Solvent-free battery electrodes reach high density, opening path to cheaper manufacturing

A research team led by Professor Young-Jun Kim at the Sungkyunkwan Advanced Institute of Nano Technology (SAINT) of SKKU has announced a breakthrough in "dry electrode" technology—a next-generation manufacturing process for batteries. The team has developed materials optimized for solvent-free electrode processing, a feat expected to shift the paradigm of battery production.

Dry electrode technology eliminates the use of toxic liquid solvents in the production of lithium-ion and all-solid-state batteries. By directly compacting solid raw materials into electrode films, the process removes the need for energy-intensive drying stages, making it both eco-friendly and highly cost-efficient. This field is currently a focal point for global industry leaders, including Tesla, as companies race to secure dominance in the future battery market.

To overcome the chronic challenges of dry processing—specifically the difficulty of uniform mixing and large-scale production—Professor Kim's team developed a "one-body" material that integrates active materials (for energy storage) and conductive agents (for electron conduction) into a single architecture. This innovation enables the mass production of high-quality, high-loading electrodes. The technical reliability and performance of this method were rigorously validated through collaborative simulations with Professor Yong-Min Lee's team at Yonsei University.

The team's findings on dry cathode technology were published in Joule, and their research on anodes was featured in the online edition of Carbon Energy.

"Dry electrode technology is more than just an eco-friendly process; it is the ultimate solution to dramatically enhancing battery performance, quality, and safety," said Professor Young-Jun Kim. "The specialized materials and production techniques we've developed will serve as a critical stepping stone to significantly reducing manufacturing costs while ensuring global competitiveness in battery performance."

Beyond academic achievement, the team is aggressively pursuing commercialization. Through Corenergy Solution, a laboratory-backed startup, the team plans to launch a Battery Electrode Foundry business specializing in dry electrode manufacturing. In collaboration with other SKKU faculty members with extensive industry experience at South Korean battery giants such as Samsung SDI and LG Energy Solution, the venture aims to advance dry electrode design and cell manufacturing technologies to strengthen the domestic battery ecosystem.

Provided by Sungkyunkwan University