New thick electrodes with higher energy density can skyrocket EV range

Researchers at Penn State University have developed a novel battery electrode technology that significantly increases energy density, potentially enabling electric vehicles (EVs) to achieve much longer driving ranges. By creating thick electrodes that are both denser and mechanically stronger, the team overcame traditional limitations where increasing electrode thickness required high porosity, which reduces the amount of active material and overall energy storage. Their approach involves designing synthetic boundaries within the electrodes that act as reservoirs for charge, facilitating rapid charge transport even in electrodes that are five to ten times thicker and twice as dense as conventional ones. This innovative method, detailed in a paper published in Nature Communications, uses a geology-inspired transient liquid-assisted densification process to form multifunctional synthetic secondary boundaries. These boundaries not only enhance charge transport but also improve mechanical toughness and strain resistance, mitigating degradation during repeated charge cycles. The resulting batteries demonstrated energy densities exceeding 500 watt-hours per kilogram at the cell level, a substantial improvement over current commercial batteries. This advancement could significantly extend EV driving ranges by increasing