DEVELOPMENT AND APPLICATION OF DRY PARTICLE FLAKING FOR LI-ION BATTERY ELECTRODE MATERIALS

Abstract

This thesis explores dry particle flaking (DPF) as a particle engineering strategy to improve electrode packing and volumetric energy density in Li-ion batteries. Conventional cathode materials, including layered oxides and olivine phosphates, are limited to irregular secondary particle morphologies that hinder efficient packing during electrode fabrication. DPF, implemented using mechanofusion processing, which enables the formation of flake-shaped particles with enhanced packing characteristics. The effects of this approach are investigated across multiple material systems, including LiFePO4, LiMn0.8Fe0.2PO4 and LiNi0.6Mn0.2Co0.2O2, with emphasis on morphology control, structural stability, and electrochemical performance. Testing results demonstrated that flake-type materials enable high-density electrodes with reduced porosity while maintaining favourable capacity and cycling behaviour. These results highlight the importance of particle morphology in electrode design and establish DPF as a promising route for improving Li-ion battery performance.