Domestic researchers have succeeded in accelerating the commercialization of Dry Electrodes technology, which is gaining attention as a next-generation battery manufacturing method.
Researchers from Yonsei University and LG Energy Solution said on the 10th that they have identified the technical challenges hindering the commercialization of "Dry Electrodes," which is recognized as a next-generation battery technology. The research results were published in the international journal "Nature Energy" on Feb. 26.
Currently, most battery manufacturers are using wet electrode processes. The wet process involves mixing active material, conductive agents, and binders with expensive solvents to create a slurry, which is then coated onto metal foils and undergoes a drying process to evaporate the solvent. However, it has drawbacks, including high energy consumption, long processing times, and the need for large-scale equipment investments, increasing manufacturing expenses. Additionally, producing thick electrodes to enhance the active material content is challenging, limiting the maximization of energy density.
Recently, the "dry electrode process" has emerged as a game changer that can complement this. The dry process manufactures electrodes by directly mixing active materials, conductive agents, and binders without solvents, resulting in solid powder forms. This technology reduces manufacturing costs as it does not require a separate drying process and maximizes production efficiency.
However, there are many technical challenges to be addressed before the dry electrodes can be commercialized. The researchers believe that ensuring electrode uniformity, developing thick electrode technology, and securing yield for mass production need to be resolved through analysis of the manufacturing process and battery performance.
Since dry electrodes are produced without solvents, if active materials, conductive agents, and binders are not uniformly distributed, there is a significant risk of performance degradation. To address this, new dispersion technology that can uniformly arrange materials within the electrodes and optimization of the calendering process are necessary.
The researchers also noted that improvements must be made to thick electrode technology. Although thick electrodes are essential for enhancing energy density, forming a uniform thickness and density is challenging. To achieve this, high-adhesion binders and conductive agents must be developed, and the process needs to be adjusted precisely to ensure uniform coating density. At the same time, securing quality stability during the mass production process of the dry electrode process through process optimization is also a critical factor.
Professor Lee Sang-young from Yonsei University stated, "This research clearly identifies the challenges of dry electrode technology and is significant for presenting a practical development direction for mass production beyond the laboratory stage," adding, "Through this, we will establish a new standard for dry electrode research and strengthen cooperation with the battery industry."
Kim Je-young, Chief Technology Officer of LG Energy Solution, emphasized, "Dry electrodes are the key technology that can reduce battery manufacturing costs and maximize production efficiency, especially as a 'super-gap technology' to stay ahead of the rapidly growing Chinese battery corporations in the global market."
References
Nature Energy (2025), DOI: https://doi.org/10.1038/s41560-025-01720-0