Dry electrode fabrication is considered a crucial next-generation process for secondary batteries because it eliminates the need for solvents and drying steps, significantly reducing energy consumption and carbon emissions. To achieve optimal performance in dry electrodes, it is essential to ensure high mechanical stability and electrical conductivity. These properties can be enhanced by controlling binder fibrillation and creating a continuous conductive network through the uniform dispersion of conductive additives. In this study, we applied mechanical shear mixing as a pre-treatment to electrode powders, which included active materials, conductive agents, and binders. We systematically investigated variations in electrical conductivity, binding structure, tensile properties, internal resistance (via IR drop), and fast-charging performance as a function of the mixing shear rate. In particular, we quantified the binder fibrillation behavior and the dispersion of conductive agents that occur simultaneously during mixing. By correlating these factors with the physical and electrochemical properties of the final electrode film, we propose design guidelines to optimize the mixing pre-treatment process.
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