Dry‐Processed Graphite Electrodes Enabling Ultra‐High Areal Capacity and Stable Fast‐Charging Performance

ABSTRACT Dry electrodes with polytetrafluoroethylene (PTFE) binders are promising candidates for sustainable lithium‐ion batteries owing to their low cost, environmental sustainability, and compatibility with high‐mass–loading designs; however, the application of PTFE in anodes is hindered by its irreversible reduction at low potentials and degradation mechanisms, which remain under investigation. This study elucidates the influence of the molecular weight of PTFE on the electro‐chemo‐mechanical stability of dry‐processed graphite anodes. Dry electrodes with a low content (0.5 wt.%) of high‐molecular‐weight PTFE show ultra‐high areal capacities of ~11, 22, and 33 mAh cm ⁻² . Under lean electrolyte conditions, pouch cells incorporating the optimized high‐molecular‐weight PTFE electrode attain a high volumetric energy density (> 840 Wh L ⁻¹ at 0.1 C) and a capacity retention of 76% over 300 cycles—significantly outperforming conventional wet‐processed electrodes (> 790 Wh L ⁻¹ at 0.1 C, capacity retention ≈56%). This study provides fundamental insights into the degradation of PTFE and presents a viable pathway toward scalable, high energy density, and environmentally sustainable battery manufacturing.