Dry Process for Fabricating Low Cost and High Performance Electrode for Energy Storage Devices
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MRS Advances © 2019 Materials Research Society DOI: 10.1557/adv.2019.29
Dry Process for Fabricating Low Cost and High Performance Electrode for Energy Storage Devices Qiang Wu1, Jim P. Zheng1, Mary Hendrickson2, and Edward J. Plichta2 1
Department of Electrical and Computer Engineering, Florida A&M University and Florida State University, Tallahassee, FL 32310, USA
2
Army Power Division, RDER-CCA, 5100 Magazine Road, Aberdeen Proving Ground, MD 21005, USA
Abstract
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 freestanding, 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.
BACKGROUND AND UNDERSTANDING OF THE PROBLEM The increasing demands of modern society for clean energy, electric vehicles, and portable consumer electronic devices necessitate the development of high-performance and low cost energy storage devices. Electric double-layer capacitor (EDLC), lithium-ion batteries (LIBs) and lithium ion capacitors (LICs) are considered as promising candidates due to their excellent electrochemical performances. [1-3]
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LIBs have been extensively investigated for decades as power sources for consumer electronics, electrical vehicles (EVs) and stationary (grid) energy storage. Modern Li-ion cells can have an energy density of up to 300 Wh/kg, compared to only 100 Wh/kg in the late 1990s.[4] However; the energy density of current LIBs does not satisfy the market requirement, and further increase in energy density and reduction in cost need to be consistently pursued to realize electric vehicles powered by LIBs. Many approaches have been used to increase the energy density and reduce the cost of LIBs, such as developing new high capacity active materials and optimizing electrode composition, cell processing, and manufacture procedure. Th
