Superior Performance of Lithium-Ion Batteries with High-Loading Graphite Anode via Dry Processible Node-Shaped Connective Binder

Abstract

As the demand for high-performance energy storage solutions increases, lithium-ion batteries (LIBs) remain the leading technology in electric vehicles (EVs) and portable electronics. However, traditional wet-casting electrode (WCE) processes have inherent limitations, such as binder migration and environmental concerns associated with solvent use. In this study, a high-loading dry-casting electrode (DCE) approach is proposed to overcome these challenges by eliminating solvent use and improving electrode uniformity. The DCE, fabricated using polyvinylidene fluoride-co-hexafluoropropylene (PVdF-HFP) binder nanoparticles, improves binder distribution among the natural graphite particles, enhances lithium-ion transport, and mitigates interfacial reactions. Electrochemical analysis reveals that the DCE outperforms the WCE, particularly under high loading conditions (≈7 mAh cm⁻²). The pouch-type full-cell test exhibits a 67.8% capacity retention after 700 cycles, indicating stable cell cycling. Consequently, this study highlights the potential of DCE to improve capacity retention, enhance rate capability, and reduce electrode degradation for commercial applications.