Application Progress of Dry Electrodes in Supercapacitors and Lithium Batteries

Amid the wave of transformation in the energy storage industry towards greenization, high efficiency, and high-endization, the innovation of electrode manufacturing processes has become the core driving force for industrial upgrading. Traditional wet electrode processes rely on toxic organic solvents such as NMP, facing environmental compliance pressures and energy consumption costs, and also have certain bottlenecks in performance improvement. With "solvent-free, low energy consumption, and high performance" as its core advantages, dry electrode technology has restructured the underlying logic of electrode manufacturing. By virtue of its simplified process, environmental friendliness, and performance leap, it has achieved large-scale application in the supercapacitor field and is gradually penetrating into the lithium battery field, becoming an important technological direction connecting the two major energy storage tracks and promoting technological iteration.

Application of Dry Electrodes in Supercapacitors: Mature Technology with Remarkable Large-Scale Implementation Results

As a new type of energy storage device, supercapacitors are widely used in smart grids, rail transit, industrial control and other fields due to their advantages of fast response, long cycle life, and wide temperature adaptability. The application of dry electrode technology further amplifies their core competitiveness, becoming an important support for the high-performance and green development of supercapacitors. At present, dry electrodes have achieved large-scale application in mid-to-high-end supercapacitors, forming a complete industrial chain from material R&D, equipment manufacturing to terminal application. However, from the perspective of the entire supercapacitor industry, wet electrodes still occupy the mainstream market position, and the popularization of dry electrodes requires continuous acceptance and cultivation within the industry.

Application Status: Gradual Replacement in High-End Segments, Covering Diverse Scenario Needs

With its solvent-free characteristics and structural advantages, dry electrodes are gradually replacing wet electrodes in the mid-to-high-end supercapacitor field, becoming the preferred process for this segment. Compared with wet electrodes, dry electrodes do not require solvent preparation and drying recovery links. Through physical mixing, fibrillation treatment and high-pressure calendering, self-supporting electrode films can be directly prepared, which not only reduces production energy consumption and environmental costs, but also effectively improves the key performance of supercapacitors. At present, dry electrode supercapacitors have achieved large-scale mass production, covering a variety of categories and adapting to extreme environmental needs. However, their market share is still lower than that of wet electrodes, and full replacement has not been achieved.

In practical applications, dry electrode supercapacitors perform prominently: in the smart grid field, as backup power for distribution network ring main units and pole-mounted FTU units, they achieve millisecond-level emergency power supply relying on low internal resistance and fast response advantages, ensuring rapid isolation of power grid faults; in the rail transit field, they are used for braking energy recovery and startup power supply, with energy recovery efficiency increased to more than 90%, helping to upgrade the green energy saving of urban rail transit; in wind farms in extremely cold areas, as backup power for wind turbine pitch control, they can reliably lock the pitch at -40℃, and their maintenance-free feature greatly reduces operation and maintenance costs. Among them, relying on core powder-in-film technology, Tsingyane Electronics has built large-scale dry electrode production lines. Its independently developed dry electrode supercapacitors have a cycle life of more than 1 million times and a service life of 10-15 years, which are widely used in multiple high-end scenarios, demonstrating the mature application value of dry electrodes in the supercapacitor field.

Technological Breakthroughs: Driven by Both Process Optimization and Material Innovation

With the continuous expansion of application scenarios, technological breakthroughs of dry electrodes in the supercapacitor field are advancing steadily, focusing on two core directions: process optimization and special material R&D. In terms of process, solvent-free dry mixing and fibrillation technology are constantly iterated to optimize the electrode structure, reduce interface impedance, improve ion transport efficiency, and further strengthen its performance advantages; in terms of materials, progress has been made in the R&D of special binders and active materials, gradually breaking the performance limitations of traditional materials, and promoting the steady improvement of performance and reasonable reduction of costs of dry electrode supercapacitors.

In terms of materials, significant progress has been made in the R&D of special binders and active materials, breaking the performance limitations of traditional materials. The special PTFE binder for dry electrodes forms a three-dimensional fiber network through fibrillation modification, firmly anchoring active materials and conductive agents. The mechanical strength of the electrode is more than 50% higher than that of wet electrodes, effectively avoiding problems such as electrode cracking and powder shedding during charge and discharge. At the same time, the localization breakthrough of high-performance active materials such as coconut shell activated carbon and carbon nanotubes has further improved the capacity and power density of supercapacitors, reduced manufacturing costs, and promoted the large-scale popularization of dry electrode supercapacitors. In addition, the synergistic optimization of dry electrodes and wide-temperature electrolytes has further improved the performance stability of supercapacitors in extreme high and low temperature environments, expanding their application boundaries in special scenarios such as polar scientific research and high-altitude equipment.

Industrialization Progress: Improved Industrial Chain and Remarkable Localization Substitution Results

At present, the industrialization of dry electrodes in the supercapacitor field has entered a mature stage, forming a complete industrial chain layout of "material-equipment-device-application". On the material side, domestic enterprises have realized large-scale mass production of special materials for dry electrodes, breaking the technological monopoly of overseas enterprises; on the equipment side, relevant enterprises have developed integrated dry electrode production equipment, realizing fully automated production; on the device side, Tsingyane Electronics has built large-scale production lines to meet the needs of the mid-to-high-end market. However, it should be clearly stated that wet electrodes, with their mature processes and low costs, are still the mainstream process in the current supercapacitor industry. The further popularization of dry electrodes requires the joint acceptance and promotion of enterprises and practitioners in the industry.

It is worth noting that with the tightening of environmental policies and the in-depth implementation of the "dual carbon" strategy, the market demand for dry electrode supercapacitors is growing continuously, and their advantages of environmental protection and high performance are gradually recognized by the industry. However, it is difficult to shake the mainstream position of wet electrodes in the short term, and the growth of dry electrodes still needs to go through a process of industry cultivation.

Application of Dry Electrodes in Lithium Batteries: Accelerated Penetration and Continuous Industrialization Progress

Compared with large-scale application in the supercapacitor field, the application of dry electrodes in the lithium battery field is still in the initial penetration stage. With their unique advantages in cost, environmental protection and performance, they have become an important exploration direction for the lithium battery industry to reduce costs, increase efficiency and break performance bottlenecks. Especially in the next-generation lithium battery technology routes such as 4680 large cylindrical batteries and all-solid-state batteries, dry electrodes are regarded as the key prerequisite technology for large-scale mass production, attracting the focus of global leading enterprises. In recent years, with the mass production of special materials, the application of dry electrodes in the lithium battery field has made initial breakthroughs, but there is still a long way to go for large-scale popularization, which requires extensive acceptance and joint growth within the industry.

Application Status: Focusing on High-End Routes and Gradually Realizing Scenario Implementation

At present, the application of dry electrodes in lithium batteries mainly focuses on three directions: 4680 large cylindrical batteries, all-solid-state batteries and high-energy-density power batteries, which is in the transition stage from laboratory R&D to small-scale mass production. In the field of 4680 large cylindrical batteries, overseas leading enterprises took the lead in applying dry electrode technology and realized large-scale production, gradually verifying its technical feasibility; in the field of all-solid-state batteries, the solvent-free characteristics of dry electrodes are suitable for the preparation needs of sulfide electrolytes, becoming the core process for the industrialization of all-solid-state batteries. Some domestic enterprises have built pilot production lines for dry electrode all-solid-state batteries and realized small-batch production; in the field of high-energy-density power batteries, domestic leading battery enterprises are actively developing dry electrode technology to explore its application feasibility. However, on the whole, wet electrodes are still the absolute mainstream in the lithium battery field, and the application of dry electrodes is still in the stage of pilot verification and gradual promotion.

In the field of all-solid-state batteries, the solvent-free characteristics of dry electrodes are perfectly suitable for the preparation needs of sulfide electrolytes, effectively avoiding electrolyte hydrolysis and oxidation caused by solvents, and becoming the core process for the industrialization of all-solid-state batteries. Relevant domestic enterprises have built pilot production lines for dry electrode all-solid-state batteries, and some enterprises have realized the landing of solid-state battery production lines. All-solid-state batteries prepared by dry electrode technology have significantly reduced interface impedance and improved cycle stability, laying a foundation for the large-scale mass production of all-solid-state batteries. In addition, in the field of high-energy-density power batteries, domestic leading battery enterprises are actively developing dry electrode technology to promote the further breakthrough of energy density of lithium iron phosphate and ternary batteries by improving electrode compaction density, adapting to the long-range demand of new energy vehicles.

Technological Breakthroughs: Dual Breakthroughs in Special Materials and Process Adaptation

The application breakthrough of dry electrodes in the lithium battery field lies in the R&D of special materials and the optimization of process adaptation, solving the industry pain point that traditional wet materials cannot adapt to dry processes. On the material side, domestic enterprises have realized the mass production of special lithium iron phosphate cathode materials for dry electrodes, and high-nickel ternary special materials for dry electrodes have also entered the customer verification stage, gradually improving the industrial chain supporting; in terms of process adaptation, dry electrode equipment technology is continuously upgraded, optimizing core production links, improving production stability and batch consistency, and at the same time carrying out technical optimization for the application difficulties of negative electrodes, promoting the adaptive application of dry electrodes in cutting-edge technologies. However, these breakthroughs are still in the initial stage, and continuous R&D investment and supporting improvement within the industry are needed to promote the gradual acceptance of dry electrodes by the market.

In terms of process adaptation, dry electrode equipment technology is continuously upgraded. Integrated dry film forming and compounding equipment developed by relevant domestic enterprises can greatly improve electrode density; relevant enterprises have taken the lead in defining the core modules of the dry electrode process, optimizing core links such as feeding and conveying, 3D fibrillation mixing, and improving production stability and batch consistency. In addition, aiming at the application difficulties of dry electrodes in lithium battery negative electrodes, enterprises have solved the problem of PTFE instability at low potential by modifying PTFE binders and optimizing particle gradation, promoting the adaptive application of dry electrodes in cutting-edge technologies such as silicon-based negative electrodes and prelithiation.

Industrialization Progress: Accelerated Global Layout and Rising Localization Strength

At present, lithium battery enterprises around the world are accelerating the layout of dry electrode technology, forming an industrial pattern of "overseas leading and domestic following". In the overseas market, some automakers and battery enterprises have realized large-scale application and technical verification of dry electrodes in new batteries; in the domestic market, enterprises in the material, equipment and battery sectors are working together to promote the gradual acceleration of the industrialization process of dry electrodes. Relevant materials and equipment have achieved large-scale supply, and some battery enterprises are also accelerating technology R&D and reserve. However, it must be clearly stated that wet electrodes, with their mature process system, improved industrial chain supporting and low costs, are still the mainstream process in the current lithium battery field. The industrialization of dry electrodes requires the joint efforts of all parties in the industry to gradually cultivate the market, improve technology, and promote the joint acceptance of this new process by the industry.

At present, the penetration rate of dry electrodes in the lithium battery field is much lower than that in the supercapacitor field, and it is difficult to shake the mainstream position of wet electrodes in the short term. With the continuous iteration of special materials, the improvement of equipment efficiency and the reduction of costs, its industrialization speed will gradually accelerate. However, this process requires the continuous acceptance of practitioners in the industry, the continuous maturity of technology and the gradual recognition of the market. It is expected that in the next 3-5 years, dry electrodes will achieve small-scale mass production in some new lithium battery fields, and gradually grow into a supplementary force for the transformation and upgrading of the lithium battery industry.

Application Comparison in Two Fields and Future Development Outlook

Application Comparison: Differentiated Adaptation to Jointly Promote the Upgrade of the Energy Storage Industry

The application of dry electrodes in supercapacitors and lithium batteries forms differentiated adaptation based on the core needs of the two major energy storage devices, and achieves coordinated development. In the supercapacitor field, the core value of dry electrodes lies in improving performance, practicing environmental protection, and making up for the performance shortcomings of wet electrodes in extreme scenarios, but their market share is still lower than that of wet electrodes; in the lithium battery field, the core value of dry electrodes lies in exploring cost reduction and efficiency improvement, breaking performance bottlenecks, and adapting to the next-generation lithium battery technology routes, but currently it is still in the pilot promotion stage and has not formed large-scale application. Although they have different application scenarios, both rely on the solvent-free and high-performance advantages of dry electrodes to provide a new technical choice for the energy storage industry. As the current mainstream of the industry, wet electrodes will still play a core role for a long time to come, and the growth of dry electrodes requires the joint acceptance and cultivation of the industry.

Future Outlook: Parallel Development of Technological Iteration and Scenario Expansion

In the future, dry electrode technology will continue to iterate, and its application scope will gradually expand in the supercapacitor and lithium battery fields. In the supercapacitor field, we will further optimize processes and materials, improve product performance, reduce costs, and gradually increase market share, but its growth still needs to rely on the acceptance and promotion of the industry; in the lithium battery field, we will focus on breaking key bottlenecks such as special material R&D and process efficiency improvement, gradually realize large-scale application in new battery routes, and be gradually widely accepted by the industry. It should be clearly stated that wet electrodes will maintain their mainstream position for a long time to come. Dry electrodes are not intended to replace wet electrodes, but as a supplementary and upgrading direction, they will work together with wet electrodes to promote the transformation of the energy storage industry towards greenization and high efficiency.

As a pioneer in the dry electrode field, Tsingyane Electronics will continue to focus on core technologies. Relying on the technological accumulation of Shenzhen Tsinghua University Research Institute, it will make continuous breakthroughs in key links such as powder film formation and fibrillation treatment, promote the in-depth application of dry electrode technology in the supercapacitor field, and at the same time layout the R&D of dry electrode technology for lithium batteries to help the industry's technological progress. We have always believed that wet electrodes are still the current mainstream of the industry. The growth of dry electrodes is inseparable from the joint efforts and acceptance of all parties in the industry. In the future, we will work together with industry peers to promote the gradual maturity and steady promotion of dry electrode technology, help the domestic energy storage industry achieve independent controllability and high-quality development, and form a good pattern of coordinated development of wet and dry processes.