A Solvent-Free Approach to Lithium-Ion Battery Electrodes Using Melt-Processable Elastomeric Binders

Lithium-ion is currently the leading technology for electrochemical energy storage, especially in the transportation sector. The electrification of vehicles through the use of lithium-ion batteries (LiBs) is at the center of the world efforts to decrease atmospheric pollution by reducing CO2 emission. Due to the high efficiency of electrical motors, a net reduction in greenhouse gases is achieved upon electrification of vehicles even in areas where electricity is generated from fossil fuels. Yet, the rapidly growing production of LiB brings new concerns on the environmental cost of the technology. The analysis of a complete their life cycle, from mining precursors to recycling batteries at the end of their life, reveals that several steps of the cycle can be improved to further reduce the environmental footprint of lithium-ion batteries. It is in this context that our group got interested in developing alternative approached to electrode fabrication, a key aspect of LiB manufacturing. Currently, most of the electrode fabrication processes involves the use of organic solvents, typically N-methyl-2-pyrrolidone (or NMP), which is toxic and costly. As such, a considerable effort is spent during electrode fabrication to recuperate NMP vapors and prevent exposure to the workers and environment. Avoiding the use of any solvents during electrode fabrication would not only minimize the environmental impact but would also result into lower energy consumption. This contribution presents a study of a new solvent-free melt process technique to LiB electrode fabrication through the use of elastomeric binders. The impact of formulation on active material dispersion, microscopic morphology, electronic percolation and porosity will be discussed. With such parameters optimized, the electrochemical response of composite electrodes based on LiFePO4 and Li4Ti5O12 active materials were characterized both individually and as full cells. The battery performance will be compared with PVDF-based electrodes made with a conventional approach.