In recent years, batteries have revolutionized electrification projects and accelerated the energy transition. Consequently, battery systems were hugely demanded based on large-scale electrification projects, leading to significant interest in low-cost and more abundant chemistries to meet these requirements in lithium-ion batteries (LIBs). As a result, lithium iron phosphate (LFP) share has increased considerably due to lower cost and higher safety compared to conventional nickel and cobalt-based chemistries. However, their fast-growing share is affected by updated chemistries, where cheaper systems like sodium-ion batteries (SIBs) are becoming more attractive. SIBs also benefited from the greener, more ethical, and evenly distributed elemental resources. SIBs are fast approaching market thanks to mature LIB’s technology and manufacturing scalability using existing Li-ion gigafactories. Additionally, SIBs can be adapted to other emerging technologies, including Li-ion batteries and silicon-based anodes, influencing projections for their broader use. However, despite the lower cost and abundance of sodium chemistries compared to lithium ones, limited manufacturing capacity discourages material suppliers from increasing production, which restricts the supply chain, raises costs, and diminishes Na battery manufacturing. Here, we aim to provide an overview of the progress of SIBs in gaining market share from LIBs. We first reviewed LIB and SIB histories, developments, and market share. Then, we analyzed the offered chemicals in battery components, their resources and supplies, material demand, and supply chain. The commercialization of each system was investigated in addition to the challenges related to energy density, environmental impact, sustainability, and safety. If all these concerns are addressed properly, LIBs and SIBs could potentially offer a more affordable, safer, and sustainable choice for the global energy storage outlook, particularly in short-range electric vehicles and stationary grid storage.

The pursuit of industrializing lithium-ion batteries (LIBs) with exceptional energy density and top-tier safety features presents a substantial growth opportunity. The demand for energy storage is steadily rising, driven primarily by the growth in electric vehicles and the need for stationary energy storage systems. However, the manufacturing process of LIBs, which is crucial for these applications, still faces significant challenges in terms of both financial and environmental impacts. Our review paper comprehensively examines the dry battery electrode technology used in LIBs, which implies the use of no solvents to produce dry electrodes or coatings. In contrast, the conventional wet electrode technique includes processes for solvent recovery/drying and the mixing of solvents like N-methyl pyrrolidine (NMP). Methods that use dry films bypass the need for solvent blending and solvent evaporation processes. The advantages of dry processes include a shorter production time, reduced energy consumption, and lower equipment investment. This is because no solvent mixing or drying is required, making the production process much faster and, thus, decreasing the price. This review explores three solvent-free dry film techniques, such as extrusion, binder fibrillation, and dry spraying deposition, applied to LIB electrode coatings. Emphasizing cost-effective large-scale production, the critical methods identified are hot melting, extrusion, and binder fibrillation. This review provides a comprehensive examination of the solvent-free dry-film-making methods, detailing the underlying principles, procedures, and relevant parameters.

The effects of global warming highlight the urgent need for effective solutions to this problem. The electrification of society, which occurs through the widespread adoption of electric vehicles (EVs), is a critical strategy to combat climate change. Lithium-ion batteries (LIBs) are vital components of the global energy-storage market for EVs, and sodium-ion batteries (SIBs) have gained renewed interest owing to their potential for rapid growth. Improved safety and stability have also put solid-state batteries (SSBs) on the chart of top batteries in the world. This review examines three critical battery technologies: LIBs, SIBs, and SSBs. Although research has historically concentrated on heavier battery components, such as electrodes, to achieve high gravimetric density, binders, which comprise less than 5% of the battery weight, have demonstrated great promise for meeting the increasing need for energy storage. This review thoroughly examines various binders, focusing on their solubilities in water and organic solvents. Understanding binder mechanisms is crucial for developing binders that maintain strong adhesion to electrodes, even during volume fluctuations caused by lithiation and delithiation. Therefore, we investigated the different mechanisms associated with binders. This review also discusses failure mechanisms and innovative design strategies to improve the performance of binders, such as composite, conductive, and self-healing binders. By investigating these fields, we hope to develop energy storage technologies that are more dependable and efficient while also helping to satisfy future energy needs.

Since their discovery over two decades ago, carbon nanotubes (CNTs) have captivated researchers due to their exceptional electrical, optical, mechanical, and thermal properties, making them versatile candidates for various advanced applications. CNTs have transformed numerous scientific domains, including nanotechnology, electronics, materials science, and biomedical engineering. Their applications range from nanoelectronics, robust nanocomposites, and energy storage devices to innovative materials, sensors, conducting polymers, field emission sources, and Li-ion batteries. Furthermore, CNTs have found critical roles in biosensing, water purification, bone scaffolding, and targeted gene and drug delivery. The chemical reactivity and functional versatility of CNTs are profoundly influenced by their structural and physicochemical properties, such as surface area, surface charge, size distribution, surface chemistry, and purity. This review comprehensively explores the current state of CNT research, focusing on widely used synthesis, purification, and characterization techniques alongside emerging applications. By highlighting recent advancements and addressing unresolved challenges, it aims to present a novel perspective on the transformative potential of CNTs, fostering innovation across diverse scientific and technological fields.

The increasing global population and, thus, energy demand have made research into renewable energy sources more critical. Lithium-ion batteries (LIBs) and sodium-ion batteries (SIBs) have been recognized as the most promising technologies for storing energy and effectively addressing this demand. Carbonaceous materials are the most widespread anode material due to their fascinating features, such as high theoretical capacity, high electrical conductivity, and excellent structural stability. Additionally, these materials’ abundance, cost-effectiveness, and environmental friendliness have emphasized the need for further investigation and development. Among these carbon-based materials, graphite (both artificial and natural) stands out as the most ubiquitous anode material due to its layered crystal structure, high mechanical strength, long cycle life, and excellent safety profile, making it ideal for intercalation with lithium and sodium. In recent years, extensive research has been conducted to enhance the efficiency of anodes and, ultimately, the overall performance of batteries. In this review, the role of carbonaceous materials in anodes for lithium-ion and sodium-ion batteries was comprehensively investigated, focusing on advancements in synthesizing and optimizing artificial graphite. Furthermore, the intercalation mechanism and the factors influencing the electrochemical properties of both LIBs and SIBs were extensively discussed. This work also provides a holistic perspective on the differences between these two types of batteries, highlighting their cost, safety applications, and future potential advancement.

Solid-state batteries (SSBs) have been recognized as promising energy storage devices for the future due to their high energy densities and much-improved safety compared with conventional lithium-ion batteries (LIBs), whose shortcomings are widely troubled by serious safety concerns such as flammability, leakage, and chemical instability originating from liquid electrolytes (LEs). These challenges further deteriorate lithium metal batteries (LMBs) through dendrite growth and undesirable parasitic reactions. Polymer electrolytes (PEs) have been considered among the few viable options that have attracted great interest because of their inherent non-flammability, excellent flexibility, and wide electrochemical stability window. However, practical applications are seriously limited due to the relatively low ionic conductivity, mechanical instability, and short operational life cycle. This review covers the recent developments in the field and applications of polymer electrolytes in SSBs, including solid polymer electrolytes (SPEs), gel polymer electrolytes (GPEs), and composite polymer electrolytes (CPEs). The discussion comprises the key synthesis methodologies, electrochemical evaluation, and fabrication of PEs while examining lithium-ion’s solvation and desolvation processes. Finally, this review highlights innovations in PEs for advanced technologies like lithium metal batteries and beyond, covering emerging trends in polymer materials and advancements in PE performance and stability to enhance commercial applications.