2, Mechanical Engineering, Missouri University of Science and Technology, Rolla, Missouri, United States
An advanced power-based spraying technology was developed by us to fabricate electrodes for the lithium-ion batteries to replace the conventional slurry cast method. The additive manufacturing technology is a low cost, highly efficient way to avoid toxic NMP solvent from electrode fabrication. The removal of solvents shortened the production time from days to seconds, analyzed to reduce 20% of production cost, and enabled a more precise control of electrode microstructure during manufacturing. With the continuous processing system, the technology has a good potential to be scaled up and commercialized. Beyond the current commercial materials, we can also demonstrate this technology with a wide range of compatibility on producing electrodes, including different types of cathodes (LCO, LMO, NCM), anodes (MCMB), advanced architecture designs (Ultra-low binder recipe (<1%), high-energy thick electrodes (>280um), hierarchical micro-structured). In addition, the flexible arrangement strategy of spraying guns promoted the development of hierarchical designs to be practically available to the lithium-ion market.