Failure Modes of Flexible LiCoO₂ Cathodes Incorporating Polyvinylidene Fluoride Binders with Different Molecular Weights

Understanding the mechanical failure modes of lithium-ion battery [Li-ion batteries (LIBs)] electrodes is exceptionally important for enabling high specific energy and flexible LIB technologies. In this work, the failure modes of lithium cobalt oxide (LCO) cathodes under repeated bending and the role of the polymer binder in improving the mechanical durability of the LCO electrodes for use in flexible LIBs are investigated. Mechanical and electrochemical evaluations of LCO electrodes (areal capacity of ≥2.5 mA h cm^-2) employing poly(vinylidene fluoride) (PVDF) binder were carried out, followed by extensive optical and electron microscopies. We find that the molecular weight (MW) of the PVDF significantly influenced the surface and bulk microstructure of the LCO electrodes, particularly the distribution of carbon additive and binder, which plays a crucial role in affecting the mechanical and electrochemical properties of the electrodes. Multiple mechanical failure modes (e.g., surface scratches and microcracks) observed in the LCO electrodes subjected to repeated bending originated from the use of low MW PVDF; these failure modes were successfully mitigated by using a high MW PVDF. Remarkably, the optimized flexible LCO electrode incorporating high MW PVDF showed comparable discharge capacity retention during galvanostatic cycling after repeated bending (7000 cycles at 50 mm bending diameter) to electrodes not subjected to the repeated bending. This study highlights the importance of carrying out a comprehensive investigation of the failure mechanisms in flexible electrodes, which identified the pivotal role of the PVDF MW in the electrode microstructure and its effects on the electrode resilience to failure during repeated bending.