Abstract The current lithium-ion battery (LIB) electrode fabrication process relies heavily on the wet coating process, which uses the environmentally harmful and toxic N-methyl-2-pyrrolidone (NMP) solvent. In addition to being unsustainable, the use of this expensive organic solvent substantially increases the cost of battery production, as it needs to be dried and recycled throughout the manufacturing process. Herein, we report an industrially viable and sustainable dry press-coating process that uses the combination of multiwalled carbon nanotubes (MWNTs) and polyvinylidene fluoride (PVDF) as a dry powder composite and etched Al foil as a current collector. Notably, the mechanical strength and performance of the fabricated LiNi 0.7 Co 0.1 Mn 0.2 O 2 (NCM712) dry press-coated electrodes (DPCEs) far exceed those of conventional slurry-coated electrodes (SCEs) and give rise to high loading (100 mg cm −2 , 17.6 mAh cm −2 ) with impressive specific energy and volumetric energy density of 360 Wh kg −1 and 701 Wh L −1 , respectively. 

/pdf/ultrahigh-loading-dry-process-for-solvent-free-lithium-ion-2gih7aa7.pdf

Ultrahigh loading dry-process for solvent-free lithium-ion battery electrode fabrication

With the depletion of global fossil fuels and the deterioration of environmental pollution, developing a new type of energy storage device has become increasingly important. In this context, the lithium-ion batteries (LIBs) have emerged as an important solution to the energy crisis due to its low self-discharge rate, high energy density. However, its poor electrochemical performance, low power density, and limited recycling ability have hindered its development and application. To address these issues, researchers have proposed the use of low temperature plasma (LTP) technology as an efficient and environmentally friendly method for lithium-ion batterys' material modification. This paper reviews the background, basic principles, and current research progress of LTP in the field of lithium-ion power battery materials, with a focus on the main research results of LTP in the material design and modification of various components of LIBs. 

Recent development of low temperature plasma technology for lithium-ion battery materials

Increasing lithium‐ion batteries' (LIBs) electrode areal capacity can boost energy density and lower manufacturing costs, but faces challenges in manufacturing, rate performance, and cycling stability. A conductive framework made of commercial micro‐sized carbon fibers (Cfs) is presented that serves as a host for both the LiNi0.5Mn0.3Co0.2O2 (NMC 532) cathode and Cfs anode. The Cf framework has multiple functions that offer high electronic conductivity (270 mS cm−1), low tortuosity (1.7), low Li+ diffusion resistance (22 Ω), and high thermal conductivity (200 W mK−1). Additionally, the Cf‐integrated electrodes can have an extremely high mass loading of NMC 532 (70 mg cm−2) with a theoretical capacity of 14 mAh cm−2. Thus, the practical full cells assembled with the Cfs‐enabled electrodes exhibit an initial areal capacity of 4.1 mAh cm−2 and capacity retention of 90.4% at 500 cycles at a cycling rate of C/3, 1.5 mA cm−2. Data collected from the operando isothermal microcalorimetry suggest that full cells utilizing the Cf anode experience less heat release from side reactions compared to cells utilizing a conventional graphite anode. This present approach is scalable and cost‐effective and can fabricate practical LIBs that boast high areal capacity, rate performance, and a lengthy cycling lifetime.

3D‐Integrated, Multi‐Functional Carbon Fibers for Stable, High‐Areal‐Capacity Batteries

Plasmas are reactive ionised gases, which enable the creation of unique reaction fields. This allows plasmas to be widely used for a variety of chemical processes for materials, recycling among others. Because of the increase in urgency to find more sustainable methods of waste management, plasmas have been enthusiastically applied to recycling processes. This review presents recent developments of plasma technologies for recycling linked to economical models of circular economy and waste management hierarchies, exemplifying the thermal decomposition of organic components or substances, the recovery of inorganic materials like metals, the treatment of paper, wind turbine waste, and electronic waste. It is discovered that thermal plasmas are most applicable to thermal processes, whereas nonthermal plasmas are often applied in different contexts which utilise their chemical selectivity. Most applications of plasmas in recycling are successful, but there is room for advancements in applications. Additionally, further perspectives are discussed.

Applications of Plasma Technologies in Recycling Processes

Efficient regeneration of waste LiFePO4 cathode material by short process low temperature plasma assisted nitrogen doped technology

Abstract Slurry casting has been used to fabricate Lithium-ion battery (LIB) electrodes for decades, which involves toxic and expensive organic solvents followed by high-cost vacuum drying and electrode calendaring. This work presents a new manufacturing method using a nonthermal plasma to create inter-particle binding without using any polymeric binding materials, enabling solvent-free manufacturing electrodes with any electrochemistry of choice. The cold-plasma-coating (CPC) technique enables fabricating electrodes with thickness (>200μm), high mass loading (>30 mg cm-2), high peel strength and the ability to print LIBs in an arbitrary geometry. This crosscutting, chemistry agnostic, platform technology would increase energy density, eliminate the use of any solvents, vacuum drying and calendaring processes during production, and reduce manufacturing cost for current and future cell designs. Here, lithium iron phosphate (LFP) and lithium cobalt oxide (LCO) were used as examples to demonstrate the efficacy of the CPC technique. It is found that the mechanical peel strength of CPC-manufactured LFP is over an order of magnitude higher than that of slurry-casted LFP electrodes. Full cells assembled with a graphite anode and the CPC-LFP cathodes offer highly reversible cycling performance with a capacity retention of 81.6% over 500 cycles. For highly conductive cathode materials LCO, an areal capacity of 4.2 mAh cm-2 at 0.2C is attained. We anticipate that this new, highly scalable manufacturing technique will re-define global LIB manufacturing providing significantly reduced plant footprints and material costs. 

https://onlinelibrary.wiley.com/doi/pdfdirect/10.1002/eem2.12503

Solvent‐Free
 Manufacturing of Lithium‐ion Battery Electrodes via Cold Plasma

Dihydroxylammonium 5, 5′-bistetrazole-1, 1′-diolate (TKX-50) is a promising new nitrogen-rich energetic material with considerable properties and low sensitivity, but unfortunately inadequate energy release may restrict its application. To enhance the reactivity of TKX-50 in the energetic materials, TKX-50/CL-20 composite material was constructed by using a facile fabrication method. Further, thermal decomposition analysis, constant-volume combustion cell test and laser ignition experiment were conducted to study the thermal behavior. The results showed that the incorporation of 2,4,6,8,10,12-hexanitro-2,4,6,8,10,12 -hexaazaisowurtzi-tane (CL-20) advanced the exothermic peak temperature for the decomposition of TKX-50, and significantly reduced the apparent activation energy obtained by the thermal decomposition kinetic methods. Moreover, CL-20 could promote the combustion and energy release rate of TKX-50 that is reflected on the increased pressurization rate, as well as the stronger and brighter flame that appeared during the combustion process. The obtained results indicated that CL-20 participated in the thermal behavior of TKX-50 and improved its overall reactivity. 

Incorporation of CL-20 into TKX-50 to improve thermal reactivity

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Solvent‐Free Manufacturing of Lithium‐ion Battery Electrodes via Cold Plasma

Incorporation of CL-20 into TKX-50 to improve thermal reactivity