Dry electrode technology: A new processing paradigm for enhancing performance and sustainability in lithium-based batteries

초록

Dry electrode technology is rapidly emerging as a transformative approach to address the technical and environmental limitations of conventional wet-slurry processes in lithium-ion batteries (LIBs) and solid-state batteries. By eliminating the use of solvents, this method reduces energy consumption and environmental burden while enabling the fabrication of thick, high-energy-density electrodes with enhanced mechanical stability. This review provides a comprehensive comparison between wet and dry electrode manufacturing, with an emphasis on the microstructural evolution, binder fibrillation behavior, and large-scale process scalability of dry-processed electrodes. Recent advances in dry electrode fabrication for all-solid-state batteries (ASSBs), the use of functional conductive additives, and interfacial challenges associated with dry-processed architectures are critically examined. Key technological highlights include the role of PTFE-based binder fibrillation in forming robust mechanical networks, mitigation strategies for PTFE decomposition under reductive conditions, and the development of bilayer dry-processed solid-state electrolytes to enhance electrochemical and mechanical stability. This review aims to provide a technical roadmap for next-generation battery manufacturing and offers insights into the commercialization challenges and environmental sustainability of dry electrode processing.

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