High-areal-capacity Na-ion battery electrode with high energy and power densities by simultaneous electrospinning-spraying fabrication

Sodium-ion batteries (SIBs) are cost-effective alternatives to lithium-ion batteries (LIBs), but their low energy density remains a challenge. Current electrode designs fail to simultaneously achieve high areal loading, high active content, and superior performance. In response, this work introduces an ideal electrode structure, featuring a continuous conductive network with active particles securely trapped in the absence of binder, fabricated using a universal technique that combines electrospinning and electrospraying (co-ESP). We found that the particle size must be larger than the network's pores for optimised performance, an aspect overlooked in previous research. The free-standing co-ESP Na₂V₃(PO4)₃ (NVP) cathodes demonstrated state-of-the-art 296 mg cm⁻² areal loading with 97.5 wt% active content, as well as remarkable rate-performance and cycling stability. Co-ESP full cells showed uncompromised energy and power densities (231.6 W h kg⁻¹/7152.6 W kg⁻¹), leading among reported SIBs with industry-relevant areal loadings. The structural merit is analysed using multi-scale X-ray computed tomography, providing valuable design insights. Finally, the superior performance is validated in the pouch cells, highlighting the electrode's scalability and potential for commercial application.