Shaping the Future: Advancing Dry Battery Electrode Fabrication with Dynamic Image Analysis

As demand for lithium-ion batteries (LIBs) continues to grow rapidly (driven by electric vehicles, portable electronics, and energy storage systems) manufacturers are under increasing pressure to boost performance, reduce costs, and minimize environmental impact. Traditional slurry-based electrode production, which relies on toxic solvents like NMP and energy-intensive drying steps, is becoming less sustainable and more expensive.
Dry electrode processing is changing the game. By eliminating the need for solvents and simplifying the production workflow, this method offers a cleaner, more cost-effective, and scalable alternative. But to fully unlock its potential, precise control over the physical properties of the powders used - such as porosity, surface area, and especially particle size and shape - is essential.
One of the most critical steps in the dry coating process is the fibrillation of PTFE (polytetrafluoroethylene) binder, which holds the electrode component in fibrous network. When mechanical shear is applied to the PTFE binder in the presence of electrode components, it forms a strong, interconnected structure. This network enables mechanical integrity of the electrode and improves battery performance, particularly at high mass loadings.
To fine-tune this process and achieve consistent, high-quality results, manufacturers need to deeply understand how the powder and binder behave at every stage - from raw materials to the final electrode layer. This is where advanced material characterization tools come in. Dynamic image analysis enables detailed measurement of particle size and shape, which are key factors that influence PTFE fibrillation, electrode structure, and ultimately, battery performance.
This application report showcases how particle size analyzers play a vital role in optimizing dry electrode technology - helping you deliver better batteries, faster and greener.