Impact of CB dispersion on the performance of lithium-ion battery cathodes

Lithium-ion battery electrode performance is heavily dependent on the carbon binder domain. Both, experimental and simulation studies have affirmed its substantial impact on electrode properties, yet a precise quantification remains challenging. This study uses a co-rotating twin-screw extruder to adjust the carbon binder domain by varying mixing intensity. Employing the Carbon Black Dispersion Index (DICB), we quantitatively evaluate changes in carbon black (CB) particle size and their impact on electrodes and cells. The results highlight the crucial role of CB dispersion in shaping the carbon binder domain. The correlation of the DICB with electrode properties reveals an optimal dispersion intensity range, especially for rate capability and ionic resistance. Customizing the dispersion process using DICB led to a remarkable 26 % enhancement in specific discharge capacity at high C-rates. This research emphasizes DICB's significance in optimizing electrode performance and offers a novel approach to tailor the dispersion process for more efficient lithium-ion battery electrodes. Such tailored approaches hold promise for creating greener energy storage solutions, with implications for industrial applications, process scaling, and quality control procedures.