Pilot-line LMFP anodefree pouch cells: a scalable, low cost, energy dense Lithium battery

The anodefree configuration of lithium batteries represents a low-cost, high energy density alternative to current generation chemistries, and coupling with Ni and Co-free LiMnxFe1-xPO4 (LMFP) cathodes further reinforces these advantages. In this work, we manufacture and evaluate this cell type in coin and pouch format, establishing key performance characteristics and optimised test protocols, while identifying outstanding challenges limiting cell lifetime. The anodefree LMFP coin cell provides a 35 % stack-level energy density advantage over a traditional full cell (with graphite anode) when using a 60:40 Mn:Fe LMFP variant, which improves to a 42 % advantage when Mn content was increased to 80 % (at the cost of more rapid capacity loss). Cycling over the potential range of 3.0 – 4.5 V maximises cell lifetime, while the dominant degradation mechanism is identified as irreversible Li loss associated with a disadvantageous evolution in plated Li morphology. Finally, anodefree battery manufacturing is scaled to large-area pouch format to demonstrate commercial viability and compatibility with current industrial processes.