Large volume expansion and serious pulverization of silicon
are two major challenges for Si-based anode batteries. Herein, a high-mass-load
(3.0 g cm–3) silicon-doped amorphous carbon (Si/a-C)
nanocomposite with a hierarchical buffer structure is prepared by
one-step magnetron sputtering. The uniform mixing of silicon and carbon
is realized on the several-nanometer scale by cosputter deposition
of silicon and carbon. The boundary of the primary particles, made
up of nanocarbon and nanosilicon, and the boundary of the secondary
particles aggregated by the primary particles can provide accommodation
space for the volume expansion of silicon and effectively buffer the
volume expansion of silicon. Meanwhile, the continuous and uniformly
distributed amorphous carbon enhances the conductivity of the Si/a-C
nanocomposites. Typically, the 20% Si/a-C cell shows a superior initial
discharge capacity of 845.3 mAh g–1 and achieves
excellent cycle performance of up to 1000 cycles (609.4 mAh g–1) at the current density of 1 A g–1. Furthermore, the 20% Si/a-C cell exhibits a high capacity of 602.8
mAh g–1 with the stable discharge/charge rate performance
in several extreme conditions (−40–70 °C). In view
of the validity and mass productivity of the magnetron sputtering,
a potential route for the industrial preparation of the Si/a-C anode
nanocomposites is therefore highlighted by this study.