Solvent-free lithium iron phosphate cathode fabrication with fibrillation of polytetrafluoroethylene

Fabricating electrode for lithium-ion batteries (LiBs) with solvent-free (SF) procedure can save energy and improve electrochemical performance simultaneously. Polymer fibrillation is one of the most promising SF procedures due to its feasibility for upscale production. The hardness of lithium iron phosphate (LFP) impedes its SF fabrication with polytetrafluoroethylene (PTFE) fibrillation. In this study, we successfully expanded PTFE fibrillation for SF LFP electrode fabrication with the help of carbon nanotubes (CNTs). CNTs increase the conductivity of electrode, and act as matrix for LFP particles to ensure relative displacement to further fibrillate PTFE to form self-supporting electrode film when the dry mixture was hot rolled. The SF LFP/hard carbon full cells were fabricated and demonstrated comparable electrochemical performance to slurry casting (SC) fabricated LFP electrode. The initial coulombic efficiency (ICE) of full cell increased to more than 95% after prelithiation.