Optimising dry electrode processing formulation with improved rate capability and volumetric capacity for batteries
File(s)
Published version
Author(s)
Type
Journal Article
Abstract
Dry electrode processing to eliminate conventionally used toxic, combustible organic solvent n-methyl-2-pyrrolidone (NMP) or any other solvent has gained interest due to its advantages of sustainability, cost reduction, and increasing electrode coating speed. However, there remains a need for understanding the dry electrode processing for relatively thick electrodes (≥70 µm), high mass loading (≥20 mg cm-2), and high active material proportion (≥94 wt%). Herein we study one of the key factors of materials composition for LiNi0.8Mn0.1Co0.1O2 (NMC811) cathodes and scaling up the dry powder rheology from the lab to the pilot scale. We compare the morphology and electrochemical performance of the electrodes made by conventional slurry coating and by dry processing. The optimised dry-processed cathode (NMC811:C65: PTFE = 94:3:3) exhibited the most homogeneous microstructure, lower porosity, and the lowest impedance among the other formulations. The optimised dry-processed electrode exhibited higher volumetric capacity at 0.05 – 3 C, e.g. 640 and 521 mAh cm-3 at 0.05 and 1 C respectively, compared with the wet-processed electrode. The results demonstrate that balancing conductive additive and PTFE binder content to form a uniform carbon-binder network reduces polarisation and enables improved high-rate performance in dry-processed NMC811 cathodes.
Date Issued
2026-06-01
Date Acceptance
2026-04-10
Citation
Journal of Alloys and Compounds Communications, 2026, 10
ISSN
2950-2845
Publisher
Elsevier BV
Journal / Book Title
Journal of Alloys and Compounds Communications
Volume
10
Copyright Statement
© 2026 The Author(s). Published by Elsevier B.V. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).
License URL
Identifier
10.1016/j.jacomc.2026.100184
Publication Status
Published
Article Number
100184
Date Publish Online
2026-04-12