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At least 91 records · Page 5

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DOE OSTI2020

Graphene nanoplatelet for enhancement the mechanical properties and durability characteristics of alkali activated binder

The effects of the addition of graphene nanoplatelets (GNPs) on the microstructure, heat of hydration, mechanical properties and durability characteristics of alkali activated binders were investigated. A simple mixing process led to reasonably uniform dispersion of GNPs in the matrix, with minor agglomeration of GNPs detected via scanning electron microscopy. Tests on engineering properties indicated that the compressive strength of the alkali activated binder increased with the addition of GNPs at relatively low concentrations. Gains were also realized in the abrasion resistance and moisture sorptivity of the binder with GNPs addition. The heat of hydration investigations indicated that the addition of GNPs accelerates the hydration process and increases the amount of hydration products, especially at early ages. Scanning electron microscope investigations further indicated that GNPs could impede the development of microcracks and mitigate their propagation within matrix; indications of good bonding between the GNPs and the alkali activated matrix were also noted.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Ameliorating the sodium storage performance of hard carbon anode through rational modulation of binder

Hard carbon anodes have emerged as promising candidates for sodium-ion batteries due to their inherent advantages. Nevertheless, the surface imperfections in these materials often culminate in irreversible electrolyte consumption, fostering the development of a heterogeneous and fragile solid electrolyte interface (SEI), thereby compromising the initial Coulombic efficiency (ICE). Here, drawing inspiration from the catalytic potential of C=O (carbonyl) bonds in directing preferential salt reduction, we introduce a novel strategy that leverages the modulation of the binder, a long-term overlooked pivotal components in the electrode process. Specifically, Polymethyl methacrylate (PMMA), abundant in C=O groups, is partially substituted for PVDF, ensuring robust adhesion of the electrode material to the current collector while preserving superior mechanical properties. The accurate combination of two binders with delightful compatibility in the state-of-art electrode process, can promote a uniform formation of the SEI on the hard carbon surface enriched in inorganic components, which can ensure long-term interfacial stability and suppresses excessive solvent decomposition and facilitates Na + transfer at the interface. Consequently, the initial Coulombic efficiency of the hard carbon anode with 70 %PMMA binder achieves 86 %, with prominent cycling stability (88 % capacity retention over 500 cycles) at a high current density of 1.2 A g −1 . When paired with high loading cathodes to assemble the pouch cell, it also demonstrates stable operational scenarios.

25 ENERGY STORAGE↗

DOE OSTI2020

Effect of binder on the overcharge response in LiFePO 4 -containing cells

Two types of small pouch cells based on LiFePO 4 /graphite, one containing a N-methyl pyrrolidinone (NMP)-soluble binder, poly(vinylidene difluoride), and the other an aqueous-soluble binder, styrene-butadiene rubber/carboxymethylcellulose were systematically charged to 100, 120, 140, 160, 180, and 250% state of charge (SOC). The cells were then discharged to 3.0 V at room temperature before being disassembled for postmortem analysis. Microstructural changes in the anode associated with increasing SOC were more pronounced in the aqueous processed cells in comparison to the NMP-processed cells. Dendrite formation was observed on the aqueous-processed anode at 120% SOC, while the NMP-processed anode surface does not show dendrites until 250% SOC. Overall, the aqueous-processed anode surfaces displayed more evidence of microstructural degradation as a function of increasing SOC. In the NMP-processed cells, four organic compounds on the anode surface were found to show a dependence on SOC, while only two displayed a similar dependency in the aqueous-processed cells. The nature of the binder changed the number and composition of the species found at the anode.

25 ENERGY STORAGE↗

DOE OSTI2022

Understanding the Solution Dynamics and Binding of a PVDF Binder with Silicon, Graphite, and NMC Materials and the Influence on Cycling Performance

The impact of the binding, solution structure, and solution dynamics of poly(vinylidene fluoride) (PVDF) with silicon on its performance as compared to traditional graphite and Li 1.05 Ni 0.33 Mn 0.33 Co 0.33 O 2 (NMC) electrode materials was explored. Through refractive index (RI) measurements, the concentration of the binder adsorbed on the surface of electrode materials during electrode processing was determined to be less than half of the potentially available material resulting in excessive free binder in solution. Using ultrasmall-angle neutron scattering (USANS) and small-angle neutron scattering (SANS), it was found that PVDF forms a conformal coating over the entirety of the silicon particle. This is in direct contrast to graphite–PVDF and NMC–PVDF slurries, where PVDF only covers part of the graphite surface, and the PVDF chains make a network-like graphite–PVDF structure. Conversely, a thick layer of PVDF covers NMC particles, but the coating is porous, allowing for ion and electronic transport. The homogeneous coating of silicon breaks up percolation pathways, resulting in poor cycling performance of silicon materials as widely reported. These results indicate that the Si–PVDF interactions could be modified from a binder to a dispersant.

25 ENERGY STORAGE↗

DOE OSTI2024

Environmentally sustainable lithium-ion battery cathode binders based on cellulose nanocrystals

Aqueous binders as environmentally sustainable alternatives to conventional polyvinylidene difluoride (PVDF) binders have not yet been successful for cathodes in lithium-ion batteries (LIBs). Here, carboxylic acid functionalized cellulose nanocrystals (CNC-COOHs) have been obtained from Miscanthus × giganteus (M×G) biomass and evaluated as aqueous binders for LIB cathodes.

Cellulose nanocrystal↗

DOE OSTI2025

Binder Jet Additive Manufacturing of Silicon Carbide Solar Reactor (CRADA Report)

Achieving high powder packing density is critical in binder jet additive manufacturing (BJAM), as it directly influences the final part density, mechanical properties, and sintering behavior. Multi-modal powder blends, which combine particles of different sizes, have been explored as a strategy to optimize packing efficiency and minimize defects. In this study, bimodal and trimodal powder blends were obtained by mixing silicon carbide powder in three different sizes. These results show that increased powder density is achievable with bimodal powder blends but is reduced in trimodal blends, and it was found that a 13% increase in the powder tap density was achieved using a bimodal blend of powder. The powder size distribution of the bimodal blend was measured at various stages during binder jet additive manufacturing and, no measurable powder separation occurred even after eight prints. Overall, this study shows limited advantage to trimodal powder blends but good promise for trimodal blends for increasing printed density while maintaining reusability in the binder jet process.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2026

Ultrasound Characterization of Plastic Bonded Explosives With Varied Binder Content and Density

Advanced explosive formulations and methods of production require rapid characterization for both processes and materials. Here, we present results for ultrasound characterization of a plastic bonded explosive (PBX) formulation as a function of binder weight percent and pressing density using through-transmission sound speed measurements. The explosive in this study was composed of 1,3,5-triamino-2,4,6-trinitrobenzene (TATB) combined with the fluoropolymer binder Kynar Ultraflex B. Binder content ranged from 2.6 wt.% to 11.5 wt.% with associated explosive formulation densities from 1.69 g/cc to 1.89 g/cc. We find linear and nonlinear changes in longitudinal and shear sound speeds, peak frequencies, and measured elastic properties for the different PBX formulations. These measured changes can differentiate the tested formulations, highlighting the potential for ultrasound as a nondestructive characterization method for newly-formulated PBXs. We also demonstrate through-transmission measurements using different coupling media and present results from an ultrasound technique called resonant ultrasound spectroscopy (RUS). Both transmission and RUS approaches may allow for rapid and even automated characterization of PBX components suitable for high-throughput manufacturing operations.

Engineering↗

DOE OSTI2026

Covalent adaptable networks for electrolyte–binder integration in recyclable lithium metal batteries

Lithium-metal batteries (LMBs) are considered a promising next-generation energy storage technology due to their exceptionally high energy density. However, the development of solid polymer electrolytes and cathode binders for LMBs faces critical challenges, including interfacial instability, poor recyclability, and growing environmental concerns. In particular, current systems often rely on non-recyclable components featuring permanently crosslinked networks and polyfluoroalkyl substances (PFAS), such as poly(vinylidene fluoride) (PVDF), which cause battery waste and environmental harm. Herein, we introduce a multifunctional covalent adaptable network (CAN) platform based on thermally reversible Diels–Alder (DA) chemistry, designed for dual functionality as a CAN-based electrolyte (CAE) and a CAN-based cathode binder. The CAE achieves high ionic conductivity and strong storage modulus (1.4 mS cm −1 and ∼ 10 5 Pa at room temperature, respectively) and enables stable long-term cycling in symmetric Li||Li cells for over 2000 h with low overpotential. When it is applied as a cathode binder in LiFePO 4 (LFP) composite electrodes (C-LFP), the CAN matrix significantly reduces interfacial resistance and enhances discharge capacity compared to conventional PVDF-based systems. Thermal treatment induces self-healing at the cathode–electrolyte interface, further improving contact and yielding a discharge capacity of 150 mAh g −1 at 0.5 C. Moreover, the dynamic CAN architecture allows efficient recovery and reuse of lithium salts from spent electrolytes through retro-DA reactions under mild conditions (∼80 °C), establishing a low-energy, cost-effective recycling pathway. In conclusion, this work presents a scalable and sustainable strategy for high-performance LMBs by integrating recyclability, interfacial healing, and PFAS-free design, offering a holistic solution aligned with circular economy principles and next-generation battery demands.

Diels–Alder↗

DOE OSTI2021

On the retardation mechanisms of citric acid in ettringite-based binders

This study aims to obtain insights into the retardation mechanism of citric acid in an ettringite-based binder from ladle slag and gypsum. The hydration kinetics and phase assemblage of the binder were experimentally investigated and thermodynamically modelled. Additionally, the effects of citric acid on synthetic ettringite were studied to obtain further understanding of the interaction between this organic ligand and the crystal. Experimental results reveal that citric acid works as an inhibitor of ettringite's formation leading to the precipitation of monosulfate and gypsum; the ettringite surface blockage by citrate ligand effectively prevents precipitation of this crystal. This leads to an overestimation in the precipitation of ettringite in the thermodynamic model due to this kinetic barrier imposed by the ligand. Thermodynamic modelling suggests ettringite, monosulfate, aluminum hydroxide, and strätlingite as main hydrates in this binder, whereas an intermixed C–(A–)S–H gel was observed experimentally instead of strätlingite.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Phase evolution and mechanical performance of an ettringite-based binder during hydrothermal aging

Little is known about the performance of ettringite-based binders in hydrothermal conditions. This investigation aims to gain insights into the phase evolution and corresponding mechanical performance of an ettringite-based binder considering crystallization pressure caused by late-reaction products. Additionally, the role of fiber reinforcement on the strength retention of the binder was investigated. When aged at an elevated temperature under water-saturated conditions, hard-burned MgO hydrated to form brucite. The precipitation and growth of the brucite crystals led to a crystallization pressure of approximately 200 MPa calculated using thermodynamic modelling. Damage was observed after 4 months of aging with cracks in the microstructure and eventually a failure at the macro scale. Ettringite remained stable at 60 °C due to the water-saturated conditions. Polypropylene fiber delayed crack propagation and thus reduced the damage caused by crystallization pressure. The fiber improved the flexural performance of composite attaining deflection-hardening behavior regardless of aging conditions.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Packing density optimization and recyclability of multi-modal SiC powder feedstocks in binder jet additive manufacturing

Achieving high powder packing density is critical in binder jet additive manufacturing (BJAM), as it directly influences the final part density, mechanical properties, and sintering behavior. Multi-modal powder blends, which combine particles of different sizes, have been explored as a strategy to optimize packing efficiency and minimize defects. In this study, bimodal and trimodal powder blends were obtained by mixing silicon carbide powder in three different sizes. These results show that increased powder density is achievable with bimodal powder blends but is reduced in trimodal blends, and it was found that a 13 % increase in the powder tap density was achieved using a bimodal blend of powder. The powder size distribution of the bimodal blend was measured at various stages during binder jet additive manufacturing and, no measurable powder separation occurred even after eight prints. Altogether, this study shows limited advantage to trimodal powder blends but good promise for bimodal blends for increasing printed density while maintaining reusability in the binder jet process.

Aguirre, Trevor G. [Oak Ridge National Laboratory ↗

DOE OSTI2023

Evaluation of adsorption and mechanical strength of 13X zeolite mixtures with phyllosilicate binders using molecular dynamics simulation and positron annihilation spectroscopy

There is growing interest in developing zeolites with novel internal structures that have optimal adsorptive capacity and high mechanical strength, while offering advantages, such as being light weight. We integrate computational and experimental methods to explore the effect of binder/zeolite types, and weight percentages on the mechanical strength of 13X zeolite and adsorption capacities of N 2 , H 2 O, and CO 2 for additive manufacturing (AM) applications with the goal of maximizing both adsorption and strength. Zeolite 13X mixtures and phyllosilicate binders (either bentonite or kaolin) are combined using molecular dynamics (MD) simulations to create structures with various binder/zeolite weight percentages. Further, adsorption capabilities and mechanical strength are assessed using the grand canonical Monte Carlo (GCMC) and ReaxFF modules, respectively. Our modeling shows that an optimized zeolite/binder ratio for N 2 adsorption is around 15 wt% for kaolin and roughly 10 wt% for bentonite. The resulting parameters can be applied to facilitate macro-scale computational fluid dynamics (CFD) and finite element method (FEM) simulations of an AM zeolite structure. We also performed Positron Annihilation Lifetime Spectroscopy (PALS) measurements on zeolite samples to explore the effect of changes in the internal volume. The results show an inverse relationship between the free volume and the solid loading and adding a binder changes the morphology of the zeolite-binder compound and decreases open-volume area significantly.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Rooting binder-free tin nanoarrays into copper substrate via tin-copper alloying for robust energy storage

The need for high-energy batteries has driven the development of binder-free electrode architectures. However, the weak bonding between the electrode particles and the current collector cannot withstand the severe volume change of active materials upon battery cycling, which largely limit the large-scale application of such electrodes. Using tin nanoarrays electrochemically deposited on copper substrate as an example, here we demonstrate a strategy of strengthening the connection between electrode and current collector by thermally alloying tin and copper at their interface. The locally formed tin-copper alloys are electron-conductive and meanwhile electrochemically inactive, working as an ideal "glue" robustly bridging tin and copper to survive harsh cycling conditions in sodium ion batteries. The working mechanism of the alloy "glue" is further characterized through a combination of electrochemical impedance spectroscopy, atomic structural analysis and in situ X-ray diffraction, presenting itself as a promising strategy for engineering binder-free electrode with endurable performance. The authors here report a binder-free electrode based on tin nanoarrays deposited on copper substrate. It is found that the locally formed electrochemically inactive tin-copper alloys work as a glue that bridges tin and copper to survive harsh cycling conditions in sodium ion batteries.

25 ENERGY STORAGE↗

DOE OSTI2021

Understanding the Role of π-Conjugated Polymers as Binders in Enabling Designs for High-Energy/High-Rate Lithium Metal Batteries

Developing lithium-ion batteries with both high specific energy and high-power capability is a challenging task because of the necessity for meeting conflicting design requirements. We show that high-energy and high-rate capability can be achieved by using various π -conjugated p-dopable polymers as binders at the cathode and by lowering the mass fraction of all the inactive components of the cell. We report a lithium-metal battery that can deliver 320 Wh kg −1 at C/2 using a mass-efficient cell design. To this end, three conducting polymers with different ionic and electronic conductivities have been studied; dihexyl-substituted poly(3,4-propylenedioxythiophene) (PProDOT-Hx 2 ), poly(3-hexylthiophene) (P3HT), and a new Random Copolymer (Hex:OE)(80:20) PProDOT. These conducting polymers are compared against a conventional polymer binder, PVDF. We show that under the mass-efficient conditions required for achieving high specific energy and rate capability, the conducting polymers play a crucial role by providing electronic and ionic conductivity, protection against rapid growth of solid electrolyte interphase (SEI), and access to a large electrochemically active surface area. Thus, the use of conducting polymers with appropriate molecular structure as binders opens a viable pathway to maximizing the specific energy and rate capability of lithium-ion battery cathodes.

25 ENERGY STORAGE↗

DOE OSTI2023

Adverse Effects of Trace Non-polar Binder on Ion Transport in Free-standing Sulfide Solid Electrolyte Separators

Sulfide solid-state electrolyte (SE) possesses high room-temperature ionic conductivity. However, fabrication of the free-standing, sheet-type thin sulfide SE film electrolyte to enable all-solid-state batteries to deliver high energy and power density remains challenging. Herein we show that argyrodite sulfide (Li 6 PS 5 Cl) SE can be slurry cast to form free-standing films with low (≤5 wt%) loadings of poly(isobutylene) (PIB) binder. Two factors contribute to a lower areal specific resistance (ASR) of the thin film SEs benchmarked to the pristine powder pellet SSE counterparts: i) 1–2 orders reduced thickness and ii) reasonably comparable ionic conductivity at room temperature after the isostatic pressing process. Nevertheless, an increasing polymer binder loading inevitably introduced voids in the thin film SEs, compromising anode/electrolyte interfacial ion transport. Our findings highlight that electrolyte/electrode interfacial stability, as well as the selection of slurry components, including sulfide SE, binder, and solvent, play essential roles in thin film sulfide electrolyte development.

25 ENERGY STORAGE↗

DOE OSTI2025

Binder jet additive manufacturing of silicon carbide solar reactor

36 MATERIALS SCIENCE↗

DOE OSTI2020

Binder Jetting and Sintering in Additive Manufacturing

This article focuses on binder-jetting technologies in additive manufacturing (AM) that produce metal artifacts either directly or indirectly. The intent is to focus on the most strategic and widespread uses of the binder jetting technology and review some of the challenges and opportunities for that technology. The discussion includes a historical overview and covers the major steps involved and the advantages of using the binder jetting process. The major steps of the process covered include printing, curing, de-powdering, and sintering.

Elliott, Amy↗

DOE OSTI2020

Redox-active supramolecular polymer binders derived from perylene bisimide nanowires enable high-rate lithium-sulfur batteries

To address the need for multi-functional binders specifically tailored for sulfur cathodes π-stacked perylene bisimide (PBI) molecules are repurposed as redox-active supramolecular binders in sulfur cathodes for Li—S cells. In operando lithiation of PBI binders permanently reduces Li—S cell impedance enabling high-rate cycling, a critical step toward unlocking the full potential of Li—S batteries.

25 ENERGY STORAGE↗