Electrostatic Dual-Layer Solvent-Free Cathodes for High-Performance Lithium-Ion Batteries

Haojin Guo, Chengrui Zhang, Yujie Ma, Ning Liu () and Zhifeng Wang ()
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Haojin Guo: School of Materials Science and Engineering, Hebei University of Technology, Tianjin 300130, China
Chengrui Zhang: School of Materials Science and Engineering, Hebei University of Technology, Tianjin 300130, China
Yujie Ma: School of Materials Science and Engineering, Hebei University of Technology, Tianjin 300130, China
Ning Liu: School of Materials Science and Engineering, Hebei University of Technology, Tianjin 300130, China
Zhifeng Wang: School of Materials Science and Engineering, Hebei University of Technology, Tianjin 300130, China

Energies, 2025, vol. 18, issue 12, 1-13

Abstract: Slurry-cast (SLC) electrode manufacturing faces problems such as thickness limitation and material stratification, which are caused by applying toxic organic solvents. Solvent-free electrode technology, as a sustainable alternative, could get rid of issues generated by solvents. In this study, dual-layer NCM811 solvent-free electrodes (DLEs) are fabricated via an electrostatic powder deposition method with an active material-rich upper layer to provide high energy output, while the more binder–conductor content base layer improves conductivity and contact with current collectors. The dual-layered structure overwhelms the single-layer electrode (SE) with stable cycling performance caused by more regulated pore structures. DLE maintains 74% capacity retention after 100 cycles at 0.3 C, while the SLC shows only 60% capacity retention. Additionally, DLE shows excellent rate performance at various rates, with 207.3 mAh g −1 , 193.9 mAh g −1 , 173.9 mAh g −1 , 157.3 mAh g −1 , and 120.4 mAh g −1 at 0.1 C, 0.2 C, 0.5 C, 1.0 C, and 2.0 C, respectively. The well-designed DLE cathodes exhibit superior discharge-specific capacities, rate performance, and improved cycling stability than traditional SLC cathodes. It enlightens the path toward new structure innovations of solvent-free electrodes.

Keywords: lithium-ion battery; solvent-free manufacturing; dual-layer; cathode (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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