3D macroporous electrode and high-performance in lithium-ion batteries using SnO2 coated on Cu foam

A three-dimensional porous architecture makes an attractive electrode structure, as it has an intrinsic structural integrity and an ability to buffer stress in lithium-ion batteries caused by the large volume changes in high-capacity anode materials during cycling. Here we report the first demonstration of a SnO2-coated macroporous Cu foam anode by employing a facile and scalable combination of directional freeze-casting and sol-gel coating processes. The three-dimensional interconnected anode is composed of aligned microscale channels separated by SnO2-coated Cu walls and much finer micrometer pores, adding to surface area and providing space for volume expansion of SnO2 coating layer. With this anode, we achieve a high reversible capacity of 750 mAh g(-1) at current rate of 0.5 C after 50 cycles and an excellent rate capability of 590 mAh g(-1) at 2 C, which is close to the best performance of Sn-based nanoscale material so far.