New dry battery process eliminates primer, cuts capacity loss 75%

Researchers in South Korea, led by Professor Won-Jin Kwak at UNIST and collaborators from Gachon and Chung-Ang Universities, have developed a novel dry-process battery electrode that significantly reduces initial capacity loss by about 75%. This innovation involves inserting a thin lithium-metal film between the anode active material and the copper current collector, replacing the conventional primer used for adhesion. The lithium film serves a triple function: it acts as an adhesion layer, eliminates the need for a separate primer, and supplies lithium to compensate for irreversible lithium loss during the first charge-discharge cycle. This approach promotes more uniform solid-electrolyte interphase formation, improving initial coulombic efficiency and cycle stability, which could increase electric vehicle (EV) driving range by approximately 20%. The new method also simplifies manufacturing by removing the wet-chemical primer coating and drying steps, enabling a more efficient, scalable dry manufacturing process compatible with existing roll-to-roll production lines. The technology is compatible with various cathode materials