electrosprayed porous fe o /carbon microspheres as anode ... · nano res. 2018, 11(2): 892–904...
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Electrosprayed porous Fe3O4/carbon microspheres as anode materials for high-performance lithium-ion batteries
Wenjie Han1,2, Xianying Qin1,3 (), Junxiong Wu3, Qing Li1,2, Ming Liu1,2, Yue Xia1, Hongda Du1,
Baohua Li1 (), and Feiyu Kang1,2
1 Engineering Laboratory for Next Generation Power and Energy Storage Batteries, and Engineering Laboratory for Functionalized
Carbon Materials, Graduate School at Shenzhen, Tsinghua University, Shenzhen 518055, China 2 School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China 3 Department of Mechanical and Aerospace Engineering, The Hong Kong University of Science and Technology, Clear Water Bay,
Kowloon, Hong Kong, China
Received: 16 May 2017
Revised: 3 June 2017
Accepted: 6 June 2017
© Tsinghua University Press
and Springer-Verlag GmbH
Germany 2017
KEYWORDS
lithium ion battery,
Fe3O4/carbon microsphere,
hierarchical pores,
electrospray technique,
electrochemical
performance
ABSTRACT
Porous Fe3O4/carbon microspheres (PFCMs) were successfully fabricated via
a facile electrospray method and subsequent heat treatment, using ferrous
acetylacetonate, carbon nanotubes (CNTs), Ketjen black (KB), polyvinylpyrrolidone
(PVP), and polystyrene (PS) as raw materials. The porous carbon sphere framework
decorated with well-dispersed CNTs and KB exhibits excellent electronic
conductivity and acts as a good host to confine the Fe3O4 nanoparticles. The
abundant mesopores in the carbon matrix derived from polymer pyrolysis can
effectively accommodate the volume changes of Fe3O4 during the charge/
discharge process, facilitate electrolyte penetration, and promote fast ion diffusion.
Moreover, a thin amorphous carbon layer on the Fe3O4 nanoparticle formed
during polymer carbonization can further alleviate the mechanical stress associated
with volume changes, and preventing aggregation and exfoliation of Fe3O4
nanoparticles during cycling. Therefore, as anode materials for lithium-ion
batteries, the PFCMs exhibited excellent cycling stability with high specific
capacities, and outstanding rate performances. After 130 cycles at a small current
density of 0.1 A·g–1, the reversible capacity of the PFCM electrode is maintained
at almost 1,317 mAh·g–1. High capacities of 746 and 525 mAh·g–1 were still achieved
after 300 cycles at the larger currents of 1 and 5 A·g–1, respectively. The optimized
structure design and facile fabrication process provide a promising way for the
utilization of energy storage materials, which have high capacities but whose
performance is hindered by large volume changes and poor electrical conductivity
in lithium or sodium ion batteries.
Nano Research 2018, 11(2): 892–904
https://doi.org/10.1007/s12274-017-1700-6
Address correspondence to Xianying Qin, [email protected]; Baohua Li, [email protected]
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893 Nano Res. 2018, 11(2): 892–904
1 Introduction
In order to address large-scale environmental
deterioration, lithium-ion batteries (LIBs) have arisen
as possible environmentally-friendly alternatives to
fossil fuel-based energy consumption. Their large
voltage-windows, high energy density, and long cycle
life [1, 2] have resulted in their widespread use in
portable electronic products, electric/hybrid vehicles,
and power storage devices. However, it is difficult for
current commercial electrode materials to meet the
performance demands for battery-powered electric
vehicles (EVs), which require higher energy and power
densities, as well as a longer cycle life. Considering
that the theoretical specific capacity of a commercial
graphite anode is low (372 mAh·g–1) [3–5], developing
high-performance anode materials with optimized
structures is an effective way to address the above
issues. In the last decade, new anode materials such
as metal oxides, sulfides, silicon, tin, and carbon
materials [6–18] have been extensively studied to
improve electrochemical performance. Among these
existing anode materials, Fe3O4 is considered as a
promising alternative for energy storage in LIBs. This
is because it is environmentally benign, low-cost, and
has a much higher theoretical capacity (926 mAh·g–1)
than commercial graphite [19, 20]. Nonetheless, the
large volume change (93%) typically observed during
lithiation/delithiation processes, results in the formation
of an unstable solid-electrolyte interphase (SEI), which
further leads to a loss of electrical contact between
the active material and conductive additives, thus,
destroying the electrode integrity and causing significant
capacity fading. Furthermore, the low electrical
conductivity and sluggish ionic diffusion rate greatly
hinder the rate performance of Fe3O4 anodes [21–23].
To solve the problems mentioned above and produce
ideal anode materials with high capacity and stability,
considerable efforts have been devoted to designing
various advanced Fe3O4-based anode materials with
optimized size, structure, and constitution [24]. One
such set of examples is the integration of a Fe3O4-based
active material into various carbonaceous matrices to
form stable hybrid nanostructures with superior
electrical conductivity. In this case, the carbon materials
can not only improve the electron propagation, but
also buffer the volume strain of Fe3O4 during the
charge/discharge process because of their good elasticity
and toughness. Various carbonaceous materials were
used in these studies, such as carbon nanotubes (CNTs)
[25, 26], graphene [27, 28] and amorphous carbon [29].
CNTs are one of the most widely used candidates
in preparing hybrid electrodes because of their high
electrical conductivity and excellent mechanical
tenacity. Recently, Cheng and co-workers have confined
electrochemically prelithiated iron oxide in CNTs by
immersing the carbon-coated anodic aluminum oxide
films into a solution of iron nitrate in ethanol [26].
The prepared nanocomposites exhibited a reversible
specific capacity of 963.7 mAh·g–1 at a current density
of 50 mA·g–1 based on the total mass after 16 cycles.
Chen and co-workers reported a facile method to
synthesize CNTs-Fe3O4@C beaded structures by de-
positing Fe3O4 and carbon layers on CNTs, thus, giving
rise to a recharge capacity retention of 720 mAh·g–1
after 80 cycles at 0.1 A·g–1 [30]. Meanwhile mesoporous
carbon is considered as another ideal framework to
encapsulate electrochemically active particles for LIB
applications [20, 31].
An additional route to improving performance is
the encapsulation of porous Fe3O4 in microstructures.
These porous and secondary structures can effectively
alleviate volume changes in Fe3O4 particles and
provide numerous channels for rapid transportation
of electrolytes as well as lithium ions. Wong and
co-workers fabricated carbon encapsulated hollow
Fe3O4 nanoparticles homogeneously anchored on
graphene nanosheets by a polyol-media solvothermal
method [32]. The hybrid materials delivered a reversible
capacity of 870 mAh·g–1 at 0.1 A·g–1 and excellent rate
performance for lithium storage. The interior voids
of the composites accommodated the large volume
change of Fe3O4 and improved the reaction kinetics.
However, the increase of void fraction can lead to
a structural collapse, and the aggregation of Fe3O4
nanoparticles into larger particles, which pulverize
upon long discharge/charge cycles [33]. In this
case, synthesizing Fe3O4/carbon nanocomposites with
optimized porous structures (porosity and pore size)
is crucial to protect Fe3O4 nanoparticles and obtain
superior electrochemical performances.
The third route for utilizing these materials is the
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894 Nano Res. 2018, 11(2): 892–904
fabrication of nano-sized Fe3O4-based particles. These
provide short diffusion pathways for lithium ions
and electrons, and therefore eliminate internal stress
on the electrode [34]. Since this route improves
both the reaction kinetics and structural stability, the
electrochemical performance is enhanced [26, 35, 36].
Meng et al. reported the synthesis of Fe3O4/carbon
composite nanofoils with an average thickness of
about 20 nm [37]. The thin nanofoils provided shorter
lithium path lengths compared with the bulk counterpart,
leading to improved rate performances. However,
due to the low conductivity and easy agglomeration of
Fe3O4 nanoparticles during cycling, Fe3O4 nanoparticles
are generally combined with carbonaceous materials
to solve the above issues [26, 33, 38].
Herein, we report an electrospray technique to
fabricate porous Fe3O4/carbon microspheres (PFCMs),
in which Fe3O4 nanoparticles are embedded in a
porous carbon framework consisting of CNTs, Ketjen
black (KB), and amorphous carbon. The resulting
PFCM anodes in LIBs demonstrate a high specific
capacity, excellent cycling stability, and outstanding
rate performance. The reversible capacity of the PFCMs
can reach almost 1,317 mAh·g–1 after 130 cycles at
0.1 A·g–1. Furthermore, high capacities of 746 and
525 mAh·g–1 are still achieved after 300 cycles at 1 and
5 A·g–1, respectively. The superior electrochemical
properties are attributed to the optimized structure
design for PFCMs. The first advantage of our optimized
structure is the intertwining of CNTs and KB particles.
This forms an excellent conductive skeleton and
mechanical scaffold, which greatly promotes the
electron/ion transportation and strengthens the structural
stability. The mesoporous structure provides a second
advantage by efficiently alleviating the large stress
resulting from internal expansion during Fe3O4 lithiation,
thus, ensuring the structural integrity of PFCMs is
maintained during cycling. Lastly, the confined Fe3O4
nanoparticles encapsulated in amorphous carbon
layers can effectively avoid particle agglomeration
and achieve fast reaction kinetics.
2 Experimental
2.1 Chemicals
All the chemicals, including ferrous acetylacetonate
(Fe(acac)2, Sigma Aldrich), polyvinylpyrrolidone (PVP,
MW = 1,300,000, Sigma Aldrich), polystyrene (PS, MW =
192,000, Sigma Aldrich), multi walled CNTs (Chengdu
Organic Chemicals Co. Ltd.), KB (EC-600JD) and
dimethyl formamide (DMF, Fisher), were used directly
without further purification.
2.2 Synthesis of PFCMs
PFCMs were synthesized by electrostatic spraying
followed by heat treatment. In a typical preparation
process, 0.5 g PVP, 0.56 g PS, 0.22 g KB, and 0.1 g CNTs
were added into 20 mL DMF to form a homogeneous
stable suspension under magnetic stirring at 80 °C for
2 h and subsequent ultrasonic dispersion for 2 h. Next,
1 g Fe(acac)2 was added into the above suspension
with magnetic stirring at 80 °C for 2 h and ultrasonic
dispersion for an additional 2 h to form the finial
precursor solution for our electrospray technique.
The spray solution was atomized with a high voltage
of 25 kV and a distance of 15 cm was maintained
between the nozzle and substrate at a flow rate of
1.0 mL·h–1. After electrostatic spraying, the as-prepared
precursor hybrids were stabilized in air at 250 °C for
2 h, and then carbonized in argon at 600 °C for 2 h
with a heating rate of 5 °C·min–1 to obtain the final
PFCMs.
2.3 Material characterization
The morphology and microstructure of PFCMs and
their precursor microspheres were characterized by a
field emission scanning electron microscope (FE-SEM,
HITCH S4800) and a high-resolution transmission
electron microscope (HRTEM, FEI TECNAIG2 F30).
The scanning transmission electron microscope (STEM)
and corresponding energy-dispersive X-ray spectros-
copy (EDX) were performed to investigate the elemental
composition and distribution in the PFCMs. The
phase and crystallographic structure of samples were
identified by X-ray diffraction (XRD, Rigaku D/max
2500/PC using Cu Kα radiation with k = 1.5418 A°).
Thermogravimetric analysis (TGA) was carried out
on a simultaneous thermal analyzer (NETZSCH
STA449F3) with a heating rate of 10 °C·min–1 in an
air atmosphere to characterize the weight content of
Fe3O4 in PFCMs. The porous structure and specific
surface of PFCMs were measured using the Brunauer–
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Emmett–Teller (BET) method based on absorption–
desorption of nitrogen tested on Micrometrics ASAP
2020 surface area and porosity analyzer.
2.4 Electrochemical characterization
Electrochemical performances of PFCMs were tested
with CR2032 coin half-cells assembled in an argon-
filled glove box with moisture and oxygen levels less
than 0.1 and 0.5 ppm. The working electrodes were
prepared by mixing active materials (PFCMs), con-
ductive agent (Super P), and binder (sodium alginate)
with a weight ratio of 8:1:1 in water, followed by
coating the above slurry on a copper foil and drying
in a vacuum oven at 80 °C for 12 h. The copper foil
coated with active materials was punched into circular
discs with a diameter of 12 mm. Metallic lithium foils
were used as both counter and reference electrodes.
Celgard 2250 polypropylene films were used as
separators for cells. The used electrolyte contained
1 M LiPF6 dissolved in a mixture of diethyl carbonate
(DEC), ethylene carbonate (EC), and ethyl methyl
carbonate (EMC) (1:1:1 by volume) with 2 vol% vinylene
carbonate (VC). The cycle life and rate capability of the
cells were tested using Land 2001A battery testing
systems at a voltage range of 0.01–3.00 V (vs. Li+/Li),
and the specific capacity was calculated based on
the total mass loading of PFCMs on electrodes
(0.32 mg·cm–2). Cyclic voltammograms (CVs) were
measured on a VMP3 electrochemical workstation
at a scan rate of 0.1 mV·s–1 within a voltage range of
0.01 to 3 V. Electrochemical impedance spectroscopy
(EIS) was performed on a CHI660C electrochemical
workstation in the frequency range from 100 kHz to
0.01 Hz with a perturbation amplitude of 5 mV.
3 Results and discussion
3.1 Fabrication of PFCMs
Figure 1 shows the detailed synthesis procedure
and structural diagram for PFCMs. In the obtained
precursor solution, the carbon materials (CNTs and
KB particles) and Fe(acac)2 are well dispersed in the
mixed polymer (PVP and PS) solution after intense
stirring dissolution and ultrasonic dispersion. CNTs
and KB were used to construct a conductive framework,
Figure 1 Schematic illustration of the synthesis procedure for the PFCMs nanostructures: (a) homogeneous solution contained CNTs, KB, PVP, PS, and Fe(acac)2; (b) electrospray process; (c) PFCMs precursor microspheres; (d) PFCMs.
Fe(acac)2 was used to form Fe3O4 nanoparticles, PS
and KB were employed to form the microsphere
morphology, and PVP was used to act as surfactant
in order to facilitate the dispersion of CNTs and KB
particles in the mixed solution. During the electrospray
process, the precursor solution was atomized into
microdroplets under a high voltage (Fig. 1(c)). After
solvent evaporation, as-sprayed microdroplets were
solidified into precursor microspheres of PFCMs
(Fig. 1(c) and Fig. S1 in the Electronic Supplementary
Material (ESM)). All components (CNTs, KB, Fe(acac)2,
PVP and PS) are tightly integrated.
The desired PFCMs (Figs. 1(d) and 2) were obtained
after final carbonization treatment. In the typical
structure, CNTs and KB combine to form a scaffold-
like carbon skeleton with good mechanical strength.
The formed Fe3O4 nanoparticles were confined in the
carbon framework, while the skeleton and Fe3O4 were
further integrated with the interconnection effect of
amorphous carbon derived from organic polymers.
In order to further explore the formation mechanism
of precursor microspheres of PFCMs and the functions
of different components in the electrospray process,
reference experiments were carried out by controlling
solution compositions for electrostatic spraying. The
detailed information of the precursor solution com-
positions is shown in the caption of Fig. S2 in the
ESM. After electrospraying under optimal conditions,
the as-sprayed products were obtained and their SEM
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896 Nano Res. 2018, 11(2): 892–904
images are shown in Fig. S2 in the ESM. For the
products without PS component (Figs. S2(a) and S2(b)
in the ESM), it is clearly noted that the microsphere
structure does not successfully form during electrostatic
spraying, suggesting that PS plays a vital role as a
template for forming the spherical morphology. It is
well-known that the carbon yield of PS is very low
due to its severe thermal degradation during heat
treatment [18]. Therefore, KB particles and CNTs
act both as a template and a conductive skeleton
to maintain the microsphere structure after PS
pyrolyzation. PVP, on the other hand, is used as a
surfactant to disperse the nano-carbon components
(KB and CNT) and promote the formation of
microspheres with uniform morphology. As shown
in Figs. S2(c) and S2(d) in the ESM, the sphericity and
uniformity of the as-sprayed precursors are considerably
different when the experiment is done without PVP.
In this case, a fibrous structure is formed together
with the spheres. Figures S2(e) and S2(f) in the ESM
show images of the as-sprayed precursor spheres
without CNTs. There is a large variation in the size
distribution of the precursor without CNTs, and the
resulting PFCM microspheres are fragile due to the
mechanical stacking of KB particles. This therefore
shows that CNTs play an important role in maintaining
the structural stability of composite microspheres.
Another important effect of CNTs on PFCMs is
the improvement of the electronic conductivity and
electrochemical properties, which will be discussed
in further detail in the subsequent section. The results
from all the control experiments further illustrate
the rationality of our procedure for optimizing the
composite structure design.
3.2 Characteristics of PFCMs
SEM and TEM images, as shown in Fig. 2, were used
to analyze the morphology and microstructure of
PFCMs. Figure 2(a) notes that the PFCM diameters are
1–2 μm after annealing the precursor microspheres
(Fig. S1 in the ESM). Figure 2(b) shows that CNTs, KB,
and amorphous carbon intertwine to form a porous
hybrid microsphere. In order to observe the size and
distribution of Fe3O4 nanoparticles in the porous
carbon framework, the microstructures of PFCMs are
further investigated by TEM imaging (Figs. 2(c) and
2(d)) and the corresponding EDX elemental maps
(Figs. 2(f)–2(i)). As shown in Fig. 2(c), CNTs penetrate
through the entire bulk structure, acting as a conductive
and structural skeleton to truss all parts together. The
Fe3O4 nanoparticles, which have diameters of ~ 20 nm,
are uniformly dispersed in the carbon matrix. Based
on the HRTEM image (Fig. 2(d)), the lattice fringes
are defined to be 0.45 nm, fitting well with the (111)
planes of a cubic Fe3O4 structure, which can be further
confirmed by subsequent XRD analysis. Furthermore,
it is also noted from Fig. 2(d) that Fe3O4 nanoparticles
are coated with a thin amorphous carbon layer,
which not only improves electron transfer, but also
buffers the volume changes of Fe3O4 during lithiation/
delithiation. This benefits device performance by
enabling the formation of stable SEI films and
preventing the loss of electrical contact. Moreover, the
EDX elemental mapping images (Figs. 2(f)–2(i)) reveals
bright spots from iron are homogeneously dispersed
in the carbon background, therefore indicating a
uniform distribution of Fe3O4 nanoparticles in PFCMs.
We can also distinctly observe that numerous voids
are distributed in the matrix uniformly, which are
formed by decomposition of the polymers and
accumulation of the CNTs and KB particles.
Figure 2 (a) and (b) SEM, (c) TEM and (d) HRTEM images of PFCMs; (e) STEM image of PFCMs and (f)–(h) EDX elemental mappings of (f) iron, (g) oxygen and (h) carbon.
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897 Nano Res. 2018, 11(2): 892–904
The crystal structure of as-prepared PFCMs was
investigated by XRD. As shown in Fig. 3(a), all the
diffraction peaks of PFCMs agree well with the standard
XRD data of cubic-phase Fe3O4 (JCPDS card, file no.
89-4319) with the exception of a broad peak at around
26°, which corresponds to the (002) reflection of the
carbon matrix. The XRD results indicate that a pure
Fe3O4 component is formed in the carbon matrix by
decomposing Fe(acac)2 under the selective annealing
conditions.
Nitrogen adsorption/desorption isotherm measure-
ments were carried out to characterize the porous
structure of PFCMs (Fig. 3(b)). The BET specific surface
area and the pore volume of PFCMs are calculated
to be 190 m2·g–1 and 0.61 cm3·g–1, respectively. The
relative pore size distribution based on Barrett–Joyner–
Halenda (BJH) desorption is also shown in the inset
of Fig. 3(b). We note that the nanopores deliver a
hierarchical size distribution, mainly ranging from 2
to 10 nm and centering around 3.5 nm. The hierarchical
pore structure can not only shorten the lithium ion
pathway by facilitating electrolyte infiltration, but also
can accommodate the volume changes Fe3O4 undergoes
during cycling.
TGA was performed from 30 to 1,000 °C with a
heating rate of 10 °C·min–1 in an air atmosphere to
verify the actual Fe3O4 content of PFCMs. The weight
loss curve of PFCMs is shown in Fig. 3. The initial
weight-loss of PFCMs below 200 °C is small and
attributed to moisture volatilization. For temperature
increases from 200 to 800 °C, the Fe3O4 component was
entirely oxidized to Fe2O3, while the carbon matrix
was completely pyrolyzed to CO2/CO gases. This
results in a drastic weight loss for the PFCMs. According
to the TGA curve, the contents of Fe3O4 and carbon
can be calculated to be 36.7 wt.% and 63.3 wt.%, res-
pectively (further details are provided in the ESM).
3.3 Electrochemical properties of PFCMs
The electrochemical characteristics of the discharge–
charge, CV, and EIS curves for PFCM anodes are
shown in Fig. 4. The discharge–charge profiles of
PCFMs are shown in Fig. 4(a) for the voltage range of
0.01–3.0 V at different current densities (from 0.1 to
Figure 3 (a) XRD pattern, (b) nitrogen adsorption/desorption isotherm and pore size distribution, and (c) TGA curve of PFCMs.
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898 Nano Res. 2018, 11(2): 892–904
5 A·g–1). The various cycles at 0.1 A·g–1 are shown
in Fig. 4(b). All the discharge–charge profiles present
obvious voltage plateaus, which is essential for the
industrial application of electrode materials. This
therefore indicates that Fe3O4 active materials are well
supported in the PFCM hybrids. As shown in Fig. 4(b),
the PFCM anode exhibits an initial charge capacity
of 999 mAh·g–1 and an initial discharge capacity of
1,795 mAh·g–1, the latter of which is considerably higher
than the theoretical specific capacity of Fe3O4. The
ultrahigh initial discharge capacity may mainly result
from irreversible processes such as the reaction of
lithium with oxygen-containing functional groups, the
inevitable decomposition of the electrolyte to form an
SEI layer, and irreversible Li+ trapping in the matrix
[24, 39]. Thus, the irreversible capacity loss of the first
discharge–charge process could be attributed to the
formation of a SEI layer via electrolyte decomposition
and trapped Li+ inserted in the abundant inner holes
of PFCMs [40, 41]. These processes are ubiquitous for
the redox reactions of most anode materials in LIBs.
Figure 4(c) shows the CV profiles of the PFCM
electrode for the initial 10 cycles. These were recorded
in the potential window of 0.01–3.0 V at a scan rate of
0.1 mV·s–1. There are two obvious peaks in the initial
discharge process. The strong peak at 0.76 V reveals
the reduction reaction Fe3O4 + Li+ → Fe0 + Li2O, and the
small peak at 0.93 V may be ascribed to the irreversible
reactions of the electrolyte to form the SEI layer [42,
43]. For the charge process, two oxidation peaks occur
at around 1.58 and 1.85 V and can be attributed to the
oxidation of Fe0 to Fe2+ and Fe3+ during the delithiation
reactions [44–46]. During the subsequent cycles, the
reduction and oxidation peaks are relatively unaltered,
therefore indicating the presence of a stable SEI film
on the PFCM surface and an excellent reversibility
for the lithiation/delithiation process.
EIS measurements were conducted in the frequency
range of 0.1 Hz to 100 kHz to further reveal the
electrochemical characteristics of the PFCM electrode.
The impedance spectra of PFCMs in the initial state,
as well as the fully charged states (after the 3rd and
100th cycles at 1 A·g–1) are both shown in Fig. 4(d).
The depressed semicircle in the high-medium frequency
region indicates a charge transfer process, while the
inclined line in the low frequency region suggests the
diffusion of lithium ions into the electrode materials.
It is noted that the semicircle radius after three cycles
Figure 4 Discharge–charge profiles of PFCM anode at (a) different current densities and (b) a current density of 0.1 A·g–1 for different cycles; (c) CV curves of PFCM electrode at a scan rate of 0.1 mV·s–1; (d) impedance spectra of PFCM electrode before and after cycling.
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is slightly smaller than in the initial state due to the
activation reaction. The slight increase of resistance
after the 100th cycle may be related to the stable SEI
film formed on the outside surface of PFCMs during
cycling [26, 47].
To better understand the aforementioned phenomena,
we further investigate the electrochemical capacities
and rate performances of PFCM anodes in detail. The
cycle performance of PFCMs in a voltage range of
0.01–3.0 V vs. Li/Li+ at 0.1 A·g–1 is shown in Fig. 5(a).
After activating for a few cycles, the PFCMs have a
stable Coulombic efficiency (above 97%) and the
reversible capacity is maintained at ~ 1,000 mAh·g–1.
Notably, the specific capacity of PFCMs keeps increasing
through almost the entire discharge/charge processes,
rising to 1,317 mAh·g–1 at the 130th cycle. Such a high
and stable capacity at a low current density (0.1 A·g–1)
resulted from the optimized and stabilized micros-
tructures of PFCMs. CNTs, KB, and amorphous carbon
are intertwined together to construct an electrically
conductive skeleton, which greatly promotes the
electron/ion transportation. Additionally, coating the
confined Fe3O4 nanoparticles with carbon layers can
efficiently avoid particle agglomeration and achieve
fast reaction kinetics. Furthermore, abundant mesopores
can buffer the volume changes of Fe3O4 during
lithiation/delithiation processes. As a result, a stable
and thin SEI layer can be generated on the surface of
Fe3O4/carbon composite. Meanwhile, consumption of
electrolyte is effectively suppressed [44, 48–50].
It is worth noting that the capacity of the PFCM
electrode clearly increased under the current density
of 0.1 A·g–1. The gradual increase of capacity might
be attributed to the formation of stable organic
polymeric/gel-like layers resulting from kinetically
activated electrolyte degradation [35]. These organic
polymeric/gel-like layers can repeatly absorb and
release lithium ions, resulting in a slight increase
of capacity during cycling. This effect is especially
pronounced under low current densities [24, 26, 33,
38, 45, 51–53]. For instance, Lou and co-authors
fabricated carbon coated α-Fe2O3 hollow nanohorns
on CNT backbones. As an anode in LIBs, the capacity
of the α-Fe2O3/carbon composite shows a gradual
increase from 660 to 820 mAh·g–1 after 100 cycles at a
current density of 500 mA·g–1 [24]. Lu et al. prepared
carbon-coated Fe3O4 nanotubes, which delivered a
capacity increase up to 1,155 mAh·g–1 during the initial
90 cycles under 0.2 A·g–1 [34]. Furthermore, while using
in-situ TEM to study the structural evolution of lithium
insertion/extraction in electrochemically prelithiated
Fe2O3 nanoparticles confined in CNTs, Cheng’s group
also observed this phenomenon [26]. Most of these
researchers ascribed this phenomenon to the reversible
growth of a polymeric gel-like film resulting from
kinetically activated electrolyte degradation [54–56].
Due to the high electrochemical activity of the nano-
sized Fe3O4 particles protected by a carbon matrix,
the thin organic polymeric/gel-like layer does not
have a serious effect on the transmission of ions and
electrons [24, 38] This effect, however, can be altered
if the layers are significantly thicker. The capacity
increase in iron oxide and other metal oxide anodes
has already been investigated both experimentally
and theoretically [57–60].
As shown in Fig. 5(b), the PFCM electrodes also
possess excellent rate performances at different current
densities. The initial discharge capacity is as high as
1,796 mAh·g–1 with a Coulombic efficiency of 56.2%.
Specifically, the composite anode exhibits high rever-
sible specific capacities of 1,084, 883, 809, 738, 648,
and 545 mAh·g–1 at current densities of 0.1, 0.2, 0.3, 0.5,
1, and 2 A·g–1, respectively. Even after cycling at a
large current density (5 A·g–1), the reversible capacity
is still maintained at 410 mAh·g–1 after total 70 cycles
under different current densities. Clearly, the co-existence
of CNTs and KB leads to a closely combined structure
with a high conductivity, which contributes to the
excellent rate capability. When the current rate returns
to its initial value of 0.1 A·g–1, the charge capacity can
recover to 1,052 mAh·g–1 at the 71st cycle and increase
slowly with further cycling. After the subsequent
80 cycles at 0.1 A·g–1, the specific capacity further
improves and increases up to 1,234 mAh·g–1, which
was higher than both the theoretical capacity of Fe3O4
(926 mAh·g–1) and the capacity during the initial
ten cycles. This phenomenon of capacity increase is
frequent in the field of various nanostructured iron
oxide electrodes [26, 33, 61]. For example, Zhang et al.
prepared hierarchically porous Fe3O4/C nanocomposite
microspheres by a hydrothermal process. After testing
as anode materials in LIBs, these porous Fe3O4/C
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900 Nano Res. 2018, 11(2): 892–904
microspheres show a high reversible capacity of
1,231 mAh·g–1 at 0.5 A·g–1 after 100 cycles [2]. Fan et al.
coated uniform Fe3O4 sheaths of 5–7 nm onto CNT
scaffolds by magnetron sputtering to fabricate a Fe3O4/
CNT electrode, which delivered a high specific capacity
of 1,670 mAh·g−1 and exhibited significant capacity
increases during cycling [61]. Recently, Cheng’s group
tried to study the structural evolution of electro-
chemically prelithiated Fe2O3 nanoparticles confined
in CNTs during lithium insertion/extraction by in situ
TEM. They observed a high reversible capacity of
2,071 mAh·g−1 for the encapsulated Fe2O3 nanoparticles
in CNTs [9]. It was also demonstrated that the capacity
increase might relate to the following factors: extra
lithium storage from the two-phase capacitive behavior
of the Li2O/Fe interface confined in the pores of the
carbon matrix, which allows for the storage of Li+ on
the Li2O compound side and electrons on the Fe side
[62, 63]; and a reversible conversion reaction of LiOH to
form LiH and Li2O on the organic polymeric/gel-like
layers [2, 26, 64].
It is well-known that, compared to gravimetric
capacity, the volumetric capacity for porous materials
is a more appropriate index for determining the
practicality of using these materials for industrial
applications. Based on the BET and TGA results, as
well as the specific capacities shown in Figs. 5(a) and
5(b), the reversible volumetric capacities of PFCM
anodes are more than 1,000 mAh·cm–1 at 0.1 A·g–1,
which is higher than that of graphite anodes (about
760 mAh·cm–3). The detailed calculation process is
provided in the ESM.
Remarkably, the PFCM electrode exhibits long
lifespans of over 300 cycles at the high current densities
of 1 and 5 A·g–1 (Fig. 5(c)). Its initial charge capacities
are 766 and 616 mAh·g–1 at 1 and 5 A·g–1, respectively.
After 300 cycles, the discharge capacities still remained
at 746 and 525 mAh·g–1 under the current densities of
Figure 5 (a) Cycling performance and Coulombic efficiency of PFCMs anode at a current density of 0.1 A·g–1; (b) rate capability and Coulombic efficiency of PFCMs anode under different current densities; (c) cycling performances and Coulombic efficiency at high current densities of 1 and 5 A·g–1.
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901 Nano Res. 2018, 11(2): 892–904
1 and 5 A·g–1, respectively. These display the corres-
ponding capacity retentions of 97% and 85%. The
superior rate performance and cycling stability of
PFCMs are fairly competitive compared to other
Fe3O4-based anodes reported in recent literatures
(Table S1 in the ESM). The excellent electrochemical
performances of PFCMs should therefore be attributed
to: (1) the well-dispersed and encapsulated Fe3O4
nanoparticles; (2) the support, protection, and high
electronic conductivity provided by the porous carbon
matrix; and (3) the high mechanical strength, abundant
pore volume, and hierarchical pore distribution.
Cycling performances of the carbon matrix anode
without Fe3O4 and the PFCM anode with a lower
concentration of CNTs (adding 0.05 g CNTs into
precursor solution, while the masses of the other
components are unchanged) is shown in Fig. S3 in
the ESM. These studies were conducted in order to
investigate the roles of both the entire carbon matrix
and CNTs in the electrochemical performances of
PFCMs. Figure S3(a) in the ESM shows the cycle
performance of the porous carbon matrix anode obtained
by etching Fe3O4 in PFCMs with hydrochloric acid. It
can be seen that the carbon matrix exhibits capacities
of 419 and 370 mAh·g–1 at 0.1 and 1 A·g–1 after 200 cycles
without significant capacity decay from the 50th to the
200th cycle. This therefore indicates that the stable
carbon matrix plays a crucial role in the electrochemical
performance of our PFCM composite anode. As shown
in Fig. S3(b) in the ESM, the reversible specific capacities
of PFCMs with lower CNT content start to clearly
decrease after 70 cycles at current densities of both
0.1 and 1 A·g–1, which further confirms the skeleton
support and conductive effects of CNTs on the whole
composite material.
The morphology and inner microstructure of the
PFCM electrode after 100 cycles at 1 A·g–1 are shown
in Fig. S5 in the ESM. The spherical structure of the
cycled PFCMs (Figs. S5(a) and S5(c) in the ESM) is
maintained and indicates a good structural stability
of the PFCM anode materials during electrochemical
cycling. Furthermore, the STEM image (Fig. S5(d)
in the ESM) and EDX elemental mapping images
(Figs. S5(e)–S5(g) in the ESM) show that the Fe3O4
nanoparticles are still homogeneously dispersed in
the carbon matrix without obvious agglomeration. The
superior structural stability of the PFCM electrode
can be ascribed to the robust support and protection
of the porous carbon matrix composed of CNTs, KB,
and amorphous carbon, which can effectively prevent
the aggregation of Fe3O4 nanoparticles, accommodate
their volumetric change, and maintain their structural
integrity during cycling, thus, leading to the excellent
electrochemical performances of the PFCM anode of
LIBs.
4 Conclusion
PFCMs with superior electrical conductivity and
mechanical strength were successfully fabricated based
on a facile electrospray synthesis. The PFCMs show
excellent electrochemical performances as the anode
of LIBs. The composite features with homogeneously
dispersed Fe3O4 nanoparticles were confined in the
highly conductive carbon matrix composed of CNTs,
KB, and amorphous carbon. The porous structure
provides enough space to accommodate the volume
change of Fe3O4 nanoparticles. Also, the interlaced
networks of interconnecting pores and carbon
framework provide perfect channels and pathways
for electrolyte penetration and electron conduction.
As a result, the PFCM electrodes exhibit high specific
capacities of 1,317 mAh·g–1 at 0.1 A·g–1 after 130 cycles,
and 746 mAh·g–1 at 1 A·g–1 and 525 mAh·g–1 at 5 A·g–1
after 300 cycles. This work has provided a facile
method to fabricate metal oxide electrodes with a
well-designed structure for high-performance energy
storage.
Acknowledgements
This work was supported by the National Basic
Research Program of China (No. 2014CB932400), Joint
Fund of the National Natural Science Foundation
of China and the China Academy of Engineering
Physics (Nos. U1330123 and U1401243), the National
Natural Science Foundation of China (No. 51232005),
and Shenzhen Technical Plan Project (No. JCYJ
20150529164918735).
Electronic Supplementary Material: Supplementary
material (calculation methods of Fe3O4 content and
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902 Nano Res. 2018, 11(2): 892–904
volumetric capacity; SEM images of various as-sprayed
precursor microspheres before annealing; electro-
chemical performances of carbon matrix and PFCM
with less CNTs; SEM, TEM and EDX elemental
mapping images of the PFCM anode after cycling;
and a comparison of electrochemical performances of
Fe3O4-based anodes for LIBs) is available in the online
version of this article at https://doi.org/10.1007/
s12274-017-1700-6.
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