Long carbon fibers boost performance of dry processed Li-ion battery electrodes

Junbin Choi; Georgios Polyzos; H. E. Humphrey; Michael Toomey; Nihal Kanbargi; Amit Naskar; Ilias Belharouak; Jaswinder Sharma

doi:10.1016/j.jpowsour.2025.236603

Long carbon fibers boost performance of dry processed Li-ion battery electrodes

Junbin Choi, Georgios Polyzos, H. E. Humphrey, Michael Toomey, Nihal Kanbargi, Amit Naskar, Ilias Belharouak, Jaswinder Sharma

Research output: Contribution to journal › Article › peer-review

Abstract

Dry processing (DP) is an advanced manufacturing technique for lithium-ion battery (LIB) electrodes. Unlike conventional wet-process-based manufacturing that involves dissolving polyvinylidene fluoride (PVDF) binder in n-methyl-2-pyrrolidone (NMP) solvent for slurry-casting, DP involves fibrillation of polymer binders. This method offers environmental and cost benefits by eliminating the need for expensive and environmentally hazardous organic solvents. However, DP-produced electrode films often lack mechanical stability due to the absence of a current collector substrate during electrode material layer fabrication. This reduced mechanical instability results in difficulty during fabricating of thin electrodes (≈5 mAh/cm²). To address this issue, long (>8 mm) carbon fiber (CF) has been incorporated to reinforce the mechanical strength of the electrode films. The study demonstrates that the inclusion of long carbon fiber boosts the mechanical, electrical, thermal, and electrochemical performance of DP electrodes.

Original language	English
Article number	236603
Journal	Journal of Power Sources
Volume	640
DOIs	https://doi.org/10.1016/j.jpowsour.2025.236603
State	Published - Jun 1 2025

Funding

This manuscript has been authored in part by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).This research at Oak Ridge National Laboratory, managed by UT Battelle, LLC for the US Department of Energy (DOE) under contract DE-AC05-00OR22725, was sponsored by the DOE Office of Energy Efficiency and Renewable Energy's Vehicle Technology Office (Grant# 1.1.5.511; Program Manager: Haiyan Croft) and Advanced Materials and Manufacturing Technologies Office (Grant # 2.1.0.245; Program Manager: Changwon Suh). This research at Oak Ridge National Laboratory, managed by UT Battelle, LLC for the US Department of Energy (DOE) under contract DE-AC05-00OR22725, was sponsored by the DOE Office of Energy Efficiency and Renewable Energy\u2019s Vehicle Technology Office (Grant# 1.1.5.511; Program Manager: Haiyan Croft) and Advanced Materials and Manufacturing Technologies Office (Grant # 2.1.0.245; Program Manager: Changwon Suh).

Keywords

Battery manufacturing
Carbon fibers
Conductivity
Dry processing
Lithium-ion batteries
Performance

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10.1016/j.jpowsour.2025.236603

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title = "Long carbon fibers boost performance of dry processed Li-ion battery electrodes",

abstract = "Dry processing (DP) is an advanced manufacturing technique for lithium-ion battery (LIB) electrodes. Unlike conventional wet-process-based manufacturing that involves dissolving polyvinylidene fluoride (PVDF) binder in n-methyl-2-pyrrolidone (NMP) solvent for slurry-casting, DP involves fibrillation of polymer binders. This method offers environmental and cost benefits by eliminating the need for expensive and environmentally hazardous organic solvents. However, DP-produced electrode films often lack mechanical stability due to the absence of a current collector substrate during electrode material layer fabrication. This reduced mechanical instability results in difficulty during fabricating of thin electrodes (≈5 mAh/cm2). To address this issue, long (>8 mm) carbon fiber (CF) has been incorporated to reinforce the mechanical strength of the electrode films. The study demonstrates that the inclusion of long carbon fiber boosts the mechanical, electrical, thermal, and electrochemical performance of DP electrodes.",

keywords = "Battery manufacturing, Carbon fibers, Conductivity, Dry processing, Lithium-ion batteries, Performance",

author = "Junbin Choi and Georgios Polyzos and Humphrey, {H. E.} and Michael Toomey and Nihal Kanbargi and Amit Naskar and Ilias Belharouak and Jaswinder Sharma",

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doi = "10.1016/j.jpowsour.2025.236603",

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AU - Choi, Junbin

AU - Polyzos, Georgios

AU - Humphrey, H. E.

AU - Toomey, Michael

AU - Kanbargi, Nihal

AU - Naskar, Amit

AU - Belharouak, Ilias

AU - Sharma, Jaswinder

PY - 2025/6/1

Y1 - 2025/6/1

N2 - Dry processing (DP) is an advanced manufacturing technique for lithium-ion battery (LIB) electrodes. Unlike conventional wet-process-based manufacturing that involves dissolving polyvinylidene fluoride (PVDF) binder in n-methyl-2-pyrrolidone (NMP) solvent for slurry-casting, DP involves fibrillation of polymer binders. This method offers environmental and cost benefits by eliminating the need for expensive and environmentally hazardous organic solvents. However, DP-produced electrode films often lack mechanical stability due to the absence of a current collector substrate during electrode material layer fabrication. This reduced mechanical instability results in difficulty during fabricating of thin electrodes (≈5 mAh/cm2). To address this issue, long (>8 mm) carbon fiber (CF) has been incorporated to reinforce the mechanical strength of the electrode films. The study demonstrates that the inclusion of long carbon fiber boosts the mechanical, electrical, thermal, and electrochemical performance of DP electrodes.

AB - Dry processing (DP) is an advanced manufacturing technique for lithium-ion battery (LIB) electrodes. Unlike conventional wet-process-based manufacturing that involves dissolving polyvinylidene fluoride (PVDF) binder in n-methyl-2-pyrrolidone (NMP) solvent for slurry-casting, DP involves fibrillation of polymer binders. This method offers environmental and cost benefits by eliminating the need for expensive and environmentally hazardous organic solvents. However, DP-produced electrode films often lack mechanical stability due to the absence of a current collector substrate during electrode material layer fabrication. This reduced mechanical instability results in difficulty during fabricating of thin electrodes (≈5 mAh/cm2). To address this issue, long (>8 mm) carbon fiber (CF) has been incorporated to reinforce the mechanical strength of the electrode films. The study demonstrates that the inclusion of long carbon fiber boosts the mechanical, electrical, thermal, and electrochemical performance of DP electrodes.

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Long carbon fibers boost performance of dry processed Li-ion battery electrodes

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