Advancing Manufacturing and High Energy Density Batteries Through Electrode and Binder Innovation

Abstract:  

As the global demand for high-energy-density storage scales, the transition from laboratory innovation to industrial-scale manufacturing remains a primary bottleneck. Electrode binders, often viewed as “inactive” components, are in fact the linchpins of successful battery production. They dictate the slurry property, coating quality, and mechanical integrity of the electrode—factors that ultimately determine manufacturing yield and device longevity. This seminar will explore how innovations in electrode and binder chemistry are driving the next generation of battery manufacturing. We will move beyond traditional passive binders to discuss the development of multifunctional conductive polymers that provide simultaneous ionic and electronic transport. A central focus will be the “manufacturability” of high-capacity materials like silicon (Si) and tin (Sn) alloys. While these materials offer a leap in energy density compared to traditional graphite, their massive volume expansion during cycling creates extreme mechanical stress that often leads to electrode failure. Dr. Liu will detail how specifically engineered conductive polymer binders can mitigate these stresses through enhanced adhesion and connectivity, enabling the use of high-loading composite electrodes in lithium-ion, sodium-ion, and solid-state systems. Furthermore, the talk will address how these molecular designs facilitate more efficient battery recycling and circularity—essential components of a sustainable manufacturing ecosystem. By aligning molecular design principles with large-scale processing requirements, this research provides a path toward the cost-effective production of high-performance energy storage systems.

Bio:

Dr. Gao Liu is a Senior Scientist and Group Leader of the Applied Energy Materials Group at Lawrence Berkeley National Laboratory (LBNL). A Fellow of the Electrochemical Society (ECS) and the Royal Society of Chemistry (RSC), Dr. Liu has over 25 years of leadership in electrical energy storage, with a specific focus on bridging the gap between fundamental synthetic chemistry and advanced battery manufacturing. His research integrates composite engineering and electrochemistry to solve the interdisciplinary challenges of high-energy-density systems. Dr. Liu is globally recognized for pioneering multifunctional conductive polymer adhesives, research that has fundamentally changed how the industry approaches binder behavior in composite electrodes. His current portfolio extends beyond material design to include building resiliency, the circular economy, and the scaling of advanced manufacturing processes for silicon, sulfur, and lithium-metal chemistries. With over 200 peer-reviewed publications and 29 patents, his work provides the blueprints for the rational design of functional materials that are both high-performing and manufacturable. Dr. Liu is the recipient of the 2025 Battery Division Technology Award from the ECS and the 2025 Outstanding Alumni Award for Natural Science from Michigan State University, where he earned his Ph.D. in 2001.