A study conducted by Ayaka Yonaga et al. has been published in Small Methods.
As electric vehicles become more widespread, lithium-ion batteries are increasingly required to achieve both higher energy density and lower environmental impact during manufacturing. However, increasing electrode thickness to improve energy density can hinder lithium-ion transport within the electrode, leading to reduced high-rate performance. In particular, particulate conductive additives conventionally used to ensure electronic conductivity can block pore pathways in the electrode and thereby impede ion transport. In addition, conventional electrode manufacturing processes rely on solvents, requiring energy-intensive drying and solvent recovery steps.
In this study, the researchers replaced particulate conductive additives with carbon fibers and developed a solvent-free electrostatic dry-coating process that aligns the carbon fibers along the through-thickness direction of the electrode. This approach enables the carbon fibers to function as long-range electronic conduction pathways, improving electronic conductivity while minimizing adverse effects on ion transport. As a result, the electronic resistance was reduced to less than one hundredth that of conventional electrodes, and high discharge capacity was maintained even under high-rate conditions.
This technology is expected to serve as a new electrode design and manufacturing strategy that enables both high-performance lithium-ion batteries and environmentally sustainable production.
Title: Electrostatic Dry Coating Strategies for Through-Plane Control of Electronic Pathways in Lithium-Ion Electrodes
Authors: Yonaga, A., Matsunaga, T.
Journal Name: Small Methods
Published: April 1, 2026