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Title: Scalable Dry Printing Manufacturing to Enable Long-Life and High Energy Lithium-Ion Batteries

Slurry casting method dominates the electrode manufacture of lithium-ion batteries. The entire procedure is similar to the newspaper printing that includes premixing of cast materials into solvents homogeneously, and continuously transferring and drying the slurry mixture onto the current collector. As a market approaching US $80 billion by 2024, the optimization of manufacture process is crucial and attractive. However, the organic solvent remains irreplaceable in the wet method for making slurries, even though it is capital-intensive and toxic. In this paper, an advanced powder printing technique is demonstrated that is completely solvent-free and dry. Through removing the solvent and related procedures, this method is anticipated to statistically save 20% of the cost at a remarkably shortened production cycle (from hours to minutes). The dry printed electrodes outperform commercial slurry cast ones in 650 cycles (80% capacity retention in 500 cycles), and thick electrodes are successfully fabricated to increase the energy density. Furthermore, microscopy techniques are utilized to characterize the difference of electrode microstructure between dry and wet methods, and distinguish dry printing's advantages on controlling the microstructure. Finally, this study proves a practical fabrication method for lithium-ion electrodes with lowered cost and favorable performance, and allows more advanced electrode designsmore » potentially.« less
 [1] ;  [2] ;  [1] ;  [1] ;  [3] ;  [3] ;  [4] ;  [4] ;  [2] ;  [1]
  1. Worcester Polytechnic Inst., MA (United States). Dept. of Mechanical Engineering
  2. Missouri Univ. of Science and Technology, Rolla, MO (United States). Dept. of Mechanical and Aerospace Engineering
  3. Rice Univ., Houston, TX (United States). Dept. of Materials Science and NanoEngineering
  4. Brookhaven National Lab. (BNL), Upton, NY (United States). National Synchrotron Light Source II
Publication Date:
Report Number(s):
Journal ID: ISSN 2365-709X
Grant/Contract Number:
SC0012704; SC0014435; AC02-06CH11357; CMMI-1462343; CMMI-1462321; IIP-1640647; CNS-1338099
Accepted Manuscript
Journal Name:
Advanced Materials Technologies
Additional Journal Information:
Journal Volume: 2; Journal Issue: 10; Journal ID: ISSN 2365-709X
Research Org:
Brookhaven National Lab. (BNL), Upton, NY (United States); Rice Univ., Houston, TX (United States); Worcester Polytechnic Inst., MA (United States); Missouri Univ. of Science and Technology, Rolla, MO (United States)
Sponsoring Org:
USDOE Office of Science (SC), Basic Energy Sciences (BES) (SC-22); National Science Foundation (NSF)
Country of Publication:
United States
25 ENERGY STORAGE; 42 ENGINEERING; electrode fabrication; lithium-ion batteries; long life; solvent-free; thick electrode
OSTI Identifier:
Alternate Identifier(s):
OSTI ID: 1375822