Silicon/C composite is a promising anode material for high-energy Li-ion batteries. However, synthesizing high-performance Si-based materials at large scale and low cost remains a huge challenge. Here, we for the first time report the preparation of an interconnected three-dimensional (3D) porous Si-hybrid architecture by using a spray drying method. In this unique structure, the highly robust C-CNT-RGO cages not only can improve the conductivity of the electrode and buffer the volume expansion but also suppress the Si nanoparticles aggregation. As a result, the 3D Si@po-C/CNT/RGO electrode achieves long-life cycling stability at high rates (a reversible capacity of 854.9 mA h g(-1) at 2 A g(-1) after 500 cycles and capacity decay less than 0.013% per cycle) and good rate capability (1454.7, 1198.8, 949.2, 597.8, and 150 mA h g(-1) at current densities of 1, 2, 4, 10, and 20 A g(-1), respectively). Moreover, this novel electrode could deliver high reversible capacities and long-life stabilities even with high mass loading density (764.9 mA h g(-1) at 1.0 mg cm(-2) after 500 cycles and 472.2 mA h g(-1) at 1.5 mg cm(-2) after 400 cycles, respectively). This cheap and scalable strategy can be extended to fabricate other materials with large volume expansion (Sn, Ge, transition-metal oxides) and 3D porous carbon for other potential applications.
Keywords: Si/C; cross-linked cage; large-scale; long cycle life; spray-drying.