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Applications of silicon as a high-performance anode material has been impeded by its low intrinsic conductivity and huge volume expansion (> 300%) during lithiation. To address these problems, nano-Si particles along with conductive coatings and engineered voids are often employed, but this results in high cost anodes. Here, we report a scalable synthesis method that can realize high specific capacity (~800 mAh g-1), ultrafast charge/discharge (at 8 A g-1 Si) and high initial Coulombic efficiency (~90%) with long cycle life (1000 cycles) at the same time. To achieve 1000 cycle stability, micron-sized Si particles are subjected to high-energy ball milling to create nanostructured Si building blocks with nano-channel shaped voids encapsulated inside a nitrogen (N)-doped carbon shell (termed as Si micro-reactor). The nano-channel voids inside a Si micro-reactor not only offer the space to accommodate the volume expansion of Si, but also provide fast pathways for Li ion diffusion into the center of the nanostructured Si core and thus ultrafast charge/discharge capability. The porous N-doped carbon shell helps to improve the conductivity while allowing fast Li ion transport and confining the volume expansion within the Si micro-reactor. Submicron-sized Si micro-reactors with limited specific surface area (35 m2 g-1) afford sufficient electrode/electrolyte interfacial area for fast lithiation/delithiation, leading to the specific capacity ranging from ~800 to 420 mAh g-1 under ultrafast charging conditions (8 A g-1), but not too much interfacial area for surface side reactions and thus high initial coulombic efficiency (~90%). Since Si micro-reactors with superior electrochemical properties are synthesized via an industrially scalable and eco-friendly method, they have the potential for practical applications in the future. 

In this study, we report the first investigation of the effectiveness of the partially converted carbon coating from polydopamine (PODA) to improve the cycle stability of Si anode for Li-ion batteries. It is hypothesized that by converting PODA to a partial carbonization condition, the resulting coating could have a higher electrical conductivity than PODA without carbonization, and at the same time may still contain some organic bonds and thus mechanical flexibility to accommodate the volume expansion of Si during lithiation. The results show that such a partial carbonization state can be obtained by carbonization of PODA at 400 °C. Furthermore, the partially converted carbon coating can offer sufficient electrical conductivity for lithiation and delithiation of Si anode while drastically reducing the charge transfer resistance for the redox reactions. In addition, the partially-converted‑carbon coated hollow Si nanospheres exhibit excellent cycle stability when the volume expansion of Si anode is not very large (~88%) even though this volume expansion is significantly larger than the engineered void space (47%of the Si volume) available inside the partially-converted‑carbon coated hollow Si nanospheres, unambiguously confirming the good tolerance of the partially converted carbon coating in withstanding some tensile strain without fracture. This study offers a new direction for systematic studies in the future as a means to provide a coating on Si material with sufficient electrical conductivity along with capability to withstand some tensile strain during the volume expansion of Si, thereby improving the cycle stability of Si anodes. 

Silicon/graphite (Si/Gr) nanocomposites with controlled void spaces and encapsulated by a carbon shell (Si/Gr@void@C) are synthesized by utilizing high-energy ball milling to reduce micron-sized particles to nanoscale, followed by carbonization of polydopamine (PODA) to form a carbon shell, and finally partial etching of the nanostructured Si core by NaOH solution at elevated temperatures. In particular, the effects of ball milling time and NaOH etching temperature on the electrochemical properties of Si/Gr@void@C are investigated. Increasing the ball milling time results in the improved specific capacity of Si-based anodes. Carbon coating further enhances the specific capacity and capacity retention over charge/discharge cycles. The best cycle stability is achieved after partial etching of the Si core inside Si/Gr@void@C particles at either 70 or 80 C, leading to little or no capacity decay over 130 cycles. However, it is found that both carbon coating and NaOH etching processes cause some surface oxidation of the nanostructured Si particles derived from high-energy ball milling. The surface oxidation of the nanostructured Si results in decreases in specific capacity and should be minimized in future studies. The mechanistic understanding developed in this study paves the way to further improve the electrochemical performance of Si/Gr@void@C nanocomposites in future. 

Utilizing silicon as an anode material for Li-ion batteries has been the subject of many studies. However, due to the huge volume change of silicon during lithiation, the electrochemical performance of silicon is poor. Here, we have investigated a novel yet simple approach to synthesize nanostructured silicon/graphite composites with a carbon coating and engineered voids. High-energy ball mill is employed to convert micrometer-sized silicon and graphite to nanostructured silicon/graphite composite building blocks, while a thin carbon coating is applied to encapsulate these composite agglomerates, followed by partial etching of silicon to create engineered voids inside the composite agglomerates. The batteries made with this tailored nanostructure exhibit improved electrochemical performance over the counterparts made with silicon nanoparticles and exhibited a specific capacity of ~1800 mA h g-1 discharge capacity at the first cycle, 580 mA h g-1 after 40 cycles, and 350 mA h g-1 after 300 cycles. This study has established a novel method scalable at industry environment and capable of producing low cost Si anodes and clearly shown that the cycle stability of the tailored nanostructure improves with increasing engineered voids in the range we have investigated.