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Lookup NU author(s): Ruifeng Zhou, Professor Mohamed MamloukORCiD, Dr Chuan ChengORCiD
This work is licensed under a Creative Commons Attribution 4.0 International License (CC BY 4.0).
Solvent-free electrode manufacturing reduces cost and carbon emissions in Li-ion battery production via eliminating the electrode drying and toxic solvent recovery processes in conventional manufacturing. Herein, lithium iron phosphate-based cathodes are solvent-free manufactured via binder fibrillation. Effects of electrode thickness, porosity, and composition on cell performance are investigated for electrode optimization. By balancing the electrode thickness and porosity, the areal capacity exhibits a collective increase under different C-rates, such as 2.0–2.6 mAh cm−2 uplifting from 0.1 to 0.75 C. These results are different from increasing electrode thickness alone where the increasing tendency in areal capacity becomes flattened with C-rate, indicating the reduction of active material unitization in thick electrodes. Adhesive lamination of electrode sheets on current collectors is found to improve C-rate and cycling performance in comparison to non-laminated electrodes, and the improvement is more effective at higher C-rates. Four-probe electrode sheet resistance tests reveal that the resistivity of dry electrodes is independent of electrode thickness when the composition is fixed, which indicates the uniformity and reproducibility the dry electrodes. By increasing the carbon to binder ratios while keeping the active material fraction the same, the electrode resistivity is decreased by 30% which leads to the improvement of C-rate performance.
Author(s): Zhou R, Ong HL, Fu YQ, Mamlouk M, Cheng C
Publication type: Article
Publication status: Published
Journal: Energy Technology
Year: 2025
Issue: ePub ahead of Print
Online publication date: 18/07/2025
Acceptance date: 30/06/2025
Date deposited: 24/07/2025
ISSN (electronic): 2194-4296
Publisher: Wiley-VCH Verlag GmbH & Co. KGaA
URL: https://doi.org/10.1002/ente.202500649
DOI: 10.1002/ente.202500649
Data Access Statement: The data that support the findings of this study are available from the cor- responding author upon reasonable request.
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