Microstructure Control of Polymer Films via Air-Assisted Electrospray for Binderless Electrodes

With the growing number of applications for thin polymer films (e.g., corrosion-resistant coatings, photovoltaics, and optoelectronics), there is an urgent need to develop or advance cost-effective, versatile, and high-throughput manufacturing processes to produce thin polymer films and coatings with controllable properties (e.g., morphology, composition). In this work, we present a simple, cost-effective, and scalable approach: the air-assisted electrospray method for thin film coating. We systematically investigate its capabilities for producing coatings with a wide range of surface morphologies, its compatibility with three-dimensional substrates, and the fundamental understanding of the process. Through systematic control of concentration, needle configuration, and polymer selection, we demonstrate the ability to produce coating morphologies with diverse structural characteristics and excellent reproducibility. Notably, the introduction of air assistance through a coaxial needle greatly enlarges the range of achievable morphologies, particularly at lower concentrations. We also found that the position of the airflow relative to the solution is critical for determining the polymer film properties. Furthermore, we demonstrate its broad application potential in the fabrication of binderless electrodes for sodium-ion batteries.