Manufacturing thick electrodes for Li-ion batteries is a challenging task to fulfill, but leads to higher energy densities inside the cell. Water-based processing even adds an extra level of complexity to the procedure. The focus of this work is to implement a multi-layered coating in an industrially relevant process, to overcome issues in electrode integrity and to enable high electrochemical performance. LiNi${}_{0.8}$Mn${}_{0.1}$Co${}_{0.1}$O${}_2$ (NMC811) was used as the active material to fabricate single- and multi-layered cathodes with areal capacities of 8.6 mA h cm⁻². A detailed description of the manufacturing process is given to establish thick defect-free aqueous electrodes. Good inter-layer cohesion and adhesion to the current collector foil are achieved by multi-layering, as confirmed by optical analysis and peel testing. Furthermore, full cells were assembled and rate capability tests were performed. These tests show that by multi-layering, an increase in specific discharge capacity (e.g., 20.7% increase for C/10) can be established for all tested C-rates.

The aqueous processing of cathode materials for lithium-ion batteries (LIBs) has both environmental and cost benefits. However, high-loading, water-based electrodes from the layered oxides (e.g., NMC) typically exhibit worse electrochemical performance than NMP-based electrodes. In this work, primary, binary, and ternary binder mixtures of aqueous binders such as CMC, PAA, PEO, SBR, and Na alginate, in combination with bare and C-coated Al current collectors, were explored, aiming to improve the rate capability performance of NMC811 electrodes with high areal capacity (≥4 mAh cm⁻²) and low binder content (3 wt.%). Electrodes with a ternary binder composition (CMC:PAA:SBR) have the best performance with bare Al current collectors, attaining a specific capacity of 150 mAh g⁻¹ at 1C. Using carbon-coated Al current collectors results in improved performance for both water- and NMP-based electrodes. This is further accentuated for Na-Alg and CMC:PAA binder compositions. These electrodes show specific capacities of 170 and 80 mAh g⁻¹ at 1C and 2C, respectively. Although the specific capacities at 1C are comparable to those for NMP-PVDF electrodes, they are approximately 50% higher at the 2C rate. This study aims to contribute to the development of sustainably processed NMC electrodes for high energy density LIBs using water as solvent.

SnS₂‐based anode active materials for lithium‐ion battery applications are synthesized with varying degrees of crystallinity via a hydrothermal method, and their electrochemical performance properties are assessed. Different ratios of tin chloride and thioacetamide precursors are used and studied to control the crystallization. In situ electrochemical impedance spectroscopy and galvanostatic intermittent titration technique experiments are used to study the lithium‐ion diffusion kinetics into the crystal structures and the conversion reaction mechanisms for discharge up to x ≈ 2.08 moles of lithiation per SnS₂, equivalent to a discharge capacity of 300 mAh g⁻¹. Transmission electron microscopy reveals the presence of amorphous and crystalline domains, as well as the existence of additional Sn₂S₃ layers on one of the samples. The highest specific reversible capacity during cycling and rate performance are 598 mAh g⁻¹ after 100 cycles and 605 mAh g⁻¹ after rate capability test, which are obtained for the samples prepared with the 1:4 tin chloride to thioacetamide ratio.