This work demonstrates the feasibility of a novel solvent‐free anode production for lithium‐ion batteries. It combines a modified dry‐mixing procedure with an innovative electrostatic coating process. The mixing is divided into two steps. At first, carbon black and binder are deagglomerated and recombined to a matrix structure by intensive mixing. In a second less intensive step, this matrix is blended with graphite. The powder mixture is fluidized and then transferred to the current collector by inducing a high voltage. After a subsequent hot pressing step, the powder coating is permanently fixed on the current collector. This procedure is presented with three different fluorinated binders. Furthermore, effects of different mixing intensities on the powder and electrode properties are examined. The electrodes are investigated in the three‐electrode T‐cell setup versus lithium metal to examine their C‐rates and cycle stabilities. The produced anodes offer comparable electrochemical performance to conventional wet‐coated ones on electrode and cell levels. Overall, this new process is a suitable alternative to the conventional electrode production techniques.

This paper presents a comprehensive study of the influences of lamination at both electrode-separator interfaces of lithium-ion batteries consisting of LiNi1/3Mn1/3Co1/3O2 cathodes and graphite anodes. Typically, electrode-separator lamination shows a reduced capacity fade at fast-charging cycles. To study this behavior in detail, the anode and cathode were laminated separately to the separator and compared to the fully laminated and non-laminated state in single-cell format. The impedance of the cells was measured at different states of charge and during the cycling test up to 1500 fast-charging cycles. Lamination on the cathode interface clearly shows an initial decrease in the surface resistance with no correlation to aging effects along cycling, while lamination on both electrode-separator interfaces reduces the growth of the surface resistance along cycling. Lamination only on the anode-separator interface shows up to be sufficient to maintain the enhanced fast-charging capability for 1500 cycles, what we prove to arise from a significant reduction in growth of the solid electrolyte interface.

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The accumulation of solid electrolyte interphases (SEI) in graphite anodes related to elevated formation rates (0.1C, 1C and 2C), cycling rates (1C and 2C), and electrode-separator lamination is investigated. As shown previously, the lamination technique is beneficial for the capacity aging in graphite-LiNi1/3Mn1/3Co1/3O2 cells. Here, surface resistance growth phenomena are quantified using electrochemical impedance spectroscopy (EIS). The graphite anodes were extracted from the graphite NMC cells in their fully discharged state and irreversible accumulations of lithium in the SEI are revealed using neutron depth profiling (NDP). In this post-mortem study, NDP reveals uniform lithium accumulations as a function of depth with lithium situated at the surface of the graphite particles thus forming the SEI. The SEI was found to grow logarithmically with cycle number starting with the main formation in the initial cycles. Furthermore, the EIS measurements indicate that benefits from lamination arise from surface resistance growth phenomena aside from SEI growth in superior anode fractions.