Due to abundant raw materials, low costs and promising high reversible specific capacities, hard carbons (HCs) are a common choice for commercially manufactured anodes in sodium-ion batteries (SIBs). Despite their potential and extensive use, the storage mechanism is still under debate. The non-stoichiometric adsorption mechanism also means that the search for an upper limit for the reversible capacity is ongoing. There is a strong requirement for synthetic anodes that enable a better understanding of the theoretical capacity associated with HC-anodes. We have developed core-shell carbon anodes consisting of a highly porous carbon core and (almost) non-porous shell. Thus, the reversible capacity can be deconvoluted from irreversible capacity losses, arising from the formation of the solid electrolyte interphase (SEI). Moreover, the porosity of the carbon-core can be linked to the reversible capacities gained.

A range of microporous activated carbons were coated via an optimized chemical vapour deposition technique.[1][2] These materials were characterised using a range of techniques including powder x-ray diffraction, small angle x-ray diffraction (SAXS), gas physisorption (N2, CO2) measurements and electrochemical characterisation at coin cell level.

After coating, the material showed a significant reduction in detectable surface area (up to a factor of 192x) by N2-physisorption. The tailor-made shell allows the stable cycling of a carbon anode vs metallic Na-electrode in coin cells at room temperature. For the best performing material, the reversible capacity increased from 139 ± 2 mAhg-1 to 396 ± 2 mAhg-1 while irreversible capacity is decreased from 636 ± 3 mAhg-1 to 89 ± 3 mAhg-1. After initial stabilization, a CE of 99% was achieved. The coating technique was usefully applied to a range of materials. [3]

The successful formation of core-shell structures with high capacities enables separation of the storage mechanism from SEI-formation. In turn a proposed calculation to rank the contributions of surface adsorption and pore filling capacity can be confirmed. The materials also create the opportunity to conduct a range of operando experiments (e.g., SAXS) that can shed further light on the sodium storage mechanism.

References:
[1] Chen, X., et al., Filling carbon: a microstructure-engineered hard carbon for efficient alkali metal ion storage. Energy & Environmental Science, 2023. 16(9): p. 4041-4053.
[2] Li, Q., et al., Sieving carbons promise practical anodes with extensible low-potential plateaus for sodium batteries. National Science Review, 2022. 9(8).
[3] Fellinger, T.P., et al. Core-Shell Carbon Anode as High Performance Negative Electrodes for Sodium Ion Batteries. in Preparation, 2024