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LiFePO4 (LFP) primary particles and secondary agglomerates have been processed into water- and solvent-based cathodes. By means of neutron and X-ray diffraction it was found that no structural changes of LiFePO4 occurred upon water- and solvent-based slurry preparation. Electrochemical characterization was carried out with full-cells and a distinct influence of particle morphology was observable. Water-based processing of primary particles leads to deficits in electrochemical performance while secondary agglomerates are non-sensitive to water during processing. In the presence of water, high mechanical stress during slurry preparation causes a partial detachment of carbon coating. However, this effect is negligible for secondary agglomerates since only surface particles are exposed to mechanical stress. Due to longer diffusion paths and the fact that secondary agglomerates represent a micro-heterogeneity in the cathode, the C-rate capability of secondary agglomerates is slightly lower than that of primary particles. This paper demonstrates that for any high energy application with moderate C-rates, secondary agglomerates hold a great potential for environmentally friendly and cost-efficient water-based cathode production.

Influence of Particle Morphologies of LiFePO4 on Water- and Solvent-Based Processing and Electrochemical Properties