Development of a feasible and scalable manufacturing method for PTFE-based solvent-free lithium-ion battery electrodes.

• Introduces fabrication-scale solvent-free dry electrode process with PTFE binder. • Defines unit process, equipment, intermediate products, and characterization methods. • Interprets the relationship between intermediate products and cell performance. Conventional wet-electrode manufacturing encounters challenges in producing thicker electrodes due to issues related to solvent evaporation. This study introduces a novel method for fabricating solvent-free dry electrodes using polytetrafluoroethylene (PTFE) as a binder, representing a significant advancement in electrode manufacturing processes. By eliminating the use of solvents, this method not only addresses these challenges but also offers a scalable and practical solution for mass production. The process is meticulously structured into sequential unit operations, each specifically tailored for a distinct function, utilizing the distinctive fibrillation properties of PTFE. Intermediate product specifications for each phase are clearly defined, accompanied by a comprehensive analysis of both physical and electrochemical performances. This analysis highlights the influence of varying PTFE contents and properties on the microstructure of the dry electrode. Notably, the study achieves a significant breakthrough with an electrode formulation of NCM811/PTFE/carbon black (CB)/carbon nanotube (CNT) = 96/2.0/1.8/0.2, which demonstrates exceptional discharge rate capability of 80 % at a 0.5 C-rate (5 mA/cm2) under the demanding parameters of 10 mAh/cm2 and 3.8 g/cc. This approach not only enhances the microstructural properties of dry electrodes but also paves the way for environmentally friendly and efficient electrode manufacturing for future energy storage applications. [ABSTRACT FROM AUTHOR]