Work

Laser‐Textured Field‐Engineered Interface for Robust Dry‐Processed Cathodes in Lithium‐Ion Batteries

Year: 2026

Type: article

Abstract: Dry‐processed thick electrodes promise greener and simpler lithium‐ion battery manufacturing, but their reliability is often limited by a weak current collector interface, where poor mechanical anchoring and contact resistance accelerate delamination and polarization. We report a laser‐textured micro‐grid Al collector that implements a field‐engineered interface for dry cathodes by co‐designing stress relief and charge‐transfer continuity. The micro‐grid enlarges real contact area and induces 3D interlocking of a PTFE‐fibrillated LiNi 0.8 Co 0.1 Mn 0.1 O 2 (SCNCM811) dry electrode, doubling adhesion strength and dramatically improving folding durability. Electrochemically, the engineered interface lowers polarization and R ct , delivering 78.9% capacity retention over 180 cycles at 0.2 C (45 °C) compared with rapid fading on pristine Al. A 1.6 Ah pouch‐cell demonstration validates scalable fabrication of high‐loading double‐sided dry cathodes. This interfacial design strategy provides a manufacturing‐relevant route to mechanically and electrically robust dry electrodes.

Source: Energy & environment materials

DOI: 10.1002/eem2.70434