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Sulfur co-milling enables white phosphorus-free and high-loading red phosphorus/carbon anode for high performance sodium-ion batteries
Nano Research 2025, 18(12): 94907771
Published: 14 November 2025
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Ball milling is a prevalent technique for synthesizing phosphorus/carbon (P/C) anodes, conventionally deemed inherently safe due to the presumed avoidance of toxic white phosphorus (WP) formation. Challenging this widespread assumption, this study firstly reveals the overlooked generation of WP during the P/C ball milling process, highlighting a significant and unrecognized hazard. To counteract this critical issue, an effective sulfur (S8) co-ball milling strategy is introduced, which not only suppresses WP formation but also promotes phosphorus polysulfide (P4Sn) generation. Critically, P4Sn converts in situ to Na3PS4 solid electrolyte upon initial sodiation, establishing an integrated three-dimensional (3D) ionic network throughout the electrode matrix. This facilitates rapid Na+ transport, especially beneficial for high-mass-loading electrodes. Consequently, the S-P/C electrode with 3.0 mg·cm−2 demonstrates superior rate capability (424 mAh·g−1 at 5.0 A·g−1) and excellent cyclic stability (86.9% capacity retention after 1000 cycles at 5.0 A·g−1) in half-cells. Furthermore, sodium-ion full cells pairing this anode with a high-loading Na3V2(PO4)3 cathode (~ 12.0 mg·cm−2) demonstrate remarkable electrochemical performance.

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