Lithium-ion batteries (LIBs) have recently become popular for energy storage due to their high energy density, storage capacity, and long-term cycle life. Although binders make up only a small proportion of LIBs, they have become the key to promoting the transformation of the battery preparation process. Along with the development of binders, the battery manufacturing process has evolved from the conventional slurry-casting (SC) process to a more attractive solvent-free (SF) method. Compared with traditional LIBs manufacturing method, the SF method could dramatically reduce and increase the energy density due to the reduced preparation steps and enhanced electrode loading. Polytetrafluoroethylene (PTFE), as a typical binder, has played an important role in fabricating high-performance LIBs, particularly in regards to the SF technique. In this paper, the development history and application status of PTFE binder was introduced, and then its contributions and the inherent problems involved in the SF process were described and analyzed. Finally, the viewpoints concerning the future trends for PTFE-based SF manufacturing methods were also discussed. We hope this work can inspire future research concerning high-quality SF binders and assist in promoting the evolution of the SF manufacturing technology in regards to LIBs.

As a popular energy storage equipment, lithium-ion batteries (LIBs) have many advantages, such as high energy density and long cycle life. At this stage, with the increasing demand for energy storage materials, the industrialization of batteries is facing new challenges such as enhancing efficiency, reducing energy consumption, and improving battery performance. In particular, the challenges mentioned above are particularly critical in advanced next-generation battery manufacturing. For batteries, the electrode processing process plays a crucial role in advancing lithium-ion battery technology and has a significant impact on battery energy density, manufacturing cost, and yield. Dry electrode technology is an emerging technology that has attracted extensive attention from both academia and the manufacturing industry due to its unique advantages and compatibility. This paper provides a detailed introduction to the development status and application examples of various dry electrode technologies. It discusses the latest advancements in commonly used binders for different dry processes and offers insights into future electrode manufacturing.

The use of silicon (Si) as a lithium-ion battery’s (LIBs) anode active material has been a popular subject of research, due to its high theoretical specific capacity (4200 mAh g⁻¹). However, the volume of Si undergoes a huge expansion (300%) during the charging and discharging process of the battery, resulting in the destruction of the anode’s structure and the rapid decay of the battery’s energy density, which limits the practical application of Si as the anode active material. Lithium-ion batteries’ capacity, lifespan, and safety can be increased through the efficient mitigation of Si volume expansion and the maintenance of the stability of the electrode’s structure with the employment of polymer binders. The main degradation mechanism of Si-based anodes and the methods that have been reported to effectively solve the Si volume expansion problem firstly are introduced. Then, the review demonstrates the representative research work on the design and development of new Si-based anode binders to improve the cycling stability of Si-based anode structure from the perspective of binders, and finally concludes by summarizing and outlining the progress of this research direction.

Solid-state electrolytes (SSEs), particularly garnet-type Li_6.4La₃Zr_1.4Ta_0.6O₁₂ (LLZTO), offer high stability and a wide electrochemical window. However, their grain boundaries limit ionic conductivity, necessitating high-temperature sintering for improved performance. Yet, this process results in brittle electrolytes prone to fracture during manufacturing. To address these difficulties, solvent-free solid-state electrolytes with a polyacrylonitrile (PAN) coating on LLZTO particles are reported in this work. Most notably, the PAN-coated LLZTO (PAN@LLZTO) electrolyte demonstrates self-supporting characteristics, eliminating the need for high-temperature sintering. Importantly, the homogeneous polymeric PAN coating, synthesized via the described method, facilitates efficient Li⁺ transport between LLZTO particles. This electrolyte not only achieves an ionic conductivity of up to 2.11 × 10⁻³ S cm⁻¹ but also exhibits excellent interfacial compatibility with lithium. Furthermore, a lithium metal battery incorporating 3% PAN@LLZTO-3%PTFE as the solid-state electrolyte and LiFePO₄ as the cathode demonstrates a remarkable specific discharge capacity of 169 mAh g⁻¹ at 0.1 °C. The strategy of organic polymer-coated LLZTO provides the possibility of a green manufacturing process for preparing room-temperature sinter-free solid-state electrolytes, which shows significant cost-effectiveness.

Phenazine-based redox-active centers are capable of averting chemical bond rearrangements by coupling during the reaction process, leading to enhanced stabilization of the material. When introduced into a high-performance polymer with excellent physicochemical properties, they can be endowed with electrochemical properties and related prospective applications while maintaining the capabilities of the materials. In this study, a facile C-N coupling method was chosen for the synthesis of serial poly(aryl ether sulfone) materials containing phenazine-based redox-active centers and to explore their electrochemical properties. As expected, the cyclic voltammetry curves of PAS-DPPZ-60, which basically overlap after thousands of cycles, indicate the stability of the electrochemical properties. As an electrochromic material, the transmittance change in PAS-DPPZ-60 exhibits only a slight attenuation after as long as 600 cycles. Meanwhile, as an organic battery cathode material, PAS-DPPZ has a theoretical specific capacity of 126 mAh g⁻¹, and the capacity retention rate is 82.6% after 100 cycles at a 0.1 C current density. The perfect combination of advantageous features between phenazine and poly(aryl ether sulfone) is considered to be the reason for the favorable electrochemical performance of the material series.