processing. Furthermore, it is necessary to mitigate the effects of the fluorine from the PVDF on the cathode material. Herein, we report a process that utilizes excess LiOH•H 2 O to react with this fluorine and thereby prevent lithium removal and doping of the cathode material. In addition, we demonstrate a one-step thermal process that can both remove the binder and relithiate the cathode material.
Rational optimization of substituted α–MnO 2 cathode for aqueous zinc–ion battery
Density functional theory (DFT) is utilized to explore the effects of increasing concentrations of vanadium (V) and chromium (Cr) substitution on the discharge of α-MnO 2 cathode in hydrated zinc-ion batteries (ZIBs). During H + -intercalation and Zn 2+ -intercalation, Cr-substitution proves to be more effective than V-substitution in promoting discharge behaviors. Transitioning from Mn 0.875 Cr 0.125 O 2 , Mn 0.75 Cr 0.25 O 2 to Mn 0.625 Cr 0.375 O 2 is found to consistently enhance the discharge voltage, along with improved tunnel structure retention and volume expansion suppression. In comparison, the promoting effect of increasing V-substitution is relatively small at initial discharge stages and leads to degradation at later stages, primarily due to an increased concentration of unstable Mn 2+ ion. The superior effect of Cr-substitution is attributed to the unique atomic and electronic structures of substituted Cr 4+ and reduced Cr 3+ ions during discharge. These ions serve as active electron acceptors to limit the formation of Mn 3+ and Mn 2+ ions, and as anchors to stabilize the α-MnO 2 framework and intercalated H + /Zn 2+ ions, respectively. Finally, our study highlights fine-tuning through substitution to enhance the performance of α-MnO 2 -based cathode materials in ZIBs.
Ethylene Carbonate–Free Electrolytes for High–Nickel Layered Oxide Cathodes in Lithium–Ion Batteries
Layered lithium nickel oxide (LiNiO 2 ) can provide very high energy density among intercalation cathode materials for lithium-ion batteries, but suffers from poor cycle life and thermal-abuse tolerance with large lithium utilization. In addition to stabilization of the active cathode material, a concurrent development of electrolyte systems of better compatibility is critical to overcome these limitations for practical applications. Here, with nonaqueous electrolytes based on exclusively aprotic acyclic carbonates free of ethylene carbonate (EC), superior electrochemical and thermal characteristics are obtained with an ultrahigh-nickel cathode (LiNi 0.94 Co 0.06 O 2 ), capable of reaching a 235 mA h g –1 specific capacity. Pouch-type graphite | LiNi 0.94 Co 0.06 O 2 cells in EC-free electrolytes withstand several hundred charge–discharge cycles with minor degradation at both ambient and elevated temperatures. In thermal-abuse tests, the cathode at full charge, while reacting aggressively with EC-based electrolytes below 200 °C, shows suppressed self-heating without EC. Through 3D chemical and structural analyses, the intriguing impact of EC is visualized in aggravating unwanted surface parasitic reactions and irreversible bulk structural degradation of the cathode at high voltages. Finally, these results provide important insights in designing high-energy electrodes for long-lasting and reliable lithium-ion batteries.
Stretchable Lithium-Ion Batteries Enabled by Device-Scaled Wavy Structure and Elastic-Sticky Separator
Fast developments and substantial achievements have been shaping the field of wearable electronic devices, resulting in the persistent requirement for stretchable lithium-ion batteries (LIBs). Despite recent progress in stretchable electrodes, stretching full batteries, including electrodes, separator, and sealing material, remains a great challenge. Here, a simple design concept for stretchable LIBs via a wavy structure at the full battery device scale is reported. All components including the package are capable of being reversibly stretched by folding the entire pouch cell into a wavy shape with polydimethylsiloxane filled in each valley region. In addition, the stretchable, sticky, and porous polyurethane/poly(vinylidene fluoride) membrane is adopted as a separator for the first time, which can maintain intimate contact between electrodes and separator to continuously secure ion pathway under dynamic state. Commercial cathode, anode, and package can be utilized in this rationally designed wavy battery to enable stretchability. The results indicate good electrochemical performances and long-term stability at repeatable release–stretch cycles. A high areal capacity of 3.6 mA h cm -2 and energy density of up to 172 W h L -1 can be achieved for the wavy battery. The promising results of the cost-effective wavy battery with high stretchability shed light on the development of stretchable energy storages.
High‐Loading Lithium‐Sulfur Batteries with Solvent‐Free Dry‐Electrode Processing
Abstract Lithium‐sulfur (Li‐S) batteries, with their high energy density, nontoxicity, and the natural abundance of sulfur, hold immense potential as the next‐generation energy storage technology. To maximize the actual energy density of the Li‐S batteries for practical applications, it is crucial to escalate the areal capacity of the sulfur cathode by fabricating an electrode with high sulfur loading. Herein, ultra‐high sulfur loading (up to 12 mg cm −2 ) cathodes are fabricated through an industrially viable and sustainable solvent‐free dry‐processing method that utilizes a polytetrafluoroethylene binder fibrillation. Due to its low porosity cathode architecture formed by the binder fibrillation process, the dry‐processed electrodes exhibit a relatively lower initial capacity compared to the slurry‐processed electrode. However, its mechanical stability is well maintained throughout the cycling without the formation of electrode cracking, demonstrating significantly superior cycling stability. Additionally, through the optimization of the dry‐processing, a single‐layer pouch cell with a loading of 9 mg cm −2 and a novel multi‐layer pouch cell that uses an aluminum mesh as its current collector with a total loading of 14 mg cm −2 are introduced. To address the reduced initial capacity of dry‐processed electrodes, strategies such as incorporating electrocatalysts or employing prelithiated active materials are suggested.
Advanced Electrode Structures for Proton Exchange Membrane Fuel Cells: Current Status and Path Forward
Abstract Proton exchange membrane fuel cells (PEMFCs) have demonstrated their viability as a promising candidate for clean energy applications. However, performance of conventional PEMFC electrodes, especially the cathode electrode, suffers from low catalyst utilization and sluggish mass transport due to the randomly distributed components and tortuous transport pathways. Development of alternative architectures in which the electrode structure is controlled across a range of length scales provides a promising path toward overcoming these limitations. Here, we provide a comprehensive review of recent research and development of advanced electrode structures, organized by decreasing length-scale from the millimeter-scale to the nanometer-scale. Specifically, advanced electrode structures are categorized into five unique architectures for specific functions: (1) macro-patterned electrodes for enhanced macro-scale mass transport, (2) micro-patterned electrodes for enhanced micro-scale mass transport, (3) electrospun electrodes with fiber-based morphology for enhanced in-plane proton transport and through-plane O 2 transport, (4) enhanced-porosity electrodes for improved oxygen transport through selective inclusion of void space, and (5) catalyst film electrodes for elimination of carbon corrosion and ionomer poisoning. The PEMFC performance results achieved from each alternative electrode structure are presented and tabulated for comparison with conventional electrode architectures. Moreover, analysis of mechanisms by which new electrode structures can improve performance is presented and discussed. Finally, an overview of current limitations and future research needs is presented to guide the development of electrode structures for next generation PEMFCs. Graphical Abstract Development of improved electrode architectures with the control of structure on length scales ranging from millimeters to nanometers could enable a new generation of fuel cells with increased performance and reduced cost. This paper presents an in-depth review and critical analysis of recent developments and future outlook on the design of advanced electrode structures.
Intercalation of Ca into a Highly Defective Manganese Oxide at Room Temperature
The utilization of oxide frameworks as intercalation cathodes for non-aqueous Ca-ion batteries potentially unlocks a new energy storage system that delivers high energy density. However, the slow kinetics of Ca 2+ in oxide electrodes strongly handicaps their activity and reversibility at room temperature. Here, nanocrystals of layered MnO x containing a high concentration of atomic defects and lattice water are shown to have remarkable electrochemical activity towards Ca 2+ , amounting to a capacity of ~130 mAh/g at room temperature. Multimodal characterization revealed the notable degree of intercalation by probing the structural, compositional and redox changes undertaken by the defective MnO x nanocrystals. The results suggest that the existence of atomic defects and lattice water played a role in improving Ca 2+ diffusivity in the oxide. These outcomes reaffirm the prospects for functional Ca-ion batteries using oxide cathodes under moderate conditions.
Collapse of LiNi 1– x–y Co x Mn y O 2 Lattice at Deep Charge Irrespective of Nickel Content in Lithium-Ion Batteries
Volume variation and the associated mechanical fracture of electrode materials upon Li extraction/insertion are a main cause limiting lifetime performance of lithium-ion batteries. For LiNi 1-x-y Co x Mn y O 2 (NCM) cathodes, abrupt anisotropic collapse of the layered lattice structure at deep charge is generally considered characteristic to high Ni content and can be effectively suppressed by elemental substitution. Herein, we demonstrate the lattice collapse is a universal phenomenon almost entirely dependent on Li utilization, and not Ni content, of NCM cathodes upon delithiation. With Li removal nearing 80 mol%, very similar c-axis lattice shrinkage of around 5% occurs concurrently for NCMs synthesized in-house regardless of nickel content (90, 70, 50, or 33 mol%); meanwhile, the a-axis lattice contracts for high-Ni NCM, but it expands for low-Ni NCM. We further reveal Co-Mn co-substitution in NCM barely, if at all, affects several key structural aspects governing the lattice distortion upon delithiation. Finally, our results highlight the importance of evaluating true implications of compositional tuning on high-Ni layered oxide cathode materials to maximize their charge-storage capacities for next-generation high-energy Li-ion batteries.
Multi-species electrolyte migration kinetics with directed flow
Here, this paper investigates an electrochemical process designed to control mixing kinetics in liquid electrolytes. The process utilizes an electrochemical cell with anode and cathode chambers connected by a channel without a membrane. This configuration depletes multiple electroactive species in the cathode chamber while selectively replenishing them in the anode chamber. A key application is the removal of impurity species from the cathode chamber electrolyte and the selective replenishment of primary electroactive species in the anode chamber. Aqueous cell experiments were conducted to validate the theoretical model, and simulations were performed for molten salt electrolytes. This approach minimizes waste by reducing the need for additional electrolyte supplies and extends the utilization of anion species, contributing to environmentally sustainable electrochemical materials processing.
A nickel-foam@carbon-shell with a pie-like architecture as an efficient polysulfide trap for high-energy Li–S batteries
A high-loading sulfur cathode is critical for establishing rechargeable lithium–sulfur (Li–S) batteries with the anticipated high energy density. However, its fabrication as well as realizing high electrochemical utilization and stability with high-loading sulfur cathodes is a daunting challenge. Here, we present a new pie-like electrode that consists of an electrocatalytic nickel-foam as a “filling” to adsorb and store polysulfide catholytes and an outer carbon shell as a “crust” for facilitating high-loading sulfur cathodes with superior electrochemical and structural stabilities. The inner electrocatalytic nickel-foam is configured to adsorb polysulfides and facilitate their redox reactions. The intertwined carbon shell assists to shield the polysulfides within the cathode region of the cell. Both the nickel-foam and the carbon shell have high conductivity and porous space, which serve simultaneously as interconnected current collectors to enhance the redox kinetics and as polysulfide reservoirs to confine the active material. The effectiveness of such a pie-like structure in improving the electrochemical efficiency enables the cathode to host an ultrahigh sulfur loading of 40 mg cm -2 and attain a high areal capacity of over 40 mA h cm -2 at a low electrolyte/sulfur (E/S) ratio of 7. The enhanced cyclability is reflected in a high reversible areal capacity approaching 30 mA h cm -2 at C/5 rate after 100 cycles and excellent rate capability up to 2C rate.
High-performance room-temperature sodium–sulfur battery enabled by electrocatalytic sodium polysulfides full conversion
Room-temperature sodium–sulfur (RT-Na–S) batteries are highly desirable for grid-scale stationary energy storage due to their low cost; however, short cycling stability caused by the incomplete conversion of sodium polysulfides is a major issue for their application. Herein, we introduce an effective sulfiphilic host, gold nanodots decorated on hierarchical N-doped carbon microspheres (CN/Au/S), to achieve completely reversible conversion reactions in the S cathode by electrocatalyzing the low-kinetics conversion of Na 2 S 4 into NaS 2 (discharge process) or S (charge process). Besides, gold nanodots and N-doped carbon can increase the conductivity of the S cathode and provide strong polar–polar adsorption of sodium polysulfides to alleviate the shuttling effects. When serving as the cathode, the CN/Au/S composite can realize enhanced sulfur utilization, excellent cycling stability, and outstanding rate capability. This work deepens our understanding of the catalytic effect of gold atoms on sulfur molecules, opening a new avenue for cathode design and development of advanced RT-Na–S batteries.
Computationally Guided Design of Multiple Impurities Tolerant Cathode for Solid Oxide Fuel Cell Applications
Solid oxide fuel cells (SOFCs) have been recognized as promising candidates in the demand of reducing the dependence on fossil fuels, which is one of the solutions to the threat of global warming. It was reported that the direct chemical-to-electrical energy conversion in SOFCs comes with negligible emission of greenhouse gases and up to 60% working efficiency. SOFC has unique advantages over traditional power generation technologies and other types of fuel cells due to the use of relatively inexpensive materials, low sensitivity to poisoning impurities in fuels, relatively high conversion efficiency, and fuel flexibility (like carbon-based fuels). However, during the SOFC operation, the cathode is exposed to intrinsic and extrinsic airborne contaminants at high temperatures (600–900°C), leading to their reaction with electrode materials, irreversible chemical and structural changes, and electrochemical performance degradation. of which CO2, SO2, Cr6+ and H2O are known to be concerns. Thus, developing a comprehensive understanding of the multiple impurities poisoning of SOFC cathodes in the presence of single or multiple impurities is necessary to address the long-term degradation of the SOFC cathode systems at operating conditions. An integrated computational and experimental approach has been utilized in the current work aiming at the comprehensive investigation of the cathode materials under single or multiple impurities poisoning effects, understanding the multiple impurities poisoning mechanism(s), and improving the long-term durability of the SOFC cathodes to develop better performing impurity-tolerant cathode materials. We first examined the agreement between the simulation approach and the experimental observations at various atmospheric and temperature conditions to confirm the reliability of CALPHAD for poisoning simulations in these cathodes. Then, using this approach, we investigated the accelerated testing protocol, which has become the standard method for conducting impurity poisoning experiments involving these cathode materials. We found our simulation approach is able to predict in which systems, i.e., cathode material and treatment environment, the accelerated testing protocols reflect actual operating conditions. Finally, in-depth simulations were done for these three candidate cathodes under different experimental conditions and suggested directions toward alternative cathode materials that have superior impurity tolerance.
Two-layer cathode architecture for high-energy density and high-power density solid state batteries
Solid state batteries with high-energy density and high-power density require the development of thick and energy dense cathodes. Structured cathode electrodes with a double-layer configuration were enabled using a freeze tape casting technique. A bottom dense layer was utilized to enhance the energy density whereas a top porous layer with vertically aligned walls was utilized to enhance the power density. The porous structure of the power layer was achieved by ice templating this layer on top of the densified energy layer of the cathode. This configuration was found to better utilize the active material of the cathodes and was optimized using numerical simulation and computer modeling. Cells with Li metal anode and LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) at approximately 5 and 20 mg/cm 2 were cycled at 70 °C at different C-rates. Poly(ethylene oxide) (PEO) with lithium bis-trifluoromethanesulfonimide (LiTFSI) was used for the catholyte and the solid-state electrolyte. The structured cathodes exhibited more than double capacity values as well as better Coulombic efficiency compared to non-structured (single-layer) thick cathodes. In conclusion, synchrotron X-ray tomography and scanning electron microscopy were used to characterize the microstructure of the cathodes.
Structure–performance relationships of lithium-ion battery cathodes revealed by contrast-variation small-angle neutron scattering
Lithium-ion battery cathodes are porous composites of active material, conductive carbon, and polymer binder. Controlling the cathode microstructure is key to achieving high energy density and cycling stability. Current characterization techniques lack the nanoscale resolution over representative volumes necessary to relate cathode microstructure to cycling performance. To address this challenge, we utilize contrast-variation small-angle neutron scattering to quantify the chemical and structural features of cathodes wet by dimethyl carbonate, representing a relevant solvent environment. Using neutron scattering measurements, we identify an expansion in carbon and polymer structures that arises after calendering and wetting with solvent. Further, we deconvolute the carbon and binder phases to obtain the solvent-accessible carbon black surface area, which we correlate to diminished capacity retention driven by electrolyte decomposition on exposed carbon. This technique provides nanoscale insight into composite cathode microstructures and resulting cycling performance, promising future applications to a broad range of porous materials that exist in energy storage systems.
Compatibility of a Conventional Non-aqueous Magnesium Electrolyte with a High Voltage V 2 O 5 Cathode and Mg Anode
A major roadblock for magnesium ion battery development is the availability of an electrolyte that can deposit Mg reversibly and at the same time is compatible with a high voltage cathode. We report a prospective full magnesium cell utilizing a simple, non-aqueous electrolyte composed of high concentration magnesium bis(trifluoromethane sulfonyl)imide in diglyme, which is compatible with a high voltage vanadium pentoxide (V 2 O 5 ) cathode and a Mg metal anode. For this system, plating and stripping of Mg metal can be achieved with magnesium bis(trifluoromethane sulfonyl)imide in diglyme electrolyte over a wide concentration range, however, reversible insertion of Mg into V 2 O 5 cathode can only be attained at high electrolyte concentrations. Reversible intercalation of Mg into V 2 O 5 is characterized and confirmed by X-ray diffraction, X-ray absorption near edge spectroscopy and energy dispersive spectroscopy.
Coupling of multiscale imaging analysis and computational modeling for understanding thick cathode degradation mechanisms
Here, using a thick NMC811 (LiNi 0.8 Mn 0.1 Co 0.1 O 2 ) electrode as an example, we present a macro- to nanoscale 2D and 3D imaging analysis approach coupled with 4D (space + time) computational modeling to probe its degradation mechanism in a lithium-ion battery cell. Particle cracking increases and contact loss between particles and carbon-binder domain are observed to correlate with the cell degradation. This study unravels that the reaction heterogeneity within the thick cathode caused by the unbalanced electron conduction is the main cause of the battery degradation over cycling. The increased heterogeneity in the system will entail more cathode regions where the degree of active material utilization is uneven, leading to higher probabilities of particle cracking. These findings shed light on the crucial role of the electronic and ionic transportation networks in the performance deterioration of the thick cathode. They also provide guidance for cathode architecture optimization and performance improvement.
A novel coronene//Na 2 Ti 3 O 7 dual-ion battery
Here we construct a novel sodium dual-ion battery (Na-DIB) with a conventional alkyl/alkylene carbonate electrolyte by using reduced-graphene-oxide-coated Na 2 Ti 3 O 7 (NTO@G) as the anode and coronene, a polycyclic aromatic hydrocarbon (PAH), as the cathode. The coronene//NTO@G configuration delivers a specific energy of 77 W h kg -1 , based on the total active mass in both electrodes, and excellent cycling stability with 80% capacity retention after 5000 cycles. In addition, this device can work well in a wide range of temperatures from -20 to 40 °C. Furthermore, the results demonstrate a proof-of-concept Na-DIB that avoids the challenges of conventional dual-graphite DIBs by utilizing non-graphite intercalation anode and cathode, and a carbonate-based electrolyte without any additives.