A Nearly Packaging-Free Design Paradigm for Light, Powerful, and Energy-Dense Primary Microbatteries.

Billions of internet connected devices used for medicine, wearables, and robotics require microbattery power sources, but the conflicting scaling laws between electronics and energy storage have led to inadequate power sources that severely limit the performance of these physically small devices. Reported here is a new design paradigm for primary microbatteries that drastically improves energy and power density by eliminating the vast majority of the packaging and through the use of high-energy-density anode and cathode materials. These light (50-80 mg) and small (20-40 µL) microbatteries are enabled though the electroplating of 130 µm-thick 94% dense additive-free and crystallographically oriented LiCoO2 onto thin metal foils, which also act as the encapsulation layer. These devices have 430 Wh kg-1 and 1050 Wh L-1 energy densities, 4 times the energy density of previous similarly sized microbatteries, opening up the potential to power otherwise unpowerable microdevices.

Revealing the role of the cathode-electrolyte interface on solid-state batteries.

Interfaces have crucial, but still poorly understood, roles in the performance of secondary solid-state batteries. Here, using crystallographically oriented and highly faceted thick cathodes, we directly assess the impact of cathode crystallography and morphology on the long-term performance of solid-state batteries. The controlled interface crystallography, area and microstructure of these cathodes enables an understanding of interface instabilities unknown (hidden) in conventional thin-film and composite solid-state electrodes. A generic and direct correlation between cell performance and interface stability is revealed for a variety of both lithium- and sodium-based cathodes and solid electrolytes. Our findings highlight that minimizing interfacial area, rather than its expansion as is the case in conventional composite cathodes, is key to both understanding the nature of interface instabilities and improving cell performance. Our findings also point to the use of dense and thick cathodes as a way of increasing the energy density and stability of solid-state batteries.

Electroplating lithium transition metal oxides.

Materials synthesis often provides opportunities for innovation. We demonstrate a general low-temperature (260°C) molten salt electrodeposition approach to directly electroplate the important lithium-ion (Li-ion) battery cathode materials LiCoO2, LiMn2O4, and Al-doped LiCoO2. The crystallinities and electrochemical capacities of the electroplated oxides are comparable to those of the powders synthesized at much higher temperatures (700° to 1000°C). This new growth method significantly broadens the scope of battery form factors and functionalities, enabling a variety of highly desirable battery properties, including high energy, high power, and unprecedented electrode flexibility.