Solvent-free processing of lithium-ion batteries via plasma treatment of electrodes for adhesive interfaces

The demand for lithium-ion batteries (LIBs) continues to increase as the world shifts toward sustainable energy solutions. However, conventional electrode fabrication depends heavily on toxic solvents and energy-intensive drying processes that raise serious environmental and economic concerns. This study introduces a pioneering solvent-free, plasma-assisted approach for electrode fabrication that eliminates the need for hazardous solvents while enhancing the adhesion between binders and current collectors. The proposed method is highly versatile and compatible with a wide range of active materials. Moreover, it significantly reduces processing complexity, making it an attractive solution for next-generation LIB production. By advancing solvent-free manufacturing, this work not only mitigates the environmental impact but also establishes a transformative platform for dry-process surface engineering, with far-reaching applications in energy storage, electronics, and beyond. • A solvent-free plasma-assisted dry process was developed for LIB electrode fabrication. • Plasma treatment improved binder adhesion to the current collector without solvent. • Fabricated electrodes showed proper operation in lithium-ion battery systems. • The method in this study advances sustainable and scalable manufacturing of battery electrodes.