High mass loading additive-free LiFePO4 cathodes with 500 μm thickness for high areal capacity Li-ion batteries.

We report the preparation of thick ceramic electrodes of the olivine LiFePO 4 (LFP) with high mass loading. These electrodes are preparated by means of Powder Extrusion Moulding (PEM), which is a technology easily scalable and cheap. These LFP cathodes are additive-free (neither binder nor extra carbon black) with ~0.5 mm thickness, allowing to develop very high areal capacity (13.7 mA h cm−2). By means of a strict control of sintering process, the carbon coating of the commercial LFP powder remains and the decomposition of the active material is prevented. The optimized self-supported LFP cathode presents good cyclability over 20 cycles at C/10 with no capacity loss. The good electrochemical performance of these novel LFP thick electrodes and their non-flammability make them interesting candidates for both mobile and stationary applications. Image 1 • Thick ceramic electrodes of LiFePO4 with high areal capacities (13.7 mA h cm-2). • Self-supported LFP cathode with good cyclability at C/10. • New generation of high performances and sustainable ultra-thick electrodes. • Thick electrodes (~500 μm) prepared by an easily scalable manufacturing process. [ABSTRACT FROM AUTHOR]