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Novel Processing

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  • Novel Processing

Novel Processing

Sustainable & Scalable Processing for Battery Electrodes

Advanced Manufacturing for High-Energy Batteries

(Environmentally friendly, scalable electrode processing)
  • In pursuit of sustainable and scalable battery fabrication, our group is pioneering novel processing techniques that minimize environmental impact and manufacturing complexity. A key focus lies in the development of solvent-free electrode manufacturing, which eliminates the use of toxic and volatile organic solvents, thereby reducing energy consumption, drying time, and carbon footprint. We investigate the binder fibrillation and particle distribution in dry-processed electrodes, optimizing their mechanical integrity and electrochemical performance for both LIBs and ASSBs. In parallel, we employ mechanofusion processing as an advanced dry coating technique to fabricate core–shell and densely packed granular particles. This method enables precise control over particle morphology, interfacial chemistry, and functional gradient formation, facilitating improved electronic/ionic conduction, interparticle adhesion, and environmental stability. Together, these solvent-free, additive-compatible processing strategies support the transition toward next-generation battery manufacturing paradigms that are material-efficient, scalable, and environmentally responsible.
  • To address the intrinsic instability of lithium metal anodes, our group explores advanced interfacial engineering strategies to suppress Li dendrite growth, improve cycling reversibility, and enable long-term operation in both liquid and solid-state batteries. We develop mechanochemical interface engineering approaches that exploit stress-driven chemical reactions to form robust, ion-conductive, and electronically insulating interphases. These artificial solid electrolyte interphases (SEIs) are tailored to accommodate volume changes and inhibit unstable Li nucleation. In addition, we employ chemical vapor deposition (CVD) and solution-based chemical treatments to construct conformal, ultrathin surface coatings on lithium metal. These engineered interlayers are designed to regulate Li+ flux, suppress side reactions, and stabilize electrode–electrolyte interfaces under both ambient and high-rate conditions. Our research also investigates the synergy between lithium host structures, interfacial chemistry, and mechanical confinement to achieve high Coulombic efficiency and uniform lithium deposition. These efforts aim to unlock the full potential of lithium metal as an ultra-high-capacity anode material and accelerate the realization of next-generation rechargeable batteries with significantly improved energy density and safety.