High Energy Li‐Ion Electrodes Prepared via a Solventless Melt Process

Abstract High areal density and high energy Li‐ion electrodes were prepared using a high throughput green, solventless and inexpensive melt process leading to electrodes of controlled porosity. Melt formulations were developed for NCA cathodes and graphite anodes. The formulations were based on commercially available and inexpensive elastomeric or thermoplastic binders, conventional conducting fillers and >90 wt% electrode active materials. A large range of loadings could be achieved, from 4 to 40 mg cm⁻² single side. Electrochemical performances in half cells (coin cells) are reported. High capacity and cyclability for high loadings of NCA cathodes and graphite anodes were demonstrated. Areal capacities over 5 mAh.cm⁻² in coin cells were obtained at a C/5 rate. Cycling at high rates, up to 5 C was demonstrated.