<2024> Technology Development Trends and Prospects of Dry Battery Electrode Process for LIBs
Electric
vehicles themselves do not emit greenhouse gases, but the manufacturing process
of electric vehicles has been criticized for emitting carbon and destroying the
environment. A representative example is the battery, which accounts for about
40% of the manufacturing cost of electric vehicles.
During
the battery manufacturing process, a considerable amount of electric energy is
consumed, especially in drying and recovering NMP, which is a cause of
greenhouse gas emissions. According to one research result, 42 kg of CO2 is
generated per kWh due to solvent drying in the wet manufacturing process, and
volatile organic compounds (VOCs), which are environmental pollutants, are also
emitted into the atmosphere. In contrast, dry electrodes do not have a solvent
drying and recovery process, so they consume less electric energy and do not
emit VOCs, making them an environmentally friendly process.
In
order to increase energy density, a thick film electrode of >100㎛ or more is
required. In the current wet process, it is difficult to make a thick film
electrode due to the layer separation phenomenon between the solvent and the
material. Since the specific gravity of each material such as the active
material, conductive material, and binder is different, if the coating is
thick, the binder and conductive material float to the electrode surface. In
the wet process, it is difficult to coat the electrode with a thickness of
about 100㎛ or more.
By
using a dry process, the active material-conductive material-binder can be
evenly distributed without this layer separation phenomenon, so a thick-film
electrode can be created, which can increase the capacity and energy density of
the battery.
In
2019, Tesla acquired Maxwell Technologies, a supercapacitor company with dry
electrode technology, and announced at Battery Day in September 2020 that it
would introduce dry electrodes. Tesla sold Maxwell to UCAP in 2021, two years
later, but was able to secure dry electrode technology. According to experts
who directly obtained and analyzed the Tesla 4680 battery, the battery applied
a dry electrode only to the anode, and the existing wet electrode was adopted
for the cathode.
It
is not known why Tesla has not yet applied the dry electrode process to the
cathode, but there is analysis that the yield of the dry electrode process is
low and cannot be mass-produced. There are also foreign media reports that the
low yield of the 4680 battery is affecting the production of the Cybertruck.
The
principle of the dry coating process is simple, but there are considerable
challenges at each stage in implementing it in practice. It is not easy to
evenly mix the active material, conductive material, and binder without using a
solvent. It is even more difficult to evenly apply the non-viscous powder to
the current collector. If the yield is low, the production cost increases. Dry
electrodes were introduced to reduce costs, but they can actually act as a cost
increase factor.
In
addition to Tesla, domestic and foreign companies are currently announcing that
they are developing a P/P scale dry process, but it is expected that all 46-phi
cylindrical batteries to be initially produced will be produced using a wet
process. The 4680 battery that LGES will produce in the fourth quarter of 2024
on a P/P scale will apply a wet process to both cathode and anode, and this
battery will be supplied to Tesla. Recently, LGES announced that it will
complete the construction of a dry electrode process P/P line in the Ochang
Energy Plant in the fourth quarter of 2024 and will apply it starting in 2028.
Samsung SDI, SK On, Panasonic, CATL, and Kumyang, which recently announced that
they are also developing dry electrode technology.
In
addition, Volkswagen of Germany announced in June 2023 that it was developing a
dry electrode process with Koenig & Bauer, a German printing equipment
specialist. Volkswagen plans to start industrial production by 2027. It is not
known exactly how Volkswagen and Koenig & Bauer are developing the dry
electrode.
The
dry process can reduce energy costs by 30% because the drying process is
unnecessary, and the area required for drying can be reduced by 50%. The 4680
battery using the dry process can theoretically be cheaper than the LFP
battery, but the technology development has not been successful yet.
The
introduction of the dry process has great potential as a carbon-neutral process
for manufacturing lithium secondary batteries, and the commercialization of dry
electrode technology is expected to greatly contribute to reducing battery
manufacturing costs while improving performance. Although no company has
succeeded in mass production so far, it is very likely that the dry electrode
process will become a trend in the near future as major companies are spurring
technology development. In addition, the development of the dry electrode
process can be applied to the manufacturing process of all-solid-state
batteries, which are next-generation batteries. In fact, interest in
all-solid-state batteries is increasing both domestically and internationally,
and plans for mass production are being established.
This
report provides technical information such as the necessity of developing a
carbon-neutral process in the secondary battery industry, issues with the
existing wet process, and issues with the current dry process, as well as
information on recent development trends in dry electrode processes and
all-solid-state battery development by many companies, with the aim of
forecasting the current and near-future status of the dry process.
Strong
Points of This Report
① Includes rich technical content on the background and development
of the dry electrode process
② Includes detailed descriptions of the types of dry electrode
processes and electrode process issues
③ Includes detailed comparisons of the pros and cons of dry and wet
processes as well as battery applications
④ Includes detailed technical content on the application of the dry
electrode process to the next-generation battery, the all-solid-state battery
⑤ Includes detailed information on the development trends of
electrode processes, materials, and equipment companies in the domestic and
international industries
⑥ Includes a list of patents related to the dry electrode process of
domestic and foreign companies and an analysis of major patents
⑦ Includes research support projects and main contents by country
related to dry electrodes
⑧ Includes market outlooks from major research companies on the dry
electrode process
[Difference between dry and wet processes for electrode manufacturing]
[Major Dry Coating Technology Types and Comparison]
[Dry composite cathode manufacturing method]
1. Dry Electrode
Processes for Thick Film Electrodes in LIBs
1.1 The need for carbon-neutral processes in
the LIB industry------9
1.1.1 Increased demand for EV due to
carbon neutrality regulations-----------9
1.1.2 Plans to limit carbon emissions and
ban sales of ICE vehicles ----------10
1.1.3 EV transition plans and verticalized
secondary battery companies------11
1.1.4 Industry Issues related to carbon
neutrality regulations -----------------12
1.1.5 Secondary battery electrode process,
costs and energy consumption 13
1.2 The need for thick film electrodes in
Li-ion batteries ---------------14
1.3 Wet-based electrode manufacturing process
issues ---------------------15
1.4 Background on adopting dry
processes-------------------------------------16
1.4.1 Historical and technological
advances in dry electrode ------------------17
1.4.2 History of key technology
developments in dry film ---------------------18
1.4.3 Dry electrode technology: overcoming
the limitations of wet coatings -19
1.4.4 Dry process and binder development:
number of papers and patents -20
1.4.5 Dry process and binder development:
patent analysis -------------------21
1.4.6 Electrode manufacturing with
extrusion technology ---------------------22
1.4.7 Extrusion and melt processing
---------------------------------------------23
1.4.8 Melt extrusion: solvent vs.
solvent-free application differences ---------24
1.4.9 Dry electrode application: Tesla
anode ------------------------------------25
1.4.10 Dry electrode application: Tesla
cathode --------------------------------26
1.4.11 Dry electrode application:
composite cathode --------------------------27
1.4.12 Dry electrode application:
Pre-lithiation ---------------------------------28
1.4.13 Battery
binder characteristics: 7 types compared --------------------29
1.4.14 Types of binders used in dry
processes -----------------------31
1.4.15 Binder properties used in dry
processes -----------------------32
1.4.16 Water (PTFE, PAA) vs. oil (PVDF)
binders: Performance & tradeoffs--33
1.4.17 Applying PTFE binders
----------------------------------------------------34
1.5 Dry electrode process types
-------------------------------------------------35
1.5.1 Selection of a dry coating process
for dry electrodes-----------------35
1.5.2 Comparison and selection of dry
coating technologies----------------37
1.5.3 Dry mixing and coating
----------------------------------------------------40
1.5.4 Comparison of electrochemical
behavior of dry and wet electrodes----41
1.5.5 Features of Dry electrode process
technologies in LIB application------42
1.5.6 Free standing electrode technology
-------------------------43
1.5.7 Direct calendaring technology
---------------------------------47
1.5.8 Powder sheeting technology
----------------------------------50
1.5.9 Electrostatic spraying technology
---------------------------51
1.5.10 Melt deposition technology
------------------------------------54
1.5.11 Powder compaction technology
------------------------------------55
1.5.12 Melt extrusion technology
------------------------------------56
1.6 Issues with dry electrode process
------------------------------------57
1.6.1 Technical hurdles in dry process
technology ---------------------------57
1.6.2 Challenges of dry process in LIB
manufacturing -------------------------58
1.6.3 Electrical properties of PTFE -----------------------------------------------59
1.7 Comparison of
dry vs. wet processes------------------------------60
1.7.1 Comparison of wet and dry process
manufacturing technologies ------60
1.7.2 Comparison of cell characteristics
for dry vs. wet process technologies 61
1.7.3 Disadvantages of the wet process
-----------------------------------------62
1.7.4 Pros and cons of wet process
alternative options ------------------------63
1.7.5 Benefits of adopting dry process
technology -----------------------------64
1.7.6 Benefits of adopting dry process
technology (speed performance)----- 66
1.7.7 Benefits of adopting dry process
technology (ion channels) ------------67
1.7.8 Benefits of adopting dry process
technology (low cost) -----------------68
1.7.9 Benefits of adopting dry process
technology (Machine characteristics)-70
1.7.10 Dry vs. wet characteristics:
Applies to cathode, anode ----------------71
1.7.11 Cell performance of electrochemical
electrodes -------------------------72
1.7.12 Fabrication and characterization of
dry electrodes for LIBs-------------73
1.7.13 Applying dry electrodes : (LFP +
CNT + PTFE) cathode ---------------74
1.7.14 Applying dry electrodes : (NCM622 +
PVDF) cathode -----------------75
1.7.15 A comprehensive comparison of dry
vs. wet process technologies ----76
1.8 PTFE
fiberization------------------------------------------77
1.8.1 PTFE fiberization
reaction--------------------------------------------------77
1.8.2 PTFE fiberization
process-------------------------------78
1.8.3 PTFE fiberization
application-------------------------------79
1.8.4 Factors affecting PTFE fibrillation
---------------------81
1.8.5 Side effects of PTFE binders
-------------------------------82
1.8.6 Blocking the adverse effects of PTFE
binders: Graphite surface coat-83
1.8.7 Preparation of graphite anodes by
PTFE fiberization method -----------85
1.8.8 Developing
PTFE modified materials ---------------------------------86
1.8.9 Innovative technologies and systems
for PTFE-based cells -------------87
2. Next Secondary
Battery (All-Solid-State Battery) Dry Electrode Processes
2.1 Global
development trends of solid-state batteries ------------------------89
2.1.1 Types and the system configurations
of solid-state batteries----------89
2.1.2 Design and solutions for high energy
density LIBs -------------------90
2.1.3 Dry composite cathode manufacturing
methods --------------------91
2.1.4 Overseas all-solid-state battery
development trends --------------------92
2.1.5 Korean all-solid-state battery
development trends---------------------93
2.2 The need for adopting dry electrode
process in solid-state batteries--94
2.3 Examples of dry electrode process
applications in solid-state batteries 95
2.3.1 Korean and international companies
-----------------------------------95
2.3.2 Korean and international papers
----------------------------------------96
2.3.3 Li-S batteries with PTFE
----------------------------------------------------97
2.3.4 Cobalt-free (LNMO) cells with PTFE
---------------------------------------98
2.3.5 Solid-state batteries with PTFE
(sulfide, oxide, halide) ----------100
2.3.6 Solid-state electrolyte membranes
for solid-state batteries with PTFE-101
2.3.7 Application of inorganic solid
electrolytes---------------102
2.3.8 Application of polymeric solid-state
electrolytes-------------104
2.3.9 Solid-state batteries with dry
process (400 Wh/kg)--------------------106
2.3.10 Solid-state batteries with dry
process (energy density comparison)--108
3. Development
Trends by Company
3.1 Dry electrode process development trends
in Korean and international industry 114
3.1.1 International dry process
development trends-------------114
3.1.2 Korean dry process development
trends --------------115
3.1.3 Challenges to dry electrode
processes ----------------119
3.1.4 Pros and cons of the dry electrode
process --------------120
3.2 Korean company development trends
---------------------------------121
3.2.1 LG Energy Solutions ----------------------------------121
3.2.2 Samsung SDI
--------------------------------------- 123
3.2.3 SK On
-----------------------------------------124
3.2.4 Cosmos Lab
---------------------------------------125
3.2.5 CNP Solutions
-----------------------------------127
3.3 Overseas company development trends
------------------------------129
3.3.1 TESLA
-----------------------------------------129
3.3.2 Sakuu
(USA)---------------------------------------132
3.3.3 Anaphite (UK)
------------------------------------135
3.3.4 LiCap Technology (USA)
-----------------------------138
3.3.5 AM Batteries
(USA)---------------------------------143
3.3.6 PowerCo
SE-------------------------------------146
3.3.7 Dragonfly Energy
(USA)------------------------------149
3.3.8
ZEON------------------------------------------150
3.3.9 Daikin
-----------------------------------------151
3.3.10 Chemours
(USA)-----------------------------------152
3.3.11 Huacai
Technology (China)----------------------------153
3.3.12 Baosheng Energy Technology
(China)--------------------156
3.3.13 Li Yuanheng
(China)---------------------------------157
3.4 Equipment manufacturer development trends
---------------------------158
3.4.1 Hanwha Momentum
---------------------------------------158
3.4.2
CIS--------------------------------------------------------------159
3.4.3
PNT-------------------------------------------160
3.4.4 Yunsung F&C
-------------------------------------161
3.4.5
NainTech----------------------------------------162
3.4.6 GITech
(Korea)--------------------------------------163
3.4.7 KATOP
(China)--------------------------------------164
3.4.8 Shanghai Lianjing Automation
Technology--------------165
3.4.9 TOB New
battery---------------------------------166
3.4.10 TMAX Battery
Equipment-------------------------167
3.4.11 Shenzhen Tsingyan Electronic
Technology-------------170
3.4.12 Huacai
Technology-------------------------------171
3.4.13 ATEIOS System
(USA)------------------------------172
3.4.14 EIRICH
(Germany)-------------------------------------174
3.4.15 Fraunhofer
IWS---------------------------------175
3.5 Development trends in academic and
research institutions -------------177
3.5.1 Korea Institute of Energy Technology
-------------------------------177
3.5.2 Yonsei University ------------------------------------------180
3.5.3 Korea University
------------------------------------------183
3.5.4 Ulsan Institute of Science and
Technology ----------------------------186
3.5.5 Sungkyunkwan
University ----------------------------------189
3.5.6 Gacheon University
------------------------------------------190
3.5.7 Fraunhofer ISIT
-----------------------------------------------------193
3.5.8 Karlsruhe Institute of Technology
(KIT) --------------------------194
3.5.9 Dry Coating
Forum---------------------------------------------------195
4. Patent Analysis
4.1 Overseas dry process development patents
-------------------------198
4.1.1 Overseas dry process development
patent list----------------------198
4.1.2 Maxwell Technologies
----------------------------------------------199
4.1.3 Fraunhofer
IWS-----------------------------------------------204
4.1.4
TESLA----------------------------------------------------------206
4.1.5 Licap New Energy Technologies
------------------------------------213
4.1.6 Dragonfly
Energy-------------------------------------------------216
4.1.7 Anaphite Ltd
-------------------------------------------------------218
4.2 Korean dry process development
patents---------------------------------219
4.2.1 LG Chem, LG Energy Solution patents
----------------------------------219
4.2.2 Samsung SDI---------------------------------------------------------------233
4.2.3 SK On
-----------------------------------------------------------------237
4.2.4 Hyundai Kia
-------------------------------------------------------------240
4.2.5 Yunsung F&C
--------------------------------------------------------------244
4.2.6 Cosmos
Lab----------------------------------------------------------------245
4.2.7 Korea Ceramic Technology Institute
-------------------------------------248
5. Research Projects
by Country
5.1 US DOE projects
------------------------------------------------------------252
5.1.1 Oak Ridge National
Lab------------------------------------------252
5.1.2 NAVITAS Systems
----------------------------------------------------255
5.2 EU projects
----------------------------------------------------------257
5.2.1 ELIBAMA program
-----------------------------------------257
5.2.2 HORIZON Europe : NOVOC project
------------------------------ 258
5.2.3 Horizon Europe : BatWoMan
------------------------------------259
5.3 Korean national projects
------------------------------------260
5.3.1 Ministry of Trade and Industry
--------------------------------260
5.3.2 Ministry of Education
----------------------------------------------264
5.3.3 Ministry of Science and Technology
-----------------------------------265
5.3.4 Ministry of Economy and Finance
---------------------------------266
6. Market outlook
(research outlook)
6.1 SNE Research
------------------------------------------------------------267
6.2 EV Tank
----------------------------------------------------------------271
6.3 ESP Analysis --------------------------------------------------------273
6.4 Industry ARC
-------------------------------------------------------274
6.5 QY Research
-------------------------------------------------------------275
6.6 Verified Market Reports
-----------------------------------------------------277