Anode interface-stabilizing dry process employing a binary binder system for ultra-thick and durable battery electrode fabrication

Polytetrafluoroethylene (PTFE)-based dry process has gained attention in the battery industry owing to their sustainability, cost-effectiveness, and ability to fabricate high loading electrodes. However, the electrochemical instability of PTFE in anodic environments causes significant capacity loss, hindering the development of high-performance dry-processed anodes. In this study, a binary binder system of PTFE and polyvinylpyrrolidone (PVP) is proposed to prevent direct contact between graphite and PTFE, mitigating unwanted interphase evolution. This strategy improves the mechanical integrity of the electrode. It maintains the binding force between the active materials and PTFE binders. PVP also forms a robust inorganic-rich SEI, enhancing Li-ion kinetics and interfacial stability. Consequently, dry-processed graphite with PVP achieved ultra-high loading anodes (∼10 mAh cm⁻²) with excellent cycle stability over 200 cycles in full cells coupled with LiNi_0.8Co_0.1Mn_0.1O₂ cathodes. This paper presents a cost-effective, high-loading electrode fabrication process and an eco-friendly approach for large-scale electrification.