Acoustic Particle Patterning Aided by Phase‐inversion for Efficient Structuring of Low‐Tortuosity Battery Electrodes

Abstract Texturing the battery electrode to create low‐tortuosity ordered structures can significantly improve the sluggish mass transport in thick electrodes (areal mass loading>20 mg/cm 2 ) during the energy storage electrochemical reactions. In this work, we presented an efficient and effective method to regulate the electrode structure by creating aligned channels throughout the thickness of the electrode. The method combines acoustic manipulation of particles and nonsolvent induced phase inversion and is highly compatible with a wide range of materials used in various battery chemistries. The textured electrodes show better structural integrity compared to electrodes of similar mass loading made with acoustic patterning only and with conventional solution casting. Compared with electrodes made with phase inversion only, it exhibits lower tortuosity, enhanced ion transport/kinetics, better rate capability and cyclic stability.