Self-assembled nano-silicon/graphite hybrid embedded in a conductive polyaniline matrix for the performance enhancement of industrial applicable lithium-ion battery anodes

Abstract Nano-structured silicon-based composite materials have generated significant excitement for use as anode materials in high-performance Li-ion batteries. For making these materials commercially applicable, a high Coulombic efficiency at the first cycle must be achieved. Additionally, scalable synthesis routes need to be developed to provide access to practically-relevant material quantities. In this work, we propose a strategy for the production of Si/graphite/polyaniline (Si/graphite/PANI) composites that addresses both above mentioned challenges. Si nanoparticles were produced in a pilot-plant-scale microwave-plasma reactor using monosilane (SiH4) as precursor. This process enables the formation of high-purity Si nanoparticles with controllable crystal sizes at a production rate of 45 g/h. Si/graphite hybrids are fabricated through self-assembly by electrostatic attraction. The Si/graphite/PANI nanocomposite is then prepared by in situ polymerization of aniline monomer in the presence of the Si/graphite hybrid. With this approach, ~40 g of Si/graphite/PANI composite per batch can be produced at lab scale. The scalability of the underlying processes enables the use for commercial products. The nanocomposite shows favorable characteristics inherited from its three components: Si nanoparticles provide high capacity, graphite acts as an electrical conductor and gives a high Coulombic efficiency, and the polyaniline coating further enhances the electrical conductivity and protects the entire structure. A very good Coulombic efficiency of 86.2% at the initial cycle is recorded for this nanocomposite material. Galvanostatic charge/discharge tests demonstrate that this material can deliver a discharge capacity of 2000 mAh/g with a very good capacity retention of 76% after 500 cycles at a discharge rate of 0.5C (1.25 A/g). The capacity is 870 mAh/g measured at 5C (12.5 A/g).