Abstract

AbstractIn stationary storage, thick electrodes can minimize inactive material components to increase energy density and decrease cost, but they face challenges in performance and manufacturability. This work discusses a method to fabricate thick‐format lithium‐ion electrodes and a model to explore transport constraints for functional thick electrodes. Thick lithium iron phosphate (LFP) electrodes were fabricated using a solvent‐free pressing process that adopts methods from alkaline electrode manufacturing for low‐cost scale‐up. LFP electrodes with thicknesses up to 1 mm and capacities up to ~15 mAh/cm2 exhibited good rate performance (~98 % utilization at C/10, ~95 % at C/5, ~76 % at C/2). A physics‐based LFP half‐cell model was developed to aid in characterizing transport within these thick electrodes, revealing opportunities to further improve performance by decreasing tortuosity.

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