Now that dendrite-suppressing Zn sponge anodes developed at the U.S. Naval Research Laboratory [1] offer a safer route to aqueous batteries that can power a wide range of end uses including electric vehicles, portable electronic devices, and backup energy storage, we need better cathodes. With high rate capability and deep theoretical utilization of the zinc (DOD ≥ 40%) now routine in alkaline electrolytes, storing and delivering more than one electron per metal-centered active material in the cathode is next. We focus on moving the Ni cathode past the 0.8–0.9 electrons per Ni characteristic of fabricating the cathode using β-Ni(OH)2 to tap the extra capacity inherent to α-Ni(OH)2 (theoretical: 1.67 electrons/Ni). Substituting Al3+ into α-Ni(OH)2 stabilizes the alpha phase from conversion to beta phase upon contact with and cycling in aqueous KOH and shifts positive the cell voltage for oxygen evolution (OER), the parasitic charging reaction that affects coulombic efficiency and limits cycle life [2]. We have now redesigned a classic powder composite Ni cathode (carbon black + Ni(OH)2 + binder) into an architected Ni electrode to improve charging efficacy. Using microwave-assisted deposition of Al-substituted α-Ni(OH)2 nanosheets onto a freestanding carbon nanofiber paper electrode wires the active material in 3D to the current-collecting carbon throughout the volume of the electrode. The architected Ni cathodes are tested in alkaline cells versus zinc sponge anodes and demonstrate that architected electron-wiring improves the capacity, rate, and cycle stability of Ni cathodes relative to conventional powder-composite electrodes. Varying the synthetic conditions achieves mass loadings that approach technologically relevant values. The enhanced electrochemical performance of architected Ni cathodes and architected Zn anodes provides a pathway to energy dense, safe, rechargeable Ni–Zn batteries.[1] Parker, J.F.; Chervin, C.N.; Pala, I.R.; Machler, M.; Burz, M.F.; Long, J.W.; Rolison, D.R. Rechargeable Nickel–3D Zinc Batteries: An Energy-Dense, Safer Alternative to Lithium-Ion. Science 2017, 356, 415–418 (10.1126/science.aak9991).[2] Kimmel, S.W.; Hopkins,B.J.; Chervin, C.N.; Skeele, N.L.; Ko, J.S.; DeBlock, R.H.; Long, J.W.; Parker, J.F.; Hudak, B.M.; Stroud, R.M.; Rolison, D.R.;Rhodes, C.P.Capacity and Phase Stability of Metal-Substituted α-Ni(OH)₂ Nanosheets in Aqueous Ni–Zn Batteries. Mater. Adv. 2021, 2, 3060–3074 (10.1039/D1MA00080B).
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