Abstract Scope |
The global shift toward electric vehicles and energy storage, driven by carbon neutrality goals and regulations, has increased demand for sustainable, high-energy-density lithium-ion batteries (LIBs). Accordingly, innovations in electrode material design, interface engineering, and electrode microstructure have improved energy/power density, safety, and cost, yet further progress is needed—particularly in scalable, sustainable manufacturing.
This lecture highlights recent efforts to increase energy density via thick electrode fabrication. While electrode thickening is essential, conventional slurry-based wet process faces limitations such as binder migration, compromising electrode microstructure and electrochemical performance. To address these issues, the roll-to-roll dry coating process has emerged as a scalable, solvent-free process that enables thick electrodes with improved microstructural homogeneity and mechanical strength. A critical component of this process is ceramic particle engineering, which facilitates the distribution of electrode components and enhances structural integrity. In our work, we fabricated dry electrodes with homogeneous microstructure by implementing three main strategies: 1) enhanced PTFE binder fibrillization, 2) improved pore and conductive network structures, and 3) maintenance of cathode particulate integrity.
The lecture concludes with perspectives on extending dry coating process beyond LIBs to systems like lithium–sulfur and all-solid-state batteries, discussing key challenges of materials and process innovation. |