Ultrahigh loading dry-process for solvent-free lithium-ion battery electrode fabrication

Scalable dry electrode process is essential for the sustainable manufacturing of the lithium based batteries. Here, the authors propose a dry press-coating technique to fabricate a robust and flexible high loading electrode for lithium pouch cells. The current lithium-ion battery (LIB) electrode fabrication process relies heavily on the wet coating process, which uses the environmentally harmful and toxic N-methyl-2-pyrrolidone (NMP) solvent. In addition to being unsustainable, the use of this expensive organic solvent substantially increases the cost of battery production, as it needs to be dried and recycled throughout the manufacturing process. Herein, we report an industrially viable and sustainable dry press-coating process that uses the combination of multiwalled carbon nanotubes (MWNTs) and polyvinylidene fluoride (PVDF) as a dry powder composite and etched Al foil as a current collector. Notably, the mechanical strength and performance of the fabricated LiNi0.7Co0.1Mn0.2O2 (NCM712) dry press-coated electrodes (DPCEs) far exceed those of conventional slurry-coated electrodes (SCEs) and give rise to high loading (100 mg cm(-2), 17.6 mAh cm(-2)) with impressive specific energy and volumetric energy density of 360 Wh kg(-1) and 701 Wh L-1, respectively.