Ultrahigh-Capacity and Scalable Architected Battery Electrodes via Tortuosity Modulation

A thick electrode with high areal capacity is a straightforward approach to maximize the energy density of batteries, but the development of thick electrodes suffers from both fabrication challenges and electron/ion transport limitations. In this work, a low-tortuosity LiFePO₄ (LFP) electrode with ultrahigh loadings of active materials and a highly efficient transport network was constructed by a facile and scalable templated phase inversion method. The instant solidification of polymers during phase inversion enables the fabrication of ultrathick yet robust electrodes. The open and aligned microchannels with interconnected porous walls provide direct and short ion transport pathways, while the encapsulation of active materials in the carbon framework offers a continuous pathway for electron transport. Benefiting from the structural advantages, the ultrathick bilayer LiFePO₄ electrodes (up to 1.2 mm) demonstrate marked improvements in rate performance and cycling stability under high areal loadings (up to 100 mg cm^-2). Simulation and operando structural characterization also reveal fast transport kinetics. Combined with the scalable fabrication, our proposed strategy presents an effective alternative for designing practical high energy/power density electrodes at low cost.