Park Joonhyeok, Kim Jiwoon, Kim Jaeik, Kim Minsung, Song Taeseup, Paik Ungyu
Department of Energy Engineering, Hanyang University Seoul Republic of Korea
Department of Battery Engineering, Hanyang University Seoul Republic of Korea.
Chem Sci. 2025 Mar 28;16(16):6598-6619. doi: 10.1039/d5sc00059a. eCollection 2025 Apr 16.
The transition to electric vehicles motivated by global carbon neutrality targets has intensified the demand for lithium-ion batteries (LIBs) with high energy density. While the innovation of cathode/anode active materials has reached a plateau, development of thick electrodes has emerged as a critical breakthrough to achieving high-energy-density LIBs. However, the conventional wet coating process has intrinsic limitations, such as binder migration during the solvent drying process, which becomes increasingly problematic with thick electrodes. To address these challenges, dry coating processes have been actively explored in three main forms: electrostatic spraying, hot pressing with thermoplastic polymers, and roll-to-roll dry coating utilizing the polytetrafluoroethylene binder. This review highlights the roll-to-roll dry coating process, a scalable and industrially viable approach, by introducing its underlying mechanisms, latest developments, and applications in all-solid-state batteries and lithium-sulfur batteries. By combining technical advancements with manufacturing scalability, the roll-to-roll dry coating process demonstrates significant potential to enable next-generation battery systems.
受全球碳中和目标推动向电动汽车的转型，加剧了对高能量密度锂离子电池（LIB）的需求。虽然阴极/阳极活性材料的创新已趋于平稳，但厚电极的开发已成为实现高能量密度LIB的关键突破。然而，传统的湿法涂布工艺存在固有局限性，例如在溶剂干燥过程中粘结剂迁移，这对于厚电极来说问题日益严重。为应对这些挑战，人们积极探索了三种主要形式的干法涂布工艺：静电喷涂、用热塑性聚合物进行热压以及利用聚四氟乙烯粘结剂的卷对卷干法涂布。本综述通过介绍其基本原理、最新进展以及在全固态电池和锂硫电池中的应用，重点阐述了卷对卷干法涂布工艺，这是一种可扩展且具有工业可行性的方法。通过将技术进步与制造可扩展性相结合，卷对卷干法涂布工艺展现出实现下一代电池系统的巨大潜力。
