New dry battery design boosts conductivity, reduces side reactions

Researchers at the University of Chicago have developed a novel dry electrode design for lithium-ion batteries that promises to make them cheaper, cleaner, and more powerful. Unlike conventional slurry-based manufacturing, which uses toxic solvents and struggles with thicker electrodes, the dry processing method eliminates solvents entirely, reducing cost and environmental impact while simplifying production. Importantly, the team discovered that dry-processed electrodes exhibit stronger conductivity, can be made thicker, and demonstrate better cycling stability at high voltages compared to traditional electrodes, marking a significant materials breakthrough beyond just manufacturing improvements. A key finding is the unexpected synergistic interaction between the carbon conductive additive and the polymer binder in the dry process. Traditionally viewed as independent components, the binder in the dry electrodes partially coats the reactive carbon surfaces, reducing their reactivity and suppressing side reactions that typically occur at high voltages. This coating effect enhances the battery’s structural and chemical stability, enabling more robust performance and improved high-voltage cycling with minimal degradation. The researchers believe this advancement could accelerate the