US study advances powerful EV batteries with dry-electrode method

Engineers at the University of Chicago have developed a novel dry-electrode manufacturing technique for lithium-ion batteries that eliminates the use of toxic liquid slurries traditionally employed in battery production. This solvent-free dry process creates a more robust electrode architecture, resulting in batteries that are more powerful, longer-lasting, and capable of cycling efficiently at high voltages. The method addresses economic, environmental, and societal concerns by reducing manufacturing complexity, energy consumption, and hazardous waste, while also enabling thicker electrodes with better conductivity. A key discovery underpinning the improved battery performance is a synergistic chemical interaction between carbon additives and binders in the dry process, which was previously unrecognized. This interaction forms a superior conductive network and reduces the reactivity of carbon at high voltages, minimizing side reactions that typically degrade battery life. The resulting electrodes are more durable and allow for denser energy storage without the fragility seen in wet-processed materials. This advancement could significantly lower production costs, enhance charging speed, and improve the affordability