Porous LiFePO4 Cathode Synthesized via Spray Drying for Enhanced Electrochemical Performance

In this study, a rough-surfaced LiFePO4 (RS-LFP) cathode material with a well-defined porous architecture was successfully synthesized via a scalable, template-assisted spray drying method. The resulting RS-LFP exhibited a high specific surface area of 41.2 m2 g−1, significantly enhancing electrode–electrolyte contact. This tailored microstructure, combined with an in-situ-formed carbon network, reduced the charge-transfer resistance and facilitated efficient ion/electron transport. Consequently, the RS-LFP demonstrated outstanding electrochemical performance, including a high initial capacity of ~140 mAh g−1 at 0.2 C, excellent cycling stability with over 95% capacity retention after 30 cycles, and superior rate capability. The RS-LFP also exhibited a remarkable capacity recovery of ~99% when the current returned to 0.2 C. These findings highlight that engineering porous architectures through template-assisted spray drying is a promising and scalable strategy for developing high-performance phosphate-based cathodes for advanced energy storage applications.