Publication date: 10th April 2024
Lithium iron phosphate (LFP) has emerged as a prominent electrode material for electric vehicles due to its high safety and low cost. However, the use of nanoscale primary particles results in low tap density, leading to a low volumetric energy density. To overcome this limitation, aggregating primary particles into spherical secondary particles with high tap density is a promising strategy. However, employing such spherical LFP secondary particles adversely affects the processability of the electrode with an exfoliation phenomenon occurring after the calendaring process. Here, we identify the reasons for this poor electrode processability and propose the effective solution by comparing the binder distribution in electrodes fabricated using primary particles versus those made from spherical secondary particles. Analysis through secondary electron microscopy and laser scanning confocal microscopy revealed that the large size of the secondary particles leads to the formation of considerable empty spaces, while the binder predominantly distributes on the surface of LFP due to its strong adhesion to LFP. These void spaces and the non-uniform distribution of the binder hinder attachment between the electrode components. To address this issue, we fill the void spaces with an appropriate amount of primary particles. By filling the void spaces, the binder distribution becomes more uniform, resulting in a significant increase in the interfacial adhesion between the electrode components by over tenfold. Furthermore, the volumetric energy density has also been improved due to introduction of secondary particles. This work provides insights into the design of electrodes to enhance electrode processability and energy density of LFP batteries.
This work was supported by LG chem.