Researchers at Oak Ridge National Laboratory (ORNL) have developed a breakthrough approach to strengthen dry-processed lithium-ion battery electrodes, potentially lowering production costs and improving performance for electric vehicles and electronic devices.

Dry processing eliminates the need for wet organic solvents, reducing factory space requirements, energy consumption, waste disposal, and startup costs. However, conventional dry-processed films are prone to tearing. ORNL scientists addressed this challenge by incorporating long carbon fibers, which improved both the mechanical strength and flexibility of the films.

Testing coin cell batteries made from the enhanced material revealed faster charging and discharging rates, due to the fibers ability to transfer electrons over longer distances. The innovation builds on earlier work with nanoscale fibers, but according to ORNL scientist Jaswinder Sharma, this is the first use of long carbon fibers in dry-processed electrodes.

The added fibers make up only 1% of the electrode s weight, and chemical cost savings are expected to outweigh their expense. Sharma said the method could accelerate the adoption of dry processing in battery manufacturing, boosting U.S. competitiveness in the global market.

The project is supported by the Department of Energy s Advanced Materials and Manufacturing Technologies Office.

Source: www.ornl.gov