Research Projects

This proposed research aimed to address critical challenges in developing high energy density sodium-ion batteries (SIBs) by using a novel dry battery electrode (DBE) process for thick electrodes. Traditional solvent-based drying processes often lead to microstructural heterogeneity, with binder migration disrupting uniformity. While solvent-free approach as proposed dry electrode fabrication (DBE) are well-suited for scaling up, as they eliminate toxic solvents, reduce costs, and contribute to an environmentally friendly manufacturing enabling scalability. The research focuses on optimizing sodium-based electrode materials, specifically Na₃V₂(PO₄)₃ (NVP) cathodes and hard carbon (HC) anodes, tailored to the unique characteristics of stable capacity and voltages. These two materials are optimal candidates for studying thickness effects, with the goal of achieving an optimal thickness for enhanced sodium-ion diffusion. Both materials are abundant and cost-effective, making them ideal for scalable, sustainable SIB production and for use in the dry electrode-making process.The methodology involves a systematic powder-to-film fabrication process to achieve high-mass-loading electrodes with areal capacities exceeding 6.0 mAh/cm², utilizing innovative combinations of conductive additives (carbon black, SWCNTs, MWCNTs, graphene) and binders (PTFE, PVDF, etc). Thick electrodes of NVP and HC will be extensively characterized for structural, mechanical, and electrochemical performance, including studies on ion transport and interface stability. The final stage of the project involves assembling and testing proof of concept SIB full cells in pouch configurations to validate the scalability and efficiency of the DBE process. By addressing the pressing need for cost-effective, sustainable, and scalable energy storage technologies, this work aligns with India’s Energy Storage Mission and contributes to renewable energy integration and grid-scale storage, paving the way for eco-friendly battery manufacturing.