Waterborne LiNi 0.5 Mn 1.5 O 4 Cathode Formulation Optimization through Design of Experiments and Upscaling to 1 Ah Li-Ion Pouch Cells

High-voltage spinel LiNi 0.5 Mn 1.5 O 4 (LNMO) is a promising candidate as a lithium-ion battery cathode material to fulfill the high-energy density demands of the electric vehicle industry. In this work, the design of the experiment’s methodology has been used to analyze the influence of the ratio of the different components in the electrode preparation feasibility of laboratory-scale coatings and their electrochemical response. Different outputs were defined to evaluate the formulations studied, and Derringer–Suich’s methodology was applied to obtain an equation that is usable to predict the desirability of the electrodes depending on the selected formulation. Afterward, Solver’s method was used to figure out the formulation that provides the highest desirability. This formulation was validated at a laboratory scale and upscaled to a semi-industrial coating line. High-voltage 1 Ah lithium-ion pouch cells were assembled with LNMO cathodes and graphite-based anodes and subjected to rate-capability tests and galvanostatic cycling. 1 C was determined as the highest C-rate usable with these cells, and 321 and 181 cycles above 80% SOH were obtained in galvanostatic cycling tests performed at 0.5 C and 1 C, respectively. Furthermore, it was observed that the LNMO cathode required an activation period to become fully electrochemically active, which was shorter when cycled at a lower C-rate.