Silicon anodes have been of great interest due to their higher theoretical capacity (4200 mAh/g) compared to traditional graphite electrodes (~372 mAh/g). Although Si has a higher capacity, its full potential has not yet been realized due to pulverization of Si anode upon lithiation. Conventionally, Si anodes are made by casting a slurry consisting of Si powder, conductive carbon additives, and a binder on a Cu foil. In such anodes, pulverization of Si particles leads to film delamination from Cu foil ensuing in battery failure. To overcome this challenge, we developed a new sandwich-structured anode by encapsulating ~100 nm Si nanoparticles in between two porous carbon nanotube buckypapers. The buckypaper is a conductive porous structure, which can incorporate active material better than Cu foil facilitating increased mass loading. More importantly, this sandwich-structured anode provides improved electrical contact even under repeated pulverization of Si nanoparticles leading to higher cyclability. We were able to achieve capacities as high as ~700-1200 mAh/g with a stable performance for >100 cycles.
