Controlled Electrochemical Etching of Nanoporous Si Anodes and Its Discharge Behavior in Alkaline Si–Air Batteries

We report the fabrication of nanoporous silicon (nPSi) electrodes via electrochemical etching to form a porous Si layer with controllable thickness and pore size. Varying the etching time and ethanolic HF concentration results in different surface morphologies, with various degrees of electrolyte access depending on the pore characteristics. Optimizing the etching condition leads to well-developed nPSi electrodes, which have thick porous layers and smaller pore diameter and exhibit improved discharge behavior as anodes in alkaline Si-air cells in contrast to flat Si anode. Although electrochemical etching is effective in improving the interfacial characteristics of Si in terms of high surface area, we observed that mild anodization occurs and produces an oxide overlayer. We then show that this oxide layer in nPSi anodes can be effectively removed to produce an nPSi anode with good discharge behavior in an actual alkaline Si-air cell. In the future, the combination of high surface area nPSi anodes with nonaqueous electrolytes (e.g., room-temperature ionic liquid electrolyte) to minimize the strong passivation behavior and self-discharge in Si could lead to Si-air cells with a stable voltage profile and high anode utilization.