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Increasing electrode thickness is a key strategy to boost energy density in lithium‐ion batteries (LIBs), which is essential for electric vehicles and energy storage applications. However, thick electrodes face significant challenges, including poor ion transport, long diffusion paths, and mechanical instability, all of which degrade battery performance. To overcome these barriers, a novel micro‐electric‐field (μ‐EF) process is introduced that enhances particle alignment during fabrication with reduced distance between anode and cathode. This process produces hyper‐thick (≈700 µm) electrodes with low tortuosity and improved ion diffusion. The μ‐EF electrodes achieve high areal capacities (≈8 mAh cm−2), while maintaining power density and long cycle life. The electrodes show stable performance under high C‐rate cycling and retain structural integrity after 1000 cycles at 2 C. By offering a scalable solution to the challenges of thick electrode fabrication, the μ‐EF process represents a significant advancement for high‐capacity LIBs in electric vehicles and energy storage systems.
Increasing electrode thickness is a key strategy to boost energy density in lithium‐ion batteries (LIBs), which is essential for electric vehicles and energy storage applications. However, thick electrodes face significant challenges, including poor ion transport, long diffusion paths, and mechanical instability, all of which degrade battery performance. To overcome these barriers, a novel micro‐electric‐field (μ‐EF) process is introduced that enhances particle alignment during fabrication with reduced distance between anode and cathode. This process produces hyper‐thick (≈700 µm) electrodes with low tortuosity and improved ion diffusion. The μ‐EF electrodes achieve high areal capacities (≈8 mAh cm−2), while maintaining power density and long cycle life. The electrodes show stable performance under high C‐rate cycling and retain structural integrity after 1000 cycles at 2 C. By offering a scalable solution to the challenges of thick electrode fabrication, the μ‐EF process represents a significant advancement for high‐capacity LIBs in electric vehicles and energy storage systems.
Single‐crystal Ni‐rich LiNi1−x−yCoxMnyO2 (NCM) cathodes have garnered widespread attention in the lithium‐ion battery community due to their unique advantages in mechanical performance and their ability to minimize interfacial electrochemical side reactions. The synthesis of single‐crystal materials with monodisperse and appropriate size, minimal lattice defects, and highly ordered structures is the key for high‐performance batteries. However, achieving this goal poses challenges due to the lack of in‐depth understanding regarding specific experimental parameters and the solid reaction mechanism during the synthesis process. In this review, the aim is to provide an in‐depth analysis of the critical process parameters involved in the synthesis and their impact on crystal morphology, structure, and electrochemical performance. Consequently, the first section focuses on the effect of the precursor morphology, lithium salt, atmosphere, and sintering procedure. In the second section, the study delves into an in‐depth discussion of the solid reaction and crystal growth mechanism. Lastly, it is concluded by highlighting the prospects and challenges associated with the synthesis and application of single‐crystal Ni‐rich NCM cathodes.
Solid‐state lithium metal batteries (LMBs), constructed through the in‐situ fabrication of polymer electrolytes, are considered a critical strategy for the next‐generation battery systems with high energy density and enhanced safety. However, the constrained oxidation stability of polymers, such as the extensively utilized polyethers, limits their applications in high‐voltage batteries and further energy density improvements. Herein, an in‐situ fabricated fluorinated and crosslinked polyether‐based gel polymer electrolyte, FGPE, is presented, exhibiting a high oxidation potential (5.1 V). The fluorinated polyether significantly improves compatibility with both lithium metal and high‐voltage cathode, attributed to the electron‐withdrawing ‐CF3 group and the generated LiF‐rich electrolyte/electrode interphase. Consequently, the solid‐state Li||LiNi0.6Co0.2Mn0.2O2 batteries employing FGPE demonstrate exceptional cycling performances of 1000 cycles with 78% retention, representing one of the best results ever reported for polymer electrolytes. Moreover, FGPE enables batteries to operate at 4.7 V, realizing the highest operating voltage of polyether‐based batteries to date. Notably, our designed in‐situ FGPE provides the solid‐state batteries with exceptional cycling stability even at practical conditions, including high cathode loading (21 mg cm‐2) and industry‐level 18650‐type cylindrical cells (1.3 Ah, 500 cycles). This work provides critical insights into the development of oxidation‐stable polymer electrolytes and the advancement of practical high‐voltage LMBs.
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