Cavitation-enhanced disrupts the agglomeration of carbon nanotubes to construct dry electrodes with high-rate and...

Driven by the urgent demand for high-energy-density lithium-ion batteries, conventional wet slurry-coating processes suffer from critical limitations. Although dry electrode manufacturing emerges as a promising alternative for energy density enhancement, challenges persist in achieving uniform active material dispersion and long-term cycle life. In this study, a dry electrode material composite strategy based on the ultrasonic microbubble cavitation-enhanced (UMC) effect was proposed. The interactions between carbon nanotubes (CNTs) could be dissociated by the transient cavitation bubble collapse energy triggered by the cavitation-enhanced, and a composite electrode system with 3D porous conductive network structure integrated with CNTs and lithium manganese iron phosphate (LMFP) was constructed. The developed dry electrode demonstrates exceptional electrochemical performance: capacity retention reaches 97.4 % after 50 cycles at 0.1C, 78.5.0 % capacity retention after 150 cycles at 1C, and delivers 85 mAh g^-1 reversible capacity at 3C. The capacity retention rate of the full cell after 50 cycles at 0.1C was 97.9 %. These results conclusively validate the superior structural stability and rate capability of the dry-processed electrodes. This groundbreaking methodology establishes a robust technical foundation for advancing next-generation lithium-ion battery systems.