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Abstract The use of silicon nanoparticles for lithium-ion batteries requires a precise control over both their average size and their size distribution. Particles larger than the generally accepted critical size of 150 nm fail during lithiation because of excessive swelling, while very small particles (<10 nm) inevitably lead to a poor first cycle coulombic efficiency because of their excessive specific surface area. Both mechanisms induce irreversible capacity losses and are detrimental to the anode functionality. In this manuscript we describe a novel approach for enhanced growth of nanoparticles to ∼20 nm using low-temperature flow-through plasma reactors via pulsing. Pulsing of the RF power leads to a significant increase in the average particle size, all while maintaining the particles well below the critical size for stable operation in a lithium-ion battery anode. A zero-dimensional aerosol plasma model is developed to provide insights into the dynamics of particle agglomeration and growth in the pulsed plasma reactor. The accelerated growth correlates with the shape of the particle size distribution in the afterglow, which is in turn controlled by parameters such as metastable density, gas and electron temperature. The accelerated agglomeration in each afterglow phase is followed by rapid sintering of the agglomerates into single-crystal particles in the following plasma-on phase. This study highlights the potential of non-thermal plasma reactors for the synthesis of functional nanomaterials, while also underscoring the need for better characterization of their fundamental parameters in transient regimes. 

Silicon has received a considerable amount of attention in the last few years because of its large lithiation capacity. Its widespread utilization in real-life lithium-ion batteries has so far been prevented by the plethora of challenges presented by this material. This review discusses the most promising technologies that have been put forward to address these issues. While silicon is now much closer to being compatible with commercial-grade storage devices, some critical barriers still deserve further attention. Most importantly, device performance is strongly dependent on particle size and size distribution, with these parameters strongly controlled by the particle synthesis technique. Moreover, the nanoparticle synthesis technique ultimately controls the material manufacturing cost and compatibility with large-scale utilization. These issues are discussed in detail, and recommendations to the community are provided.