Roll-to-roll prelithiation of Sn foil anode suppresses gassing and enables stable full-cell cycling of lithium ion batteries

Tin foil should have outstanding volumetric capacity as a Li-ion battery anode; however, it suffers from an unacceptable initial coulombic efficiency (ICE) of 10-20%, which is much poorer than that of Si or SnO 2 nanoparticles. Herein, we demonstrate that bare Sn catalyzes liquid electrolyte decomposition at intermediate voltages to generate gas bubbles and Leidenfrost gas films, which hinder lithium-ion transport and erode the solid-electrolyte interphase (SEI) layer. By metallurgically pre-alloying Li to make Li x Sn foil, the lower initial anode potential simultaneously suppresses gassing and promotes the formation of an adherent passivating SEI. We developed a universally applicable roll-to-roll mechanical prelithiation method and successfully prelithiated Sn foil, Al foil and Si/C anodes. The as-prepared Li x Sn foil exhibited an increased ICE from 20% to 94% and achieved 200 stable cycles in LiFePO 4 //Li x Sn full cells at ∼2.65 mA h cm −2 . Surprisingly, the Li x Sn foil also exhibited excellent air-stability, and its cycling performance sustained slight loss after 12 h exposure to moist air. In addition to LiFePO 4 , the Li x Sn foil cycled well against a lithium nickel cobalt manganese oxide (NMC) cathode (4.3 V and ∼4-5 mA h cm −2 ). The volumetric capacity of the Li x Sn alloy in the LFP//Li x Sn pouch cell was up to ∼650 mA h cm −3 , which is significantly better than that of the graphite anode on a copper collector, with a rate capability as high as 3C. Li x Sn foil anode prepared by mechanical prelithiation suppresses gassing and achieves stable full-cell cycling in lithium ion batteries.