Objective:

To develop a method for mapping polymer binders in lithium-ion battery anodes at the nanoscale to optimize manufacturing processes.

Key Findings:

• CMC formed continuous surface films as thin as 10–15 nm in pristine graphite anodes.
• SBR appeared as discrete nanoparticle agglomerates.
• Calendering caused CMC layers to fracture and delaminate, exposing bare graphite.
• Commercial electrodes showed similar disrupted binder morphologies.
• Optimized slurry mixing reduced electronic resistivity by 14%.
• Phase-inversion processing reduced ionic resistance by approximately 40%.

Interpretation:

Direct visualization of binder distribution allows for better understanding of how processing choices affect electrode performance, facilitating quality control and optimization.

Limitations:

• The study primarily focuses on CMC and SBR binders, which may not represent all binder systems.
• The effects observed may vary with different manufacturing conditions and materials.

Conclusion:

The developed staining methods provide insights into binder microstructure, supporting improvements in lithium-ion battery manufacturing and performance.