Monolithic Layered Silicon Composed of a Crystalline–Amorphous Network for Sustainable Lithium-Ion Battery Anodes

While nanostructural engineering holds promise for improving the stability of high-capacity silicon (Si) anodes in lithium-ion batteries (LIBs), challenges like complex synthesis and the high cost of nano-Si impede its commercial application. In this study, we present a local reduction technique to synthesize micron-scale monolithic layered Si (10–20 μm) with a high tap density of 0.9–1.0 g cm–3 from cost-effective montmorillonite, a natural layered silicate mineral. The created mesoporous structure within each layer, combined with the void spaces between interlayers, effectively mitigates both lateral and vertical expansion throughout repeated lithiation/delithiation cycles. Furthermore, the remaining SiO2 network fortifies the layered structure, preventing it from collapsing during cycling. Half-cell tests reveal a capacity retention of 92% with a reversible capacity of 1130 mAh g–1 over 500 cycles. Moreover, the pouch cell integrated with this Si anode (with a mass loading of 3.0 mg cm–2) and a commercial NCM811 cathode delivers a high energy density of 655 Wh kg–1 (based on the total mass of the cathode and anode) and maintains 82% capacity after 200 cycles. This work demonstrates a cost-efficient and scalable strategy to manufacture high-performance micron Si anodes for the ever-growing demand for high-energy LIBs.