Performance optimization of freestanding MWCNT-LiFePO₄ sheets as cathodes for improved specific capacity of lithium-ion batteries

The typical lithium-ion-battery positive electrode of "lithium-iron phosphate (LiFePO₄) on aluminum foil" contains a relatively large amount of inactive materials of 29 wt% (22 wt% aluminum foil + 7 wt% polymeric binder and graphitic conductor) which limits its maximum specific capacity to 120.7 mA h g^-1 (71 wt% LiFePO₄) instead of 170 mA h g^-1 (100 wt% LiFePO₄). We replaced the aluminum current-collector with a multi-walled carbon nanotube (MWCNT) network. We optimized the specific capacity of the "freestanding MWCNT-LiFePO₄" positive electrode. Through the optimization of our unique surface-engineered tape-cast fabrication method, we demonstrated the amount of LiFePO₄ active materials can be as high as 90 wt% with a small amount of inactive material of 10 wt% MWCNTs. This translated to a maximum specific capacity of 153 mA h g^-1 instead of 120.7 mA h g^-1, which is a significant 26.7% gain in specific capacity compared to conventional cathode design. Experimental data of the freestanding MWCNT-LiFePO₄ at a low discharge rate of 17 mA g^-1 show an excellent specific capacity of 144.9 mA h g^-1 which is close to its maximum specific capacity of 153 mA h g^-1. Furthermore, the freestanding MWCNT-LiFePO₄ has an excellent specific capacity of 126.7 mA h g^-1 after 100 cycles at a relatively high discharge rate of 170 mA g^-1 rate.