Publication date: 15th December 2025
The fabrication of electrodes through dry-processing represents the oportunity to develop a sustainable, low-cost next generation sodium ion batteries, enabling wide adoption of this novel technology. However, dry processing presents several challenges, particularly concerning the integration of binder materials and porosity for efficient electrolyte impregnation. While polytetrafluoroethylene (PTFE), a fluorine-rich fibrillating polymer, is traditionally used in dry-processed electrodes, is unsuitable for anodic lithium-ion materials due to its decomposition at low potentials, compromising electrode stability and capacity retention. [1] Additionally, fluorine-containing polymers are well-recognized for their health hazards and challenging recyclability, highlighting the need for safer and more sustainable options. [2]
In this study, both PTFE and various fluorine-free polymers were tested to improve the mechanical and electrochemical performance of carbonaceous and layered oxide electrodes. Changes in materials’ particle size and the inclusion of foams were explored to optimize electrode structure and porosity. However, the primary challenge was insufficient porosity, which limited electrolyte penetration and overall performance. These results highlight the need for novel polymer materials and processing strategies to achieve the necessary porosity for improved performance and sustainability in dry-manufactured electrodes.
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