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Abstract Increasing the thickness of the electrodes is considered the primary strategy to elevate battery energy density. However, as the thickness increases, rate performance, cycling performance, and mechanical stability are affected due to the sluggish ion transfer kinetics and compromised structural integrity. Inspired by the natural hierarchical porous structure of trees, electrodes with bioinspired architecture are fabricated to address these challenges. Specifically, electrodes with aligned columns consist of tree‐inspired vertical channels, and hierarchical pores are constructed by screen printing and ice‐templating, imparting enhanced electrochemical and mechanical performance. Employing an aqueous‐based binder, the LiNi0.8Mn0.1Co0.1O2cathode achieves a high areal energy density of 15.1 mWh cm−2at a rate of 1C at mass loading of 26.0 mg cm−2, benefitting from the multiscale pores that elevated charge transfer kinetics in the thick electrode. The electrodes demonstrate capacity retention of 90% at the 100th cycle at a high current density of 5.2 mA cm−2. To understand the mechanisms that promote electrode performance, simplified electro‐chemo‐mechanical models are developed, the drying process and the charge‐discharge process are simulated. The simulation results suggested that the improved performance of the designed electrode benefits from the lower ohmic overpotential and less strain gradient and stress concentration due to the hierarchical porous architecture.
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This content will become publicly available on March 10, 2026
Print‐and‐Plate Architected Electrodes for Electrochemical Transformations Under Flow
Abstract Flow cell electrodes are typically composed of porous carbon materials, such as papers, felts, and cloths. However, their random architecture hinders the fundamental characterization of electrode structure‐performance relationships during in situ operation of porous electrochemical flow systems. This work describes a “print‐and‐plate” method that combines direct ink writing of micro‐periodic lattices with a two‐step metal plating process that converts them into highly conductive (sheet resistance 40 mΩ sq−1) electrodes. Theiroperandoperformance is assessed in an anthraquinone disulfonic acid half‐cell using widefield electrochemical fluorescence microscopy, where output current and fluorescence intensity are in excellent agreement. The pressure drop associated with flow through three electrode designs is determined via simulations from which the most efficient design is identified and manufactured via print‐and‐plate. Confocal fluorescence microscopy is then used to create a 3D map of the state of charge (SOC) inside this print‐and‐plate electrode. The experimental state of the charge map is in good agreement with computational predictions. The rapid design, simulation, and fabrication of print‐and‐plate electrodes enable fundamental investigations of how architected porosity affects electrochemical performance under flow.
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- Award ID(s):
- 2122195
- PAR ID:
- 10610330
- Publisher / Repository:
- Advanced Functional Materials, Wiley
- Date Published:
- Journal Name:
- Advanced Functional Materials
- ISSN:
- 1616-301X
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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