Publication date: 15th December 2025
The rapid growth of electric vehicles and energy storage systems has accelerated the demand for high energy density lithium-ion batteries (LIBs) with low manufacturing cost. Recent advances in electrode material and processing/design have enabled energy density approaching 310 Wh kg⁻¹ while improving manufacturing cost-efficiency. Nevertheless, continued innovation is required to further improve both energy density and manufacturing cost-efficiency.
The development of thick electrodes via roll-to-roll dry coating has gained significant industrial interest as an environmentally benign and low-cost technology for achieving high-energy-density lithium-ion batteries (LIBs). However, its practical implementation remains challenging due to inhomogeneity of electrode microstructure and insufficient mechanical integrity, attributed to the non-uniform distribution of binders and conductive agents. In dry electrodes, the interfacial interactions between PTFE and carbonaceous conductive agents (London dispersion forces enhanced by π-electron polarizability) mediate the transmission of shear force to PTFE, thereby driving fibrillization and the formation of nano-/micro-scale fibril networks. This robust fibril scaffolding network enables the construction of a homogeneous electrode microstructure.
In this work, the surface crystallinity of carbon black (CB) was engineered via flash lamp annealing (FLA) treatment to enhance the π-electron cloud delocalization, thereby strengthening its interfacial interactions with PTFE. As a result, the developed dry cathodes with homogeneous microstructure exhibited superior mechanical integrity and electrochemical performance, even at low PTFE content (~1.0wt%), demonstrating the potential of PTFE-based dry coating as a scalable and sustainable technology for next generation high-energy-density LIBs.
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