By submitting this form, you are agreeing to the Terms of Use and Privacy Policy.
In the battery business, dry battery electrodes (DBE) is a new idea and technology that reinvents the process of making electrodes from powder to film. The DBE approach can greatly improve material compatibility, recreate electrode microstructures, and simplify the production process. A coating technique for solid pharmaceutical dosage forms called dry coating evolved from the powder coating of metals. In this technology, powdered coating components are applied directly, without the use of a solvent, to solid dosage forms to produce a coat that is then heated and cured.
Dry electrodes can be made of a variety of materials and geometries, including silicone conductive rubber, foam-based sensors, bristle-type electrodes, comb-like electrodes, electrodes with several pins, and electrodes that are gold-plated.
In the battery business, dry battery electrodes (DBE) is a new idea and technology that reinvents the process of making electrodes from powder to film. The DBE approach can greatly improve material compatibility, recreate electrode microstructures, and simplify the production process. A coating is a covering that is put on an object’s surface, also known as the substrate. The coating may be used for practical, ornamental, or a combination of both purposes. It is possible to apply coatings as liquids, gases, or solids, such as powder coatings.
The Global dry electrode coating market accounted for $XX Billion in 2023 and is anticipated to reach $XX Billion by 2030, registering a CAGR of XX% from 2024 to 2030.
Tesla Inc. is introducing a brand-new method of making batteries for its new 4680 battery cells called dry electrode coating. The wet, complex procedure of covering the electrode foil with a wet chemical slurry is replaced by the dry technique, which Tesla acquired through its acquisition of California company Maxwell Technologies.
Before final assembly, the coated foil must go through a drawn-out drying process, and the toxic solvents used in the slurry must be recovered and disposed of.In addition to increasing the energy density and power of battery cells, the dry coating technique has the potential to significantly lower the size, cost, energy consumption, and production cycle time of battery manufacturing plants.
In its battery cell manufacturing facilities in Europe and North America, Volkswagen’s PowerCo SE wants to implement an electrode dry-coating manufacturing method. The new method will greatly improve sustainability and efficiency in the production of large quantities of battery cells.
The Salzgitter-based battery manufacturer, a division of the Volkswagen Group, wants to make the dry coating process more widely used. Internal studies have already shown that the technique successfully reduces energy use by roughly 30%.
PowerCo will advance and industrialise the dry coating process in collaboration with Koenig & Bauer AG, a leading German manufacturer of printing machines. The battery components are combined with chemicals and liquid solvents to create a slurry in the manufacturing of industrial electrodes.
Then, they are coated onto copper- or aluminium-based foils, dried, and calendered. With PowerCo’s dry coating method, it is possible to print-like directly apply the powdery fundamental components to the foil. Two of the four steps in the production process for electrodes are thereby rendered obsolete. The powder coating can be applied to the foil in a very precise and even manner, leaving behind a layer that is about the thickness of a hair.
This increases the battery’s capacity for rapid charging and ensures a high spatial energy density throughout a lengthy life cycle. They will work together to create a roller press for powder coating electrodes on an industrial scale. The dry coating process enables the production of electrodes without wet coating and drying them afterwards at high prices. The most energy-consuming step in cell manufacturing, as well as the use of chemical solvents, are no longer necessary with the new method.
The technology is already being tested and improved by PowerCo in a trial line at one of its labs in Northern Germany. Koenig & Bauer, a printing expert, will create a device for commercial powder coating. The new technology has the potential to save around 30% of energy and 15% of needed floor area, according to PowerCo estimates.
Four parallel coating and drying lines can be saved per building block of a standard Gigafactory with a manufacturing capacity of 20 GWh, or an area of 7.000 square metres. The outside length of the plant can be cut by roughly 100 metres as a result.
The energy saved will be equal to what 40,000 private houses consume in a year if the energy-guzzling drying furnaces and suction systems are not used. Furthermore, it is no longer required to utilise chemical solvents that must be laboriously recycled outside of the plants in towers resembling silos at substantial energy costs. They are built with quick and simple retrofits in mind. They have estimated roughly 30 future product and production breakthroughs in total.
