Boosting the potassium storage property of spongia-like copper phosphide anode via nano-in-micro construction

[Display omitted] •Mesoporous carbon microspheres encapsulated with CuP2 nanoparticles are prepared by a salt template-assisted spray-drying method.•The nano-in-micro structure can offer many reactive sites, promote electrolyte penetration, and maintain structural stability.•The salt template-assisted spray-drying method is suit for the industrial manufacture.•Composite CuP2 material shows the good electrochemical performances in potassium-ion batteries. Metal phosphides (MPs) show great promise as anode material in potassium-ion batteries (PIBs) owing to their cost-effectiveness and high theoretical capacity. Despite that, MPs anode usually manifests inferior poor cyclability as a result of dramatic volume fluctuation during discharge–charge cycling. Herein, a scalable salt template-assisted spray-drying method is developed to fabricate the porous carbon microspheres wrapped CuP2 nanoparticles (p-CuP2/C) with a nano-in-micro structure. The combination of the CuP2 nanoparticles, large meso-porous carbon microspheres can simultaneously offer plenty of reactive sites, promote electrolyte penetration, and maintain structural integrity. Additionally, the proposed synthesis strategy is suit for the industrial manufacture. As an anode for PIBs, the p-CuP2/C anode presents a high reversible capacity (494 mAh/g at 0.05 A/g), excellent cycling stability (a capacity degradation rate of 0.04 % per cycle during 2000 cycles at 2 A/g), and superior rate capability (244 mAh/g at 2 A/g). More impressively, pairing with a potassium Prussian blue cathode, the potassium-ion coin cell shows an excellent cycling lifespan with 87.1 % capacity retention after 200 cycles at a current density of 0.1 A/g, the assembled pouch cell also maintains stable cycling at 0.3 A/g over 80 cycles. This research could offer a facile approach to develop other advanced anodes with industrial practicability for alkali ion batteries.