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Dry Process for Fabricating Low Cost and High Performance Electrode for Energy Storage Devices

  • Qiang Wu (a1), Jim P. Zheng (a1), Mary Hendrickson (a2) and Edward J. Plichta (a2)


We report a roll-to-roll dry processing for making low cost and high performance electrodes for lithium-ion batteries (LIBs). Currently, the electrodes for LIBs are made with a slurry casting procedure (wet method). The dry electrode fabrication is a three-step process including: step 1 of uniformly mixing electrode materials powders comprising an active material, a carbonaceous conductor and the soft polymer binder; step 2 of forming a free-standing, continuous electrode film by pressing the mixed powders together through the gap between two rolls of a roll-mill; and step 3 of roll-to-roll laminating the electrode film onto a substrate such as a current collector. Compared with the conventional wet slurry electrode manufacturing method, the dry manufactural procedure and infrastructure are simpler, the production cost is lower, and the process eliminates volatile organic compound emission and is more environmentally friendly, and the ability of making thick (>120µm) electrodes with high tap density results in high energy density of final energy storage device. A prototype LIBs of LiNi0.6Mn0.2Co0.2O2 (NMC622)/graphite also has 230 Wh/ kg energy density.


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