Korean researchers have achieved a breakthrough in next-generation eco-friendly battery manufacturing by improving the "kneading" process—mixing battery materials like bread dough. The innovation reduces production time to one-quarter while tripling electrode strength.
A joint research team from POSTECH (Pohang University of Science and Technology), UNIST (Ulsan National Institute of Science and Technology), and KIST (Korea Institute of Science and Technology) announced on the 13th that they solved key challenges in dry electrode manufacturing by innovating the kneading process.
Dry electrode technology produces battery electrodes without water or chemical solvents. The solvent-free approach is environmentally friendly and cost-effective. The technology has attracted global attention as it enables thicker electrodes that store more energy in the same volume.
However, dry electrodes faced commercialization hurdles due to lengthy production times and structural fragility. Researchers explained that reducing binder and conductive additives to increase energy storage improves energy density but destabilizes electrode structure and sharply degrades performance.
The team identified kneading as the critical factor determining dry electrode success. Kneading mixes battery materials similar to working flour dough to achieve a chewy texture. This stage determines electrode structure and properties, but precisely controlling the changes during this process proved extremely difficult.
The researchers coated carbon nanotubes onto the surface of active materials that store energy. This created microscopic surface irregularities that helped materials interlock while binders formed dense connections throughout. The kneading process—previously the most time-consuming step—was shortened by more than 75%, and electrode strength improved up to threefold. Notably, reducing binder usage to one-tenth of previous levels freed more internal electrode space for greater energy storage.
The team also fabricated a 1Ah pouch-type battery, confirming mass production potential beyond laboratory scale. Professor Park Kyu-young said, "This research simultaneously solved 'process speed' and 'structural vulnerability'—the biggest challenges in dry electrode manufacturing. We hope this becomes a starting point for accelerating next-generation high-energy battery production."
The research was supported by the Ministry of Science and ICT, the Ministry of Trade, Industry and Energy, and Samsung SDI.