Open Access Article
Ali J. Saadun†
a,
Steven D. Lacey†
b,
Yuri Surace
c,
Irshad Mohammad
c,
Karin Jägled,
Ivan Trentind,
Antonino Curcioa,
Aliki Moysiadoua,
Edouard Quérel
a,
Francesco Bizzottoa,
Carlota Bozal Ginestaa,
Peter Axmann
d,
Corsin Battaglia
aefg,
Florian Klunkerb and
Ruben-Simon Kühnel
*a
aEmpa – Swiss Federal Laboratories for Materials Science and Technology, 8600 Dübendorf, Switzerland. E-mail: ruben-simon.kuehnel@empa.ch
bHuntsman Advanced Materials GmbH, 4057 Basel, Switzerland
cAIT Austrian Institute of Technology GmbH, Center for Transport Technologies, Battery Technologies, 1210 Vienna, Austria
dZSW Center for Solar Energy and Hydrogen Research Baden-Württemberg, 89081 Ulm, Germany
eETH Zurich, Department of Information Technology and Electrical Engineering, 8092 Zurich, Switzerland
fETH Zurich, Department of Materials, 8093 Zurich, Switzerland
gEPFL, School of Engineering, Institute of Materials, 1015 Lausanne, Switzerland
First published on 17th June 2026
Alternative conductive additives for lithium-ion batteries, such as carbon nanotubes and graphene, are academically well-established with pursued industrial opportunities while carbon black represents the global standard. However, further advancements are necessary to improve battery performance beyond current industrial metrics. Herein, a mixed-dimensional carbon material is introduced, featuring a network of 1D multi-walled nanotubes with 2D sheetlets, synthesized through a cost-effective process separating methane – a potent greenhouse gas – into carbon and low carbon intensity hydrogen. With proper slurry mixing, this material forms an expansive 3D conductive network within the electrode, enhancing electrical transport and thermal conductivity compared to carbon black electrodes. With only one-third of the carbon content (1 wt%), the electrical conductivity of a LiNi0.5Mn0.3Co0.2O2 cathode is 13 times higher than a carbon black reference, increasing both energy density and rate performance. The thermal conductivity is further improved by 40% (through-plane) and 200% (in-plane), promoting better heat dissipation. This carbon network also effectively retains transition metals during electrochemical cycling, limiting their migration to the anode, and thus reducing overall impedance build-up. The excellent compatibility of this conductive additive with state-of-the-art nickel-rich (85% nickel) layered oxides is also demonstrated, where 11.5 Ah pouch cells display >88% capacity retention after 1000 cycles at C/3.
Focusing on the development of conductive additives for the electrodes, a well-established material for lithium-ion batteries is carbon black (CB), which can be seen as the industry's standard.8 However, the use of advanced carbon nanomaterials, such as two-dimensional (2D) graphene and 1D carbon nanotubes (CNTs), has gained significant attention in academia and industry due to their enhanced electrical, thermal, and mechanical properties.8,11,12 A key advantage of such materials is that much lower carbon contents are needed compared to carbon black. Hence, energy density can be increased by replacing carbon black with 1D or 2D carbon materials. Another advantage is that their high electrical conductivity can improve rate performance. There are important differences between graphene and CNTs as a conductive additive for battery electrodes. While both classes of materials offer high thermal and electrical conductivity, large graphene sheets have been shown to block lithium-ion transport, thus negating the benefit of improved electronic conductivity at high rates.13 On the other hand, graphene has been reported to be particularly suitable for silicon-based electrodes by accommodating the volume change of silicon upon lithiation/delithiation.14
There are only a few reports on combining 1D and 2D carbon materials as the conductive additive. For example, Gao et al.15 prepared a composite material by mixing silicon particles, graphene (reduced graphene oxide), and CNTs. The much-improved cycling stability compared to an electrode only with carbon black as conductive additive was attributed to a synergistic effect of the two different carbon nanomaterials. Ye et al.16 combined carbon black, CNTs, and graphene in a graphite anode and attributed the improved cycling stability in part to a more effective solid-electrolyte interphase (SEI) forming in the presence of this multidimensional conducting network. Xue et al.17 obtained better rate performance and cycling stability of LiCoO2 cathodes containing three different carbons (i.e., carbon black, CNTs, and graphene) compared to an electrode containing only carbon black but in a 50% higher content.
This work investigates a novel mixed-dimensional carbon nanotube material, composed of interconnected 1D tubules that can unfold into an intricate 3D network of 2D sheetlets, as a conductive additive for LiNixMnyCozO2 (NMC)-based cathodes. Slurries of this carbon nanotube network (CNT-N) material can be integrated seamlessly into conventional electrode manufacturing protocols and enhance overall electrode properties versus the reference carbon black cathode. Both the intrinsic material and electrode properties are quantified and their effect on battery performance is evaluated herein by electrical, thermal, mechanical, rheological, and electrochemical means. It is proposed that the combination of 1D and 2D material properties enables higher electrical and thermal conductivities of the resulting cathode coating, thereby positively influencing the overall cell performance, including higher capacity and enhanced rate capability. The results for CNT-N are compared to those obtained for conventional C65 carbon black as well as KS6L graphite.
For comparison, commonly used battery-grade C65 was used as a representative standard for the family of carbon black materials while KS6L graphite was also included in this study. SEM images confirm the sphere-like agglomerations of C65, whereas KS6L exhibits irregularly-shaped flakes (Fig. 1a). The BET surface area of the carbon materials are 18.6, 64.9, and 119 m2 g−1 for KS6L, C65, and CNT-N, respectively (Table 1). Whereas the surface area of CNT-N surpasses that of C65 by nearly two times, its pore volume is only about 1.6 times larger (Table 1). The low pore volume value of KS6L indicates that the majority of the flakes have minimal accessible porosity. The Raman spectrum of the CNT-N material is shown in Fig. S3. The low D-band-to-G-band intensity ratio indicates a low defect density and a high degree of graphitic ordering of the CNTs.
| Material | Surface area SBETa (m2 g−1) | Pore volume Vporeb (cm3 g−1) | Specific heat capacity cpc (J g−1 K−1) |
|---|---|---|---|
| a BET model.b Volume of N2 adsorbed at p/p0 = 0.98.c DSC measured at 293 K and calculated with the cp-ratio method, using sapphire as reference material. | |||
| C65 | 64.9 | 0.27 | 0.69 |
| CNT-N | 119 | 0.43 | 0.72 |
| KS6L | 18.6 | 0.07 | 0.59 |
| NMC532 | 0.3 | 0.001 | 1.04 |
| Al foil | — | — | 0.96 |
| Cu foil | — | — | 0.42 |
| Cathode with 3% C65 | — | — | 1.07 |
| Cathode with 1% CNT-N | — | — | 0.97 |
| Graphite anode | — | — | 0.60 |
To investigate the conductive properties of a standard cathode coating, a slurry with a NMC
:
PVDF
:
carbon weight ratio of 97 − x
:
3
:
x was prepared. For reliable comparisons, the PVDF content of all cathode slurries was kept constant to eliminate influences impacting the electrode's conductivity. Herein, dry powders of C65 and KS6L were processed directly into a uniform cathode slurry through centrifugal mixing, whereas CNT-N was prepared separately into a dispersion by high-shear mixing in order to homogenously distribute it in a PVDF/NMP solution beforehand. In general, dispersing CNTs can be a challenging task requiring careful optimization of surfactants, dispersants, or other polymeric additives to ensure the individualized tubes remain separated and stable in solution.22 Hence, the dry CNT-N was processed in the PVDF/NMP solution with an additional polymeric material (distinct from PVDF) as a dispersant to sufficiently disperse the nanotube network and reduce agglomeration. The resulting CNT-N dispersion was subsequently combined with NMC and further homogenized during electrode slurry preparation. The dispersant remains in the electrode after drying and is therefore part of the inactive component fraction. A CNT-N-to-dispersant ratio of 10
:
3 was chosen to enable dispersions with sufficient long-term storage stability. The dispersion process also aids in unfurling some tubules into 2D sheetlets with dimensions on the order of tens of microns, which wrap around the active NMC particles when prepared into a cathode slurry. Specifically, we found that mixing the active material with the CNT-N dispersion before adding the remaining PVDF and NMP amounts (if needed) promotes the desired wrapping of CNT-N sheetlets around the active-material particles.
As expected, slurries containing CNT-N exhibit significantly higher viscosities than slurries containing C65 at the same carbon content. Fortunately, the required amount of CNT-N is substantially lower than that of C65, as indicated by the electrical and thermal conductivity data in Fig. 1c and d and by the electrochemical data presented below. Fig. S4 summarizes the rheological data of the NMC slurries investigated in this study, all prepared with the same PVDF binder content (3 wt%) unless stated otherwise. Note that, in all cases, the viscosities were sufficient to cast the slurries onto Al foil. At 1 wt% CNT-N, the viscosity remains up to one order of magnitude higher over the investigated shear-rate range compared to a slurry with 3 wt% C65 (both containing 3 wt% PVDF binder). When the CNT-N content is reduced to 0.5 wt% while keeping the binder content at 3 wt%—a CNT-N level that is sufficient based on the electrochemical data presented below—the viscosity difference decreases markedly. When the binder content is further reduced to 1.5 wt%, the resulting slurry exhibits a lower viscosity than the slurry containing 3 wt% C65 and 3 wt% binder, particularly at high shear rates. Thus, by tuning the slurry composition, the desired viscosity can be achieved with CNT-N while retaining high electrical and thermal conductivity.
Beyond slurry rheology, the casting process is another critical factor for the resulting electrode properties, such as thermal conductivity. In this process, the alignment of large-aspect-ratio materials like CNTs is more significantly affected by the casting direction than that of spherical carbon black particles (not considering the shape of carbon black agglomerates) (Fig. 1b).
To evaluate the effect of directionality on thermal conductivity, electrodes designated for laser flash analysis (LFA) were carefully fabricated by casting the slurry in a single direction followed by precisely stacking the dried electrode cutouts to ensure alignment in either the parallel (in-plane) or perpendicular (through-plane) direction (Fig. S5). Importantly, these measurements were performed on free-standing electrodes without a current collector, thereby reflecting the intrinsic conductivity of the cathode coatings.
The LFA technique measures the time required for the opposite side of the sample to register a temperature increase upon exposure to laser pulses. The output is the thermal diffusivity α (in mm2 s−1), which is aligned with the test sample's orientation. Multiplying the diffusivity by the volumetric heat capacity (density × specific heat capacity, ρ cp in J m−3 K−1) gives the thermal conductivity λ (in W m−1 K−1). The density across all samples was maintained at ca. 3.0 g cm−3 to ensure comparability, and the specific heat capacity was assumed to be constant at 1 J g−1 K−1, reflecting the specific heat capacity of the dominant NMC component and is in good agreement with values measured for two select cathodes (Table 1).
Thermal conductivity measurements reveal distinct enhancements for CNT-N cathodes compared to those with graphite and carbon black, with pronounced differences between the in-plane and through-plane directions (Fig. 1c).
In summary, these results underscore the anisotropy in thermal transport within the cathodes and highlight the capability of CNT-N to enhance heat conduction, particularly in the in-plane direction.
These improvements in thermal conductivity can be expected to mitigate thermal gradients within a cell, which have been shown to be detrimental for cycle life and are a key consideration in battery thermal management.24,25 Previous experimental studies demonstrated that non-uniform temperature distributions accelerate battery degradation even when the average cell temperature is unchanged. Cloos and Wetzel showed for 20 Ah NMC–LMO/graphite pouch cells that both in-plane and through-plane temperature gradients lead to faster capacity loss compared to homogeneous thermal conditions, with through-plane gradients being more detrimental, especially at elevated average temperatures.24 Similarly, long-term cycling studies by Cavalheiro et al. demonstrated that spatial temperature gradients inside pouch-cell stacks result in non-uniform and accelerated degradation, with regions exposed to higher local temperatures aging more rapidly.25 As the core of large-format cells typically experiences higher temperatures than the outer regions during operation, especially at high charge and discharge rates, reducing internal thermal gradients through improved electrode thermal conductivity is expected to benefit cycle life under otherwise comparable cell and operating conditions. Even when the total heat generation remains unchanged, enhanced heat spreading at the electrode level is expected to lower peak core temperatures, which can reduce the peak cooling power required to maintain cells within safe and durable operating limits.
To further investigate the conductivity metrics of the electrodes, a four-point probe was employed to measure the electrical conductivity of the cathodes. When 1% CNT-N is incorporated into an NMC cathode, a 13-fold increase in electrical conductivity is achieved relative to 3% C65 (Fig. 1d, right axis). Even at a modest 0.5% loading, CNT-N cathodes exhibit conductivity 4.5 times higher than that of 3% C65 cathodes. Overall, these trends are consistent with percolation behavior in composite electrodes, where electronic transport increases sharply once a continuous conductive network forms above a critical filler loading. For C65, the strong increase from 1% to 3% combined with the minimal additional improvement when increasing C65 further to 9% suggests that the effective percolation threshold in the NMC/PVDF composite is reached around a 3% loading. In contrast, CNT-N reaches substantially higher conductivity at 0.5–1% loading, indicating a lower effective percolation threshold and more efficient conductive-network formation, which we attribute to the high-aspect-ratio nanotube component and the mixed-dimensional morphology that facilitate particle bridging and long-range connectivity. Regardless of the carbon content, the electrical conductivity of cathodes containing KS6L graphite proves challenging. The flake-like structure of graphite likely hinders the formation of an uninterrupted flow path for electrons, a limitation that may also apply to the electrode with 1% C65, where the number of carbon spheres may be insufficient to form a connected electrical network within the NMC cathode. Overall, CNT-N electrodes exhibit both enhanced heat- and electron transport within the positive electrode compared to the industry standard C65 based on the aforementioned thermal conductivity and electrical conductivity results, respectively.
Expressing the dataset per cathode weight (Fig. 2) is more relevant for industrial applications, as it reflects energy density while accounting for variations in both NMC and carbon contents in the cathodes. This plot highlights another key advantage of CNT-N in that it requires less carbon within the electrode. Note that the PVDF binder content (3%) is maintained constant across all tested cathodes herein. However, for the 0.5% CNT-N cathode, the capacity falls below that of the 3% C65 cathode at discharge rates above 1C. This, along with surface area considerations, is a strong indication that a PVDF content of 3% may be excessive for the 0.5% CNT-N cathode, hindering kinetics, especially at high rates. Accordingly, the binder content for the 0.5% CNT-N cathode was reduced by half (1.5% PVDF) and the cathode was retested to assess the effect of PVDF on rate performance. On a per-cathode-weight basis, the 0.5% CNT-N cathode with 1.5% PVDF displays discharge capacities comparable to the 3% C65 cathode for a discharge rate of 3D, and higher capacity at all lower discharge rates (Fig. 2a). We expect that further optimization of the binder:carbon ratio is required to fully utilize the potential of CNT-N in industrially relevant NMC cathodes. For 3% C65 and 1% CNT-N, the discharge rate was increased beyond 3C to 10C (Fig. 2b). At this very high discharge rate, the cell with 1% CNT-N delivers a 7.5% higher capacity per cathode weight.
In full cells, 1% CNT-N and 3% C65 cathodes were evaluated against standard graphite anodes (Fig. 3). At C/2 charge–discharge rates, 1% CNT-N cells rival the performance of those with conventional 3% C65, displaying a comparable capacity retention after 1000 cycles while the absolute discharge capacity is higher both per cathode and per NMC weights (Fig. 3a and b, S9). Note around cycle 400 a significant increase in discharge capacities is shown for all tested cells. During this time period, a temperature chamber malfunction caused the cell storage environment to increase by ∼10 °C to ∼35 °C. The 1% CNT-N cells also prove interesting for fast charging at 2C (with C/2 discharge), maintaining 74% of their initial capacity after 1000 cycles (Fig. 3a inset, Fig. 3c).
To estimate the benefit in terms of energy density for a realistic high-energy cell when switching from 3% C65 to 1% or 0.5% CNT-N, we assumed double-side-coated electrodes with an areal capacity of 5 mAh cm−2 per side, a gravimetric capacity of the cathode active material of 200 mAh g−1, a binder content of 3%, and an aluminum current collector thickness of 10 µm. Under these assumptions, the gain in specific capacity on the electrode level is 2.1% when decreasing the conductive additive content from 3% to 1%. When further decreasing the CNT-N content to 0.5% and the binder content to 1.5%, the gain is 4%. These gains in specific capacity on the electrode level translate to gains in gravimetric energy density on the cell level of 0.8% and 1.6%, respectively, assuming a weight fraction of the cathode of 40%. Assuming no change in porosity, a gain in volumetric energy density on the cell level of ca. 1.5% and 2.5% can be expected for the 1% and 0.5% CNT-N cases, respectively, assuming a cathode volume fraction of 35%. To support this assumption, we performed a machine-learning-based porosity analysis on cross-sectional SEM images of fresh NMC532 electrodes containing either 1% CNT-N or 3% C65 and obtained similar porosity values for both formulations. Representative segmentation maps of the SEM images, distinguishing solid phases (active material, conductive additive, and binder where identifiable) from pore space, are provided in Fig. S10 and S11. These estimated gains in volumetric energy density are higher than the gravimetric ones as the carbon materials have less than half the density of NMC and are quite significant considering the high maturity of lithium-ion battery technology.
To further study the role of CNT-N on transition metal dissolution, post-mortem analyses of the cells cycled to 1000 cycles were performed including EDX (Fig. 4c), SEM (cross section and top view) (Fig. 5a), and ICP-OES (Fig. 5b). In the EDX maps for the cycled CNT-N cathode, signals from Mn and C overlap, highlighting again that CNT-N can wrap around NMC particles. In contrast, there is no clear overlapping pattern for the C65 cathode as the C65 particles cover a smaller area of the NMC particle surface. The SEM images, particularly the cross-sectional images, show that the NMC particles are not damaged or cracked after 1000 cycles in either CNT-N or C65 cathodes. While we did not observe cracking for the NMC532 active material, we have no indication to expect that CNT-N significantly alters the cracking behavior of NMC materials with a high nickel content that are much more prone to cracking. We expect that the anisotropic strain due to volume changes upon lithiation/delithiation of such materials is not significantly altered by the presence of CNT-N due to the expected relatively flexible nature of the thin sheetlets. This indicates that the capacity fading shown in Fig. 3a is not a consequence of NMC particle cracking over prolonged cycling. In the top-view SEM images, the ‘net’ morphology of CNT-N is clearly visible, where the tubule bundles and 2D sheetlets wrap around the NMC particles forming a network (Fig. S13 and S14). Additionally, the graphite anodes recovered from the CNT-N and C65 cells after 1000 cycles were analyzed by ICP-OES to quantify the transition metal content (Fig. 5b). Importantly, the concentrations for all three tested transition metals, especially Mn and Ni, for the C65 anode far exceed the values for the anode from the CNT-N cell. Top-view SEM paired with EDX also showcases that Mn depositions are more pronounced on the cycled graphite anode surface for the C65 cell (Fig. S15). These findings suggests that the CNT-N within the cathode indeed suppresses transition metal dissolution. In literature, stabilization of NMC upon coating it prior with reduced graphene oxide has been beneficial and explained by the lower surface area of NMC that is in direct contact with the electrolyte.27 Considering that the CNT-N does not fully cover the NMC particles in our case and hence electrolyte might still be able to reach some of the NMC surface, CNT-N might alternatively act as a kind of ‘net’ for dissolved transition metals, reducing its concentration in the electrolyte. A more detailed understanding of the mechanism of suppressed transition metal dissolution from NMC in the presence of CNT-N, particularly regarding the interaction between the electrolyte and the CNT-N-covered NMC particles, and to distinguish between the two proposed mechanisms, would be desirable and should be studied in future.
After an initial drop in capacity of ca. 7% during the first 100 cycles, the cells display very stable capacity at C/3 as reflected in an average capacity retention around 88% after 1000 cycles, demonstrating excellent compatibility between CNT-N and Ni-rich NMC. Based on the decay rate over the last few hundred cycles, these multilayer NMC85/graphite pouch cells are expected to reach >1500 cycles before 80% capacity retention is met, which surpasses the desired metric for industrial automotive batteries.28
In the broader literature on advanced conductive additives, performance gains are commonly reported for high-aspect-ratio 1D carbons (CNTs and carbon nanofibers) and multidimensional carbon blends because they reach percolation at low loadings. Carbon blacks, which typically require higher fractions, and 2D graphene-type platelets can introduce Li-ion transport limitations by obstructing pore pathways.13,15–17 Against this backdrop, the electrical conductivity increase achieved here at only 0.5–1 wt% CNT-N (up to 13 times vs. 3 wt% C65) places CNT-N in the regime targeted by the CNT-based literature, while additionally quantifying a pronounced thermal-transport benefit (200% in-plane and 40% through-plane) that is rarely reported at the electrode level for such low additive loadings. Notably, prior work has shown that reduced graphene oxide and other coatings on NMC can mitigate degradation of the active material by reducing direct electrolyte contact area.27,29 In contrast to these coating strategies, the reduced impedance build-up and suppressed transition-metal migration observed herein are achieved through a conductive additive introduced during slurry processing, suggesting that partial particle coverage and network formation can deliver interfacial stabilization without a dedicated active-material coating step. Overall, CNT-N therefore combines the low-loading percolation advantage typical of 1D carbons with an additional heat-management and aging-mitigation contribution that helps rationalize the improved rate capability and long-term stability observed in both coin and pouch cells.
Moreover, excellent rate capability and long-term cycling stability is shown for mid-nickel NMC532 cathodes with CNT-N, reaching higher capacities per cathode weight and per NMC weight in half cells across all investigated C-rates as well as having similar capacity retention to C65 full cells after 1000 cycles at both C/2 and 2C charge rates. EIS and post-mortem analyses reveal a unique phenomenon enabled by CNT-N: suppression of transition metal dissolution into the electrolyte and hence less poisoning of the SEI. To the best of our knowledge, this is the first report of a conductive carbon additive that is added to the slurry and not coated on the active material that plays an active role in mitigating transition metal dissolution. Finally, CNT-N demonstrates excellent compatibility with nickel-rich NMC (85% Ni) cathodes, achieving a capacity retention of 88% in 11.5 Ah multilayer pouch cells after 1000 cycles at a C/3 rate, rendering it a promising solution for the automotive industry.
:
3 ratio of carbon
:
binder) and non-ionic surfactant/dispersant with loadings of 1.25 wt%, 3.75 wt%, and 0.375 wt%, respectively. An additional CNT-N dispersion with a higher carbon:binder ratio of 1
:
6, consisting of 0.5 wt% CNT-N, 3 wt% PVDF, and 0.15 wt% non-ionic surfactant/dispersant, was also available to ensure slurry preparation procedures were consistent across all evaluated carbons (carbon black and graphite). The CNT-N dispersions were supplied by Huntsman Advanced Materials and used directly to prepare cathode slurries.
:
PVDF
:
carbon of 94
:
3
:
3, unless otherwise indicated. The components were mixed in a centrifugal Thinky Are-250 mixer for 20 min at 2000 rpm followed by degassing for 5 min at 500 rpm. To create the CNT-N cathode slurries, NMC powder was added to the CNT-N dispersion and mixed in a Thinky mixer using an identical protocol as described above to achieve a homogeneous slurry with final NMC
:
PVDF
:
CNT-N
:
surfactant ratio of 95.7
:
3
:
1
:
0.3 or 96.35
:
3
:
0.5
:
0.15. Slurries with reduced PVDF binder content resulted in a final ratio of 97.85
:
1.5
:
0.5
:
0.15. All slurries contained a total solids content of 50% and were coated on an aluminum current collector using a Zehntner ZUA series film applicator. The wet electrodes were subsequently dried under air atmosphere at 80 °C for 30 min. The electrodes for the coin-cell experiments were precision cut into discs with a diameter of 15 mm (graphite anode) or 14 mm (cathode) using an EL-Cut (EL-Cell) punching tool and dried at 80 °C under vacuum for 15 h prior to cell assembly.N2 sorption at 77 K was measured in a Micromeritics ASAP 2020 analyzer. Samples (approximately 0.10 g) were evacuated to 50 mbar at 100 °C for 12 h prior to the measurement. The Brunauer–Emmett–Teller (BET) method was applied to calculate the total surface area, SBET. The pore volume, Vpore, was determined from the amount of N2 adsorbed at a relative pressure of p/p0 = 0.98.
:
7 with (full cells) or without (half cells) 2 wt% vinylene carbonate (VC) (Solvionic) was employed as electrolyte. Half cells were assembled using Li foil as counter electrode and cathodes with a typical areal active material loading of 8.0 mg cm2 (areal capacity of 1.35 mA h cm−2). For full cells, anodes and heavier cathodes with an areal capacity of 2.4 mA h cm−2 and 2.0 mAh cm−2, respectively, were used, leading to an N/P ratio of 1.2. After assembly of the full cells, the cells were charged to 1.5 V at C/3 to minimize corrosion of the Cu current collector, subsequently rested for 12 h to ensure wetting of separator and electrodes before starting constant-current charge–discharge tests. Charge/discharge full cell cycling data and electrochemical impedance (EIS) measurements were recorded on a BCS-805 (BioLogic), whereas a CT3001A (Wuhan LAND Electronic) battery cycler was used for the half cells.
All half- and full cells were cycled between 2.9–4.3 V and 2.8–4.2 V, respectively. Two formation cycles at C/10 followed by continuous charge and discharge cycling at C/2 was performed, if not otherwise stated. The full cells were subjected to constant current-constant voltage (CCCV) cycling. Full cells were also subjected to higher charge–discharge rates of 2C–C/2. Charging rates did not exceed 2C to alleviate dendrite growth in the cells. Unless otherwise stated, all electrochemical measurements were conducted at 25 °C.
Cycled cells were disassembled in the charged state inside an Ar-filled glove box. The positive electrode was recovered and thoroughly rinsed with EMC to remove electrolyte residues. Prior to post-mortem characterization, the electrode was maintained inside the glovebox for one hour to ensure the quantitative evaporation of the solvent.
The multilayer pouch cells were prepared in-house and consisted of 19 cathode and 20 anode layers. The cathodes had a composition of 97.35% W-coated NMC850708 (prepared in-house at ZSW), 0.5% CNT-N, 0.15% surfactant, and 2% PVdF (Solef 5130, Solvay). The anodes had a composition of 94% graphite (SPGT807, Targray), 1% carbon black (Super C45, Imerys), 1.5% carboxymethyl cellulose (Walocel CRT 30000 PA, Dow), and 3.5% styrene-butadiene rubber (Lipaton SB-5521, Synthomer). The cathode and anodes had a size of 68 × 98 mm2 and 70 × 100 mm2, respectively. All electrode sheets were coated double-sided. The cathodes and anodes had an areal capacity of 5.0 and 6.0 mAh cm−2, respectively, resulting in an N/P ratio of 1.2. The areal capacity of the cathode is based on the reversible capacity of the NMC cathode material measured in a full coin cell with a graphite anode of 180 mAh g−1. Further information about the pouch cells can be found in Table S1. Based on this information and the cathode loading, the calculated capacity of the cells is 5.0 mAh cm−2 × 6.8 cm × 9.8 cm × 19 × 2 = 12.7 Ah. Trilayer Celgard 2320 foil was used as separator. The electrolyte content of the cells was 3.2 mL Ah−1. The electrolyte composition was 1 M LiPF6 in EC
:
EMC 3
:
7 (by volume) + 2 wt% VC. The cells were degassed after two CCCV cycles of formation at C/20 and then subjected to long-term CCCV cycling at C/3 and two recovery cycles at C/10 every 100 cycles. The voltage range was set to 2.8 to 4.2 V and the cycling experiments were conducted at 25 °C using a Maccor S4000 battery test system.
Porosity was estimated by computing the ratio of pixels assigned to the pore phase, Npore, relative to the total number of pixels in both pore and cross-section phases, Npore + Ncross-section:
The reported porosity and its uncertainty correspond to the mean and standard deviation, respectively, obtained from three cross-sectional images of equal size (2024 µm2 each).
Supplementary information is available. See DOI: https://doi.org/10.1039/d6ta01878e.
Footnote |
| † Equal contribution. |
| This journal is © The Royal Society of Chemistry 2026 |