Researchers have discovered a breakthrough that may revolutionize the way batteries are built. Dry electrode manufacturing has been hailed for years as a sustainable alternative to the solvent-intensive wet process, but its reliance on polytetrafluoroethylene (PTFE) binders has raised major alarm bells.
Due to its solubility, and the high content of fluorine in PTFE it is used contrary to the growing bans against PFAS. Its poor adhesion also forces manufacturers to use wet primers which compromises many of the goals for sustainability that dry processing was designed to achieve.
A research team, led by Professor Kim Jinsoo at the Department of Energy System Engineering, has now developed a novel technology for dry electrode binders using paraffin as the primary component of candles. To overcome the limitations of the dry electrode process, Parafilm (r) M is a commonly used laboratory sealing film.
The high C-H bonds in Parafilm and its large energy gap between molecular orbitals make it a chemically stable material. It’s cheaper, fluorine free, and safer for the environment than PTFE.
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The Parafilm is a low-glass transition temperature film that can be used to join the materials without primer or solvent. It is a milestone for dry electrode technology that demonstrates a solvent-free adhesive process.
The Parafilm M is a cost-effective and cleaner alternative to dry electrode manufacturing. The active material can be connected at 60 degrees C without the need for an extra layer of wet adhesive on collectors.
The binders can reduce manufacturing costs up to 95% compared with traditional PTFE binders and its global warming potential is reduced by only 1/22,200 of PTFE. The battery industry has made a significant step towards carbon neutrality with this development.
8Co0. When tested using LiNi0. 8Co0.
1Mn0. The electrodes were made from 1O2 cathode (NCM811) material and showed excellent electrochemical properties. They stabilized more than 5mAh cm-2 after 600 cycles. This allows for sustainable living without sacrificing efficiency.
The research team went beyond the proof-of concept and demonstrated that its dry-electrode-based Parafilm device was commercially feasible.
The researchers have shown that the device is not only feasible but can also be scaled up to industrial levels using twin-screw extrusion.
Batteries form the heart of all renewable energy systems, portable electronics, and electric vehicles. Their design is a testament to the progress made in sustainability. Scientists have succeeded in displacing a binder known to affect the quality of liquids. They did this by introducing a film that was previously used to seal lab samples.
This is essentially a cheaper, more stable and environmentally friendly alternative.
Kim Jinsoo, Professor at DGIST, said: The parafilm-based binding agent we have developed is an important proprietary technology which can optimize the environmental and economic benefits of dry processes. We will contribute to enhancing South Korea’s leadership in the battery industry by supplying sustainable battery-manufacturing technologies.”
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The convergence of sustainable chemistry with industrial pragmatism could lead to batteries that are both powerful and environmentally friendly.
Journal Reference
- Kim, M.K., Yu, T., Jang, S. et al. The use of Parafilm(r), a fluorine-free binder, to make dry thick electrodes is a step towards achieving sustainable and efficient batteries. Nat Commun 16, 11174 (2025). DOI: 10.1038/s41467-025-66082-3
