Towards Scalable Production of Sodium-Ion Batteries: Solvent-Free Layered-Oxide Cathodes and Aqueous-Processed Hard Carbon Anodes for Cost-Effective Full-Cell Manufacturing

Publikation: Beitrag in FachzeitschriftForschungsartikelBeigetragenBegutachtung

Beitragende

  • Johannes Kühn - , Professur für Anorganische Chemie (I) (AC1), Fraunhofer-Institut für Werkstoff- und Strahltechnik (Autor:in)
  • Florian Schmidt - , Fraunhofer-Institut für Werkstoff- und Strahltechnik (Autor:in)
  • Pascal Seete - , Professur für Anorganische Chemie (I) (AC1), Fraunhofer-Institut für Werkstoff- und Strahltechnik (Autor:in)
  • Tom Boenke - , Fraunhofer-Institut für Werkstoff- und Strahltechnik (Autor:in)
  • Florian S. Hoffmann - , Fraunhofer-Institut für Werkstoff- und Strahltechnik (Autor:in)
  • Arthur Dupuy - , Fraunhofer-Institut für Werkstoff- und Strahltechnik (Autor:in)
  • Benjamin Schumm - , Fraunhofer-Institut für Werkstoff- und Strahltechnik (Autor:in)
  • Thomas Abendroth - , Fraunhofer-Institut für Werkstoff- und Strahltechnik (Autor:in)
  • Holger Althues - , Fraunhofer-Institut für Werkstoff- und Strahltechnik (Autor:in)
  • Stefan Kaskel - , Professur für Anorganische Chemie (I) (AC1), Fraunhofer-Institut für Werkstoff- und Strahltechnik (Autor:in)

Abstract

Achieving commercial viability for more sustainable sodium-ion batteries (SIB) necessitates reducing the environmental impact of production, particularly originating from electrode drying and the use of toxic solvents like N-methyl-2-pyrrolidone (NMP). This study presents the dry-processing of commercial P2-type Na0.75Ni0.25Fe0.25Mn0.50O2 (NFM) via the DRYtraec® process, aiming to lower the binder content of 1 wt.% polytetrafluoroethylene (PTFE) and eliminating the need for electrode drying and NMP recovery. Assessments of electrode morphology and active material crystallinity were conducted to gauge the effects of mechanical stress during processing. The resulting cathodes, loaded at a commercially relevant 2.3–2.7 mAh cm−2 loading, were successfully paired with aqueous-processed hard carbon (HC) anodes, demonstrating stable performance in full-cells. Comparative analysis with entirely wet-processed electrodes revealed comparable capacity accessibility and comparable long-term stability. This showed the competitiveness of dry-processed cathodes. Finally, the integration of NMP-free, dry-processed cathodes and aqueous-processed anodes was scaled to the commercially relevant prototype pouch-cell. The cell demonstrates stable cycling for 400 cycles with an energy density of 102 Wh kg−1 as well as reduced processing costs and environmental footprint.

Details

OriginalspracheEnglisch
Aufsatznummere202400572
FachzeitschriftBatteries and Supercaps
Jahrgang8
Ausgabenummer5
Frühes Online-Datum25 Jan. 2025
PublikationsstatusVeröffentlicht - Mai 2025
Peer-Review-StatusJa

Schlagworte

Schlagwörter

  • batteries, dry-coating, full-cell, NFM, pouch-cell, sodium-ion, solvent-free