Enable superior performance of ultra-high loading electrodes through the cost-efficient solvent-free electrode manufacturing technology

This research explores an innovative solvent-free method for fabricating ultra-high loading NMC811 and graphite electrodes (∼6mAh∙cm−2), showcasing remarkable electrochemical performance enhancements compared to the electrodes prepared by conventional slurry-casting method. The optimized microstructure with dry-printed (DP) electrodes enhanced electrolyte penetration and minimized lithium-ion diffusion tortuosity resulting in improved rate performance at high current rates. Additionally, this innovative electrode manufacturing approach enables more uniform CEI and SEI formation and growth, which effectively doubles the cycle life of single layer pouch cells with DP electrodes. Beyond the performance enhancements, this method also offers a notable 29.2% overall cost advantages, potentially revolutionizing future battery manufacturing. The findings presented in this work underscore the potential of solvent-free manufacturing technology as a high loading capable and cost-efficient path for advanced battery production.