Dual-layer electrode design powers next-generation silicon-based batteries, enabling faster charging and extended range for EVs

New research led by Queen Mary University of London has demonstrated that a dual-layer electrode design based on basic science using operando imaging can significantly improve the cycle stability and fast charging performance of car batteries, with great potential to reduce costs by 20-30%.

The research, published today in the journal Nature Nanotechnology, was led by Dr. Xuekun Lu, Senior Lecturer in Green Energy at Queen Mary University of London.

In this study, researchers introduce a science-based dual-layer design of silicon-based composite electrodes to address key challenges in silicon-based electrodes, a breakthrough that holds great promise for the next generation of high-performance batteries.

The evolution of automotive batteries has been driven by increasing demands for range and charging speed since EVs became popular 15 years ago. Although silicon electrodes have 10 times higher theoretical capacity and allow for faster charging, they undergo significant volume changes of up to 300% during charge-discharge cycles, which precludes large-scale deployment. This means that it deteriorates quickly and does not last long.

Utilizing multiscale, multimodal operando imaging techniques, this study reveals unprecedented insights into electrochemical-mechanical processes in graphite/silicon composite electrodes. Guided by these improved mechanistic understandings, new bilayer structures have been proposed that address key challenges in materials design and exhibit significantly higher capacity and lower degradation compared to conventional formulations.

“In this study, by integrating multimodal operand imaging techniques, we visualize for the first time the interaction between microstructural design and electrochemical-mechanical performance across length scales from single particles to complete electrodes,” said Dr. Xuekun Lu, who led the study.

“This research opens new avenues to innovate 3D composite electrode architectures and push the limits of energy density, cycle life, and charging speed for automotive batteries, thereby accelerating large-scale EV deployment.”

Professor David Greenwood, CEO of the WMG High Value Manufacturing Catapult Center, commented: “High silicon anodes are an important technology pathway for high energy density batteries in applications such as automotive. This research will provide a deeper understanding of how their microstructure affects battery performance and degradation, providing the basis for better battery designs in the future.”