Beyond slurry cast: patterning of a monolithic active material sheet to form free-standing, solvent-free, and low-tortuosity battery electrodes
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Published version
Author(s)
Hair, Samuel W
Cooper, Samuel J
Shaffer, Milo SP
Type
Journal Article
Abstract
Commercial lithium-ion battery electrodes today are manufactured by slurry casting active material powder onto a metal current collector foil. This manufacturing process has become embedded over recent decades but limits commercial cell performance. This paper presents patterning of a monolithic active material sheet as an alternative to slurry casting. The concept is proven experimentally by laser drilling a pyrolytic graphite sheet to increase the gravimetric active material capacity from 10 mA h g−1 to 450 mA h g−1, when used as a negative lithium-intercalation electrode. Cell-level calculations show that, without changing the chemistry, a pyrolytic graphite sheet electrode with a hexagonal array of 5 μm diameter, 20 μm pitch channels could increase the gravimetric energy density of a LGM50 cell by 22% to 322 W h kg−1. By moving beyond slurry casting, patterned monolithic electrodes could enable batteries with lower cost, reduced energy intensity, and enhanced performance.
Date Issued
2024-08-21
Date Acceptance
2024-07-15
Citation
Cell Reports Physical Science, 2024, 5 (8)
ISSN
2666-3864
Publisher
Elsevier
Journal / Book Title
Cell Reports Physical Science
Volume
5
Issue
8
Copyright Statement
© 2024 The Author(s). Published by Elsevier Inc.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
Identifier
http://dx.doi.org/10.1016/j.xcrp.2024.102143
Publication Status
Published
Article Number
102143
Date Publish Online
2024-08-08