Easily recyclable lithium-ion batteries: Recycling-oriented cathode design using highly soluble LiFeMnPO4 with a water-soluble binder

Recycling lithium-ion batteries (LIBs) is fundamental for resource recovery, reducing energy consumption, decreasing emissions, and minimizing environmental risks. The inherited properties of materials and design are not commonly attributed to the complexity of recycling LIBs and their effects on the recycling process. The state-of-the-art battery recycling methodology consequently suffers from poor recycling efficiency and high consumption from issues with the cathode and the binder material. As a feasibility study, high-energy-density cathode material LiFeMnPO₄ with a water-soluble polyacrylic acid (PAA) binder is extracted with dilute hydrochloric acid at room temperature under oxidant-free conditions. The cathode is wholly leached with high purity and is suitable for reuse. The cathode is easily separated from its constituent materials and reduces material and energy consumption during recycling by 20% and 7%, respectively. This strategy is utilized to fabricate recyclable-oriented LiFeMnPO₄/graphite LIBs with a PAA binder and carbon paper current collector. Finally, the limitation of the solubility of the binder is discussed in terms of recycling. This research hopefully provides guidance for recycling-oriented design for the circular economy of the LIB industry.