Roll-to-roll solvent-free manufactured electrodes for fast-charging batteries

In response to the growing demand for lithium-ion batteries (LIBs), we demonstrate a solvent-free manufacturing technology that can avoid toxic organic solvents and form unique electrode structures to overcome the bottlenecks in low costs and fast charging. The lower tortuosity achieved by the open pores in the dry-printed (DP) electrode allows for a shorter Li+ diffusion pathway, which leads to better rate performance. The DP pouch cells exhibit higher capacity retention of 78% and 69% at 3C and 4C, respectively, compared with 67% and 52% for the slurry cast (SL) cells at the same rates. Moreover, the coating layer on the surface of active ma-terials prevents the excess side reaction between active materials and electrolytes, which prolongs the cycle life of the DP cells. This manufacturing process is a roll-to-roll system with immense poten-tial to be scaled up, providing a more efficient and economical way for battery manufacturing.

Automated summary

In response to the demand for LIBs, a solvent-free manufacturing technology is demonstrated to avoid toxic organic solvents and improve electrode structures. The dry-printed (DP) electrodes have lower tortuosity, allowing for better rate performance and higher capacity retention compared to slurry cast (SL) electrodes. The coating layer on active materials in DP cells prevents side reactions and prolongs cycle life. This roll-to-roll manufacturing process has immense potential for scalable and efficient battery production.