Suppressing Corrosion of Aluminum Foils via Highly Conductive Graphene-like Carbon Coating in High-Performance Lithium-Based Batteries

Aluminum foil is the predominant cathodic current collector in lithium-based batteries due to the high electronic conductivity, stable chemical/electrochemical properties, low density, and low cost. However, with the development of next-generation lithium batteries, Al current collectors face new challenges, such as the requirement of increased chemical stability at high voltage, long-cycle-life batteries with different electrolyte systems, as well as improved electronic conductivity and adhesion for new electrode materials. In this study, we demonstrate a novel graphene-like carbon (GLC) coating on the Al foil in lithium-based batteries. Various physical and electrochemical characterizations are conducted to reveal the electronic conductivity and electrochemical stability of the GLC-Al foil in both carbonate- and ether-based electrolytes. Full-cell tests, including Li–S batteries and high-voltage Li-ion batteries, are performed to demonstrate the significantly improved cycling and rate performance of batteries with the use of the GLC-Al foil as current collectors. The cell using the GLC-Al foil can greatly reduce the potential polarization in Li–S batteries and can obtain a reversible capacity of 750 mAh g –1 over 100 cycles at 0.5C. Even with high-sulfur-loading cathodes, the Li–S battery at 1C still maintains over 500 mAh g –1 after 100 cycles. In high-voltage Li-ion batteries, the GLC-Al foil significantly improves the high-rate performance, showing an increased retained capacity by over 100 mAh g –1 after 450 cycles at 1C compared to the bare foil. It is believed that the developed GLC-Al foil brings new opportunities to enhance the battery life of lithium-based batteries.