Ultrahigh loading dry-process for solvent-free lithium-ion battery electrode fabrication

Polymer design for solid-state batteries and wearable electronics

Solid-state batteries are increasingly centre-stage for delivering more energy-dense, safer batteries to follow current lithium-ion rechargeable technologies. At the same time, wearable electronics powered by flexible batteries have experienced rapid technological growth. This perspective discusses the role that polymer design plays in their use as solid polymer electrolytes (SPEs) and as binders, coatings and interlayers to address issues in solid-state batteries with inorganic solid electrolytes (ISEs). We also consider the value of tunable polymer flexibility, added capacity, skin compatibility and end-of-use degradability of polymeric materials in wearable technologies such as smartwatches and health monitoring devices. While many years have been spent on SPE development for batteries, delivering competitive performances to liquid and ISEs requires a deeper understanding of the fundamentals of ion transport in solid polymers. Advanced polymer design, including controlled (de)polymerisation strategies, precision dynamic chemistry and digital learning tools, might help identify these missing fundamental gaps towards faster, more selective ion transport. Regardless of the intended use as an electrolyte, composite electrode binder or bulk component in flexible electrodes, many parallels can be drawn between the various intrinsic polymer properties. These include mechanical performances, namely elasticity and flexibility; electrochemical stability, particularly against higher-voltage electrode materials; durable adhesive/cohesive properties; ionic and/or electronic conductivity; and ultimately, processability and fabrication into the battery. With this, we assess the latest developments, providing our views on the prospects of polymers in batteries and wearables, the challenges they might address, and emerging polymer chemistries that are still relatively under-utilised in this area.

Facile Lithium Densification Kinetics by Hyperporous/Hybrid Conductor for High-Energy-Density Lithium Metal Batteries

Lithium metal anode (LMA) emerges as a promising candidate for lithium (Li)-based battery chemistries with high-energy-density. However, inhomogeneous charge distribution from the unbalanced ion/electron transport causes dendritic Li deposition, leading to "dead Li" and parasitic reactions, particularly at high Li utilization ratios (low negative/positive ratios in full cells). Herein, an innovative LMA structural model deploying a hyperporous/hybrid conductive architecture is proposed on single-walled carbon nanotube film (HCA/C), fabricated through a nonsolvent induced phase separation process. This design integrates ionic polymers with conductive carbon, offering a substantial improvement over traditional metal current collectors by reducing the weight of LMA and enabling high-energy-density batteries. The HCA/C promotes uniform lithium deposition even under rapid charging (up to 5 mA cm-2) owing to its efficient mixed ion/electron conduction pathways. Thus, the HCA/C demonstrates stable cycling for 200 cycles with a low negative/positive ratio of 1.0 when paired with a LiNi0.8Co0.1Mn0.1O2 cathode (areal capacity of 5.0 mAh cm-2). Furthermore, a stacked pouch-type full cell using HCA/C realizes a high energy density of 344 Wh kg-1 cell/951 Wh L-1 cell based on the total mass of the cell, exceeding previously reported pouch-type full cells. This work paves the way for LMA development in high-energy-density Li metal batteries.

Fusion Bonding Technique for Solvent-Free Fabrication of All-Solid-State Battery with Ultrathin Sulfide Electrolyte

For preparing next-generation sulfide all-solid-state batteries (ASSBs), the solvent-free manufacturing process has huge potential for the advantages of economic, thick electrode, and avoidance of organic solvents. However, the dominating solvent-free process is based on the fibrillation of polytetrafluoroethylene, suffering from poor mechanical property and electrochemical instability. Herein, a continuously solvent-free paradigm of fusion bonding technique is developed. A percolation network of thermoplastic polyamide (TPA) binder with low viscosity in viscous state is constructed with Li6PS5Cl (LPSC) by thermocompression (≤5 MPa), facilitating the formation of ultrathin LPSC film (≤25 µm). This composite sulfide film (CSF) exhibits excellent mechanical properties, ionic conductivity (2.1 mS cm-1), and unique stress-dissipation to promote interface stabilization. Thick LiNi0.83Co0.11Mn0.06O2 cathode can be prepared by this solvent-free method and tightly adhered to CSF by interfacial fusion of TPA for integrated battery. This integrated ASSB shows high-energy-density feasibility (>2.5 mAh cm-2 after 1400 cycles of 9200 h and run for more than 10 000 h), and energy density of 390 Wh kg-1 and 1020 Wh L-1. More specially, high-voltage bipolar cell (≥8.5 V) and bulk-type pouch cell (326 Wh kg-1) are facilely assembled with good cycling performance. This work inspires commercialization of ASSBs by a solvent-free method and provides beneficial guiding for stable batteries.

Enhancing Electrode Performance through Triple Distribution Modulation of Active Material, Conductive Agent, and Porosity

The increasing demand for large-scale energy storage propels the development of lithium-ion batteries with high energy and high power density. Low tortuosity electrodes with aligned straight channels have proved to be effective in building such batteries. However, manufacturing such low tortuosity electrodes in large scale remains extremely challenging. In contrast, high-performance electrodes with customized gradients of materials and porosity are possible to be made by industrial roll-to-roll coating process. Yet, the desired design of gradients combining materials and porosity is unclear for high-performance gradient electrodes. Here, triple gradient LiFePO4 electrodes (TGE) are fabricated featuring distribution modulation of active material, conductive agent, and porosity by combining suction filtration with the phase inversion method. The effects and mechanism of active material, conductive agent, and porosity distribution on electrode performance are analyzed by experiments. It is found that the electrode with a gradual increase of active material content from current collector to separator coupled with the distribution of conductive agent and porosity in the opposite direction, demonstrates the best rate capability, the fastest electrochemical reaction kinetics, and the highest utilization of active material. This work provides valuable insights into the design of gradient electrodes with high performance and high potential in application.

Bottom Deposition Enables Stable All-Solid-State Batteries with Ultrathin Lithium Metal Anode

Modern strides in energy storage underscore the significance of all-solid-state batteries (ASSBs) predicated on solid electrolytes and lithium (Li) metal anodes in response to the demand for safer batteries. Nonetheless, ASSBs are often beleaguered by non-uniform Li deposition during cycling, leading to compromised cell performance from internal short circuits and hindered charge transfer. In this study, the concept of "bottom deposition" is introduced to stabilize metal deposition based on the lithiophilic current collector and a protective layer composed of a polymeric binder and carbon black. The bottom deposition, wherein Li plating ensues between the protective layer and the current collector, circumvents internal short circuits and facilitates uniform volumetric changes of Li. The prepared functional binder for the protective layer presents outstanding mechanical robustness and adhesive properties, which can withstand the volume expansion caused by metal growth. Furthermore, its excellent ion transfer properties promote uniform Li bottom deposition even under a current density of 6 mA·cm-2. Also, scanning electron microscopy analysis reveals a consistent plating/stripping morphology of Li after cycling. Consequently, the proposed system exhibits enhanced electrochemical performance when assessed within the ASSB framework, operating under a configuration marked by a high Li utilization rate reliant on an ultrathin Li.

Aliphatic Polycarbonate-Based Binders for High-Loading Cathodes by Solvent-Free Method Used in High Performance LiFePO4|Li Batteries

The binder ratio in a commercial lithium-ion battery is very low, but it is one of the key materials affecting the battery's performance. In this paper, polycarbonate-based polymers with liner or chain extension structures are proposed as binders. Then, dry LiFePO4 (LFP) electrodes with these binders are prepared using the solvent-free method. Polycarbonate-based polymers have a high tensile strength and a satisfactory bonding strength, and the rich polar carbonate groups provide highly ionic conductivity as binders. The batteries with poly (propylene carbonate)-plus (PPC-P) as binders were shown to have a long cycle life (350 cycles under 1 C, 89% of capacity retention). The preparation of dry electrodes using polycarbonate-based polymers can avoid the use of solvents and shorten the process of preparing electrodes. It can also greatly reduce the manufacturing cost of batteries and effectively use industrial waste gas dioxide oxidation. Most importantly, a battery material with this kind of polycarbonate polymer as a binder is easily recycled by simply heating after the battery is discarded. This paper provides a new idea for the industrialization and development of a novel binder.

New insights into algal-bacterial sludge granulation based on the tightly-bound extracellular polymeric substances regulation in response to N-Methylpyrrolidone

Algal-bacterial granular sludge (ABGS) system is promising in wastewater treatment for its potential in energy-neutrality and carbon-neutrality. However, traditional cultivation of ABGS poses significant challenges attributable to its long start-up period and high energy consumption. Extracellular polymeric substances (EPS), which could be stimulated as a self-defense strategy in cells under toxic contaminants stress, has been considered to contribute to the ABGS granulation process. In this study, photogranulation of ABGS by EPS regulation in response to varying loading rates of N-Methylpyrrolidone (NMP) was investigated for the first time. The results indicated the formation of ABGS with a maximum average diameter of ∼3.3 mm and an exceptionally low SVI5 value of 67 ± 2 mL g-1 under an NMP loading rate of 125 mg L-1 d-1, thereby demonstrating outstanding settleability. Besides, almost complete removal of 300 mg L-1 NMP could be achieved at hydraulic retention time of 48 h, accompanied by chemical oxygen demand (COD) and total nitrogen (TN) removal efficiencies higher than 90 % and 70 %, respectively. Moreover, possible degradation pathway and metabolism mechanism in the ABGS system for enhanced removal of NMP and nitrogen were proposed. In this ABGS system, the mycelium with network structure constituted by filamentous microorganisms was a prerequisite for photogranulation, instead of necessarily leading to granulation. Stress of 100-150 mg L-1 d-1 NMP loading rate stimulated tightly-bound EPS (TB-EPS) variation, resulting in rapid photogranulation. The crucial role of TB-EPS was revealed with the involved mechanisms being clarified. This study provides a novel insight into ABGS development based on the TB-EPS regulation by NMP, which is significant for achieving the manipulation of photogranules.

MoS2, WS2, and MoWS2 Flakes as Reversible Host Materials for Sodium-Ion and Potassium-Ion Batteries

Transition-metal dichalcogenides (TMDs) and their alloys are vital for the development of sustainable and economical energy storage alternatives due to their large interlayer spacing and hosting ability for alkali-metal ions. Although the Li-ion chemically correlates with the Na-ion and K-ion, research on batteries with TMD anodes for K+ is still in its infancy. This research explores TMDs such as molybdenum disulfide (MoS2) and tungsten disulfide (WS2) and TMD alloys such as molybdenum tungsten disulfide (MoWS2) for both sodium-ion batteries (NIBs) and potassium-ion batteries (KIBs). The cyclic stability test analysis indicates that in the initial cycle, the MoS2 NIB demonstrates exceptional performance, with a peak charge capacity of 1056 mAh g-1, while retaining high Coulombic efficiency. However, the WS2 KIB underperforms, with the least charge capacity of 130 mAh g-1 in the first cycle and exceptionally low retention at a current density of 100 mA g-1. The MoWS2 TMD alloy exhibits a moderate charge capacity and cyclic efficiency for both NIBs and KIBs. This comparison study shows that decreasing sizes of alkali-metal ions and constituent elements in TMDs or TMD alloys leads to decreased resistance and slower degradation processes as indicated by cyclic voltammetry and electrochemical impedance spectroscopy after 10 cycles. Furthermore, the study of probable electrochemical intercalation and removal processes of Na-ions and K-ions demonstrates that large geometrically shaped TMD flakes are more responsive to intercalation for Na-ions than K-ions. These performance comparisons of different TMD materials for NIBs and KIBs may promote the future development of these batteries.

Shear force effect of the dry process on cathode contact coverage in all-solid-state batteries

The state-of-the-art all-solid-state batteries have emerged as an alternative to the traditional flammable lithium-ion batteries, offering higher energy density and safety. Nevertheless, insufficient intimate contact at electrode-electrolyte surface limits their stability and electrochemical performance, hindering the commercialization of all-solid-state batteries. Herein, we conduct a systematic investigation into the effects of shear force in the dry electrode process by comparing binder-free hand-mixed pellets, wet-processed electrodes, and dry-processed electrodes. Through digitally processed images, we quantify a critical factor, 'coverage', the percentage of electrolyte-covered surface area of the active materials. The coverage of dry electrodes was significantly higher (67.2%) than those of pellets (30.6%) and wet electrodes (33.3%), enabling superior rate capability and cyclability. A physics-based electrochemical model highlights the effects of solid diffusion by elucidating the impact of coverage on active material utilization under various current densities. These results underscore the pivotal role of the electrode fabrication process, with the focus on the critical factor of coverage.

Designing Reliable Cathode System for High-Performance Inorganic Solid-State Pouch Cells

All-solid-state batteries (ASSBs) based on inorganic solid electrolytes fascinate a large body of researchers in terms of overcoming the inferior energy density and safety issues of existing lithium-ion batteries. To date, the cathode designs in the ASSBs achieve remarkable achievements, adding the urgency of scaling up the battery system toward inorganic solid-state pouch cell configuration for the application market. Herein, the recent developments of cathode materials and the design considerations for their application in the pouch cell format are reviewed to straighten out the roadmap of ASSBs. Specifically, the intercalation compounds and the conversion materials with conversion chemistries are highlighted and discussed as two potentially valuable material types. This review focuses on the basic electrochemical mechanisms, mechanical contact issues, and sheet-type structure in inorganic solid-state pouch cells with corresponding perspectives, thus guiding the future research direction. Finally, the benchmarks for manufacturing inorganic solid-state pouch cells to meet practical high energy density targets are provided in this review for the development of commercially viable products.

Architecting the Microenvironment Skeleton of Active Materials in High-Capacity Electrodes by Self-Assembled Nano-Building Blocks

In analogy to the cell microenvironment in biology, understanding and controlling the active-material microenvironment (ME@AM) microstructures in battery electrodes is essential to the successes of energy storage devices. However, this is extremely difficult for especially high-capacity active materials (AMs) like sulfur, due to the poor controlling on the electrode microstructures. To conquer this challenge, here, a semi-dry strategy based on self-assembled nano-building blocks is reported to construct nest-like robust ME@AM skeleton in a solvent-and-stress-less way. To do that, poly(vinylidene difluoride) nanoparticle binder is coated onto carbon-nanofibers (NB@CNF) via the nanostorm technology developed in the lab, to form self-assembled nano-building blocks in the dry slurry. After compressed into an electrode prototype, the self-assembled dry-slurry is then bonded by in-situ nanobinder solvation. With this strategy, mechanically strong thick sulfur electrodes are successfully fabricated without cracking and exhibit high capacity and good C-rate performance even at a high AM loading (25.0 mg cm-2 by 90 wt% in the whole electrode). This study may not only bring a promising solution to dry manufacturing of batteries, but also uncover the ME@AM structuring mechanism with nano-binder for guiding the design and control on electrode microstructures.

High-Area-Capacity Cathode by Ultralong Carbon Nanotubes for Secondary Binder-Assisted Dry Coating Technology

Thick electrodes with high mass loading and increased content of active materials are critical for achieving higher energy density in contemporary lithium-ion batteries (LIBs). Nonetheless, producing thick electrodes through the commonly used slurry coating technology remains a formidable challenge. In this study, we have addressed this challenge by developing a dry electrode technology by using ultralong multiwalled carbon nanotubes (MWCNT) as a conductive additive and secondary binder. The mixing process of electrode compositions and the fibrillation process of the polytetrafluoroethylene (PTFE) binder were optimized. The resulting LiCoO2 (LCO) electrode exhibited a remarkable mass loading of 48 mg cm-2 and an active material content of 95 wt %. Notably, the thick LCO electrode demonstrated a superior mechanical strength and electrochemical performance. After 100 cycles at a current density of 1/3 C, the electrode still exhibited a capacity retention of 91% of its initial capacity. This dry electrode technology provides a practicable and scalable approach to the powder-to-film LIB electrode manufacturing process.

Dry Electrode Processing Technology and Binders

As a popular energy storage equipment, lithium-ion batteries (LIBs) have many advantages, such as high energy density and long cycle life. At this stage, with the increasing demand for energy storage materials, the industrialization of batteries is facing new challenges such as enhancing efficiency, reducing energy consumption, and improving battery performance. In particular, the challenges mentioned above are particularly critical in advanced next-generation battery manufacturing. For batteries, the electrode processing process plays a crucial role in advancing lithium-ion battery technology and has a significant impact on battery energy density, manufacturing cost, and yield. Dry electrode technology is an emerging technology that has attracted extensive attention from both academia and the manufacturing industry due to its unique advantages and compatibility. This paper provides a detailed introduction to the development status and application examples of various dry electrode technologies. It discusses the latest advancements in commonly used binders for different dry processes and offers insights into future electrode manufacturing.

High-Loading Lithium-Sulfur Batteries with Solvent-Free Dry-Electrode Processing

Lithium-sulfur (Li-S) batteries, with their high energy density, nontoxicity, and the natural abundance of sulfur, hold immense potential as the next-generation energy storage technology. To maximize the actual energy density of the Li-S batteries for practical applications, it is crucial to escalate the areal capacity of the sulfur cathode by fabricating an electrode with high sulfur loading. Herein, ultra-high sulfur loading (up to 12 mg cm-2 ) cathodes are fabricated through an industrially viable and sustainable solvent-free dry-processing method that utilizes a polytetrafluoroethylene binder fibrillation. Due to its low porosity cathode architecture formed by the binder fibrillation process, the dry-processed electrodes exhibit a relatively lower initial capacity compared to the slurry-processed electrode. However, its mechanical stability is well maintained throughout the cycling without the formation of electrode cracking, demonstrating significantly superior cycling stability. Additionally, through the optimization of the dry-processing, a single-layer pouch cell with a loading of 9 mg cm-2 and a novel multi-layer pouch cell that uses an aluminum mesh as its current collector with a total loading of 14 mg cm-2 are introduced. To address the reduced initial capacity of dry-processed electrodes, strategies such as incorporating electrocatalysts or employing prelithiated active materials are suggested.

Reprecipitation: A Rapid Synthesis of Micro-Sized Silicon-Graphene Composites for Long-lasting Lithium-Ion Batteries

Silicon microparticles (SiMPs) have gained significant attention as a lithium-ion battery anode material due to their 10 times higher theoretical capacity compared to conventional graphite anodes as well as their much lower production cost than silicon nanoparticles (SiNPs). However, SiMPs have suffered from poorer cycle life relative to SiNPs because their larger size makes them more susceptible to volume changes during charging and discharging. Creating a wrapping structure in which SiMPs are enveloped by carbon layers has proven to be an effective strategy to significantly improve the cycling performance of SiMPs. However, the synthesis processes are complex and time-/energy-consuming and therefore not scalable. In this study, a wrapping structure is created by using a simple, rapid, and scalable "modified reprecipitation method". Graphene oxide (GO) and SiMP dispersion in tetrahydrofuran is injected into n-hexane, in which GO and SiMP by themselves cannot disperse. GO and SiMP therefore aggregate and precipitate immediately after injection to form a wrapping structure. The resulting SiMP/GO film is laser scribed to reduce GO to a laser-scribed graphene (LSG). Simultaneously, SiOx and SiC protection layers form on the SiMPs through the laser process, which alleviates severe volume change. Owing to these desirable characteristics, the modified reprecipitation method successfully doubles the cycle life of SiMP/graphene composites compared to the simple physically mixing method (50.2% vs. 24.0% retention at the 100th cycle). The modified reprecipitation method opens a new synthetic strategy for SiMP/carbon composites.

Non-Electroconductive Polymer Coating on Graphite Mitigating Electrochemical Degradation of PTFE for a Dry-Processed Lithium-Ion Battery Anode

Polytetrafluoroethylene (PTFE)-based dry process for lithium-ion batteries is gaining attention as a battery manufacturing scheme can be simplified with drastically reducing environmental damage. However, the electrochemical instability of PTFE in a reducing environment has hampered the realization of the high-performance dry-processed anode. In this study, we present a non-electroconductive and highly ionic-conductive polymer coating on graphite to mitigate the electrochemical degradation of the PTFE binder and minimize the coating resistance. Poly(ethylene oxide) (PEO) and poly(vinylidene fluoride-trifluoroethylene-chlorofluoroethylene) (P(VDF-TrFE-CFE)) coatings on the anode material effectively inhibit the electron transfer from graphite to PTFE, thereby alleviating the PTFE breakdown. The graphite polymer coatings improved initial Coulombic efficiencies of full cells from 67.2% (bare) to 79.1% (PEO) and 77.8% (P(VDF-TrFE-CFE)) and increased initial discharge capacity from 157.7 mAh g(NCM)-1 (bare) to 185.1 mAh g(NCM)-1 (PEO) and 182.5 mAh g(NCM)-1 (P(VDF-TrFE-CFE)) in the full cells. These outcomes demonstrate that PTFE degradation in the anode can be surmounted by adjusting the electron transfer to the PTFE.

Polymeric Binder Design for Sustainable Lithium-Ion Battery Chemistry

The design of binders plays a pivotal role in achieving enduring high power in lithium-ion batteries (LIBs) and extending their overall lifespan. This review underscores the indispensable characteristics that a binder must possess when utilized in LIBs, considering factors such as electrochemical, thermal, and dispersion stability, compatibility with electrolytes, solubility in solvents, mechanical properties, and conductivity. In the case of anode materials, binders with robust mechanical properties and elasticity are imperative to uphold electrode integrity, particularly in materials subjected to substantial volume changes. For cathode materials, the selection of a binder hinges on the crystal structure of the cathode material. Other vital considerations in binder design encompass cost effectiveness, adhesion, processability, and environmental friendliness. Incorporating low-cost, eco-friendly, and biodegradable polymers can significantly contribute to sustainable battery development. This review serves as an invaluable resource for comprehending the prerequisites of binder design in high-performance LIBs and offers insights into binder selection for diverse electrode materials. The findings and principles articulated in this review can be extrapolated to other advanced battery systems, charting a course for developing next-generation batteries characterized by enhanced performance and sustainability.

Significant Strain Dissipation via Stiff-Tough Solid Electrolyte Interphase Design for Highly Stable Alloying Anodes

The pulverization of alloying anodes significantly restricts their use in lithium-ion batteries (LIBs). This study presents a dual-phase solid electrolyte interphase (SEI) design that incorporates finely dispersed Al nanoparticles within the LiPON matrix. This distinctive dual-phase structure imparts high stiffness and toughness to the integrated SEI film. In comparison to single-phase LiPON film, the optimized Al/LiPON dual-phase SEI film demonstrates a remarkable increase in fracture toughness by 317.8 %, while maintaining stiffness, achieved through the substantial dissipation of strain energy. Application of the dual-phase SEI film on an Al anode leads to a 450 % enhancement in cycling stability for lithium storage in dual-ion batteries. A similar enhancement in cycling stability for silicon anodes, which face severe volume expansion issues, is also observed, demonstrating the broad applicability of the dual-phase SEI design. Specifically, homogeneous Li-Al alloying has been observed in conventional LIBs, even when paired with a high mass loading LiNi0.5 Co0.3 Mn0.2 O2 cathode (7 mg cm-2 ). The dual-phase SEI film design can also accelerate the diffusion kinetics of Li-ions through interface electronic structure regulation. This dual-phase design can integrate stiffness and toughness into a single SEI film, providing a pathway to enhance both the structural stability and rate capability of alloying anodes.

Engineering Polymer-Based Porous Membrane for Sustainable Lithium-Ion Battery Separators

Due to the growing demand for eco-friendly products, lithium-ion batteries (LIBs) have gained widespread attention as an energy storage solution. With the global demand for clean and sustainable energy, the social, economic, and environmental significance of LIBs is becoming more widely recognized. LIBs are composed of cathode and anode electrodes, electrolytes, and separators. Notably, the separator, a pivotal and indispensable component in LIBs that primarily consists of a porous membrane material, warrants significant research attention. Researchers have thus endeavored to develop innovative systems that enhance separator performance, fortify security measures, and address prevailing limitations. Herein, this review aims to furnish researchers with comprehensive content on battery separator membranes, encompassing performance requirements, functional parameters, manufacturing protocols, scientific progress, and overall performance evaluations. Specifically, it investigates the latest breakthroughs in porous membrane design, fabrication, modification, and optimization that employ various commonly used or emerging polymeric materials. Furthermore, the article offers insights into the future trajectory of polymer-based composite membranes for LIB applications and prospective challenges awaiting scientific exploration. The robust and durable membranes developed have shown superior efficacy across diverse applications. Consequently, these proposed concepts pave the way for a circular economy that curtails waste materials, lowers process costs, and mitigates the environmental footprint.

Insights into the Chemistry of the Cathodic Electrolyte Interphase for PTFE-Based Dry-Processed Cathodes

Dry processing is a promising method for high-performance and low-cost lithium-ion battery manufacturing which uses polytetrafluoroethylene (PTFE) as a binder. However, the electrochemical stability of the PTFE binder in the cathodes and the generated chemistry of the cathode electrolyte interphase (CEI) layers are rarely reported. Herein, the CEI properties and PTFE electrochemical stability are studied via cycling the high-loading dry-processed electrodes in electrolytes with LiPF6 or LiClO4 salt. Using LiClO4 salt can eliminate other possible F sources, allowing the decomposition of PTFE to be studied. The detection of LiF in cells with the LiClO4 salt confirms that PTFE undergoes side reaction(s) in the cathodes. When compared with LiClO4, the CEI layer is much thicker when LiPF6 is used as the electrolyte salt. These results provide insights into the CEI layer and may potentially enlighten the development of binders and electrolytes for the high efficiency and long durability of DP-based LIBs.