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Mechanical-Thermal Decoupling Engineering Unlocks Ultra-Stable Dry Thick Iodine Cathodes for Ah-Level Zinc-Based
Hengrui Guo1,2, Hao Luo1,2,3, Fulong Zhu3
1School of Materials Science and Engineering, Xiamen University of Technology, Xiamen, Fujian, China.
Advanced Materials (Deerfield Beach, Fla.)
|April 11, 2026
Summary
A novel water-cooled pulse shearing method prevents iodine loss during dry processing of thick iodine electrodes. This strategy enhances cycling stability and energy density for advanced battery applications.
Area of Science:
- Materials Science
- Electrochemistry
- Energy Storage
Background:
- Solvent-free dry processing offers advantages for fabricating thick iodine electrodes.
- However, this method suffers from slow kinetics and poor cycling stability due to mechanical stress and frictional heating during high-shear processing.
- These factors lead to destroyed mass-transport channels and uncontrolled iodine loss.
Purpose of the Study:
- To develop a processing strategy that overcomes the limitations of traditional dry processing for thick iodine electrodes.
- To precisely decouple and regulate mechanical force and frictional heat accumulation during electrode fabrication.
- To enhance the kinetics, cycling stability, and overall performance of iodine-based energy storage devices.
Main Methods:
- A targeted energy intermittent release strategy using water-cooled pulse shearing was employed.
- Mechanical force and frictional heat accumulation were precisely controlled below damage and desorption thresholds.
- The processing parameters were optimized to maintain strong van der Waals confinement between carbon and iodine, preventing abnormal iodine migration.
Main Results:
- The water-cooled pulse shearing method prevented the destruction of carbon host structures and minimized iodine loss.
- This resulted in uniform and stable thick iodine electrodes at both micro and macro scales.
- The fabricated electrodes demonstrated over 50,000 stable cycles at 100 C with an ultra-high area capacity of 16.27 mAh cm-2 at a high iodine loading of 82.84 mgiodine cm-2.
Conclusions:
- The proposed water-cooled pulse shearing strategy effectively addresses the challenges of solvent-free dry processing for thick iodine electrodes.
- This approach preserves electrode integrity, enhances electrochemical performance, and enables long-term cycling stability.
- A large-scale pouch cell demonstrated excellent capacity retention (98.5% after 300 cycles), highlighting the practical viability and scalability of the developed technique for advanced energy storage.
