Long carbon fibers boost performance of dry processed Li-ion battery electrodes

Choi, Junbin; Polyzos, Georgios; Humphrey, Holly E.; Toomey, Michael; Kanbargi, Nihal; Naskar, Amit K.; Belharouak, Ilias; Sharma, Jaswinder

doi:10.1016/j.jpowsour.2025.236603

Long carbon fibers boost performance of dry processed Li-ion battery electrodes

Journal Article · Fri Mar 14 00:00:00 EDT 2025 · Journal of Power Sources

DOI:https://doi.org/10.1016/j.jpowsour.2025.236603· OSTI ID:2575332

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Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Dry processing (DP) is an advanced manufacturing technique for lithium-ion battery (LIB) electrodes. Unlike conventional wet-process-based manufacturing that involves dissolving polyvinylidene fluoride (PVDF) binder in n-methyl-2-pyrrolidone (NMP) solvent for slurry-casting, DP involves fibrillation of polymer binders. This method offers environmental and cost benefits by eliminating the need for expensive and environmentally hazardous organic solvents. However, DP-produced electrode films often lack mechanical stability due to the absence of a current collector substrate during electrode material layer fabrication. This reduced mechanical instability results in difficulty during fabricating of thin electrodes (≈5 mAh/cm²). To address this issue, long (>8 mm) carbon fiber (CF) has been incorporated to reinforce the mechanical strength of the electrode films. In conclusion, the study demonstrates that the inclusion of long carbon fiber boosts the mechanical, electrical, thermal, and electrochemical performance of DP electrodes.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2575332

Journal Information:: Journal of Power Sources, Journal Name: Journal of Power Sources Vol. 640; ISSN 0378-7753

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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