BREYER has been selected to supply a dry-coating system for electrode manufacturing to the Fraunhofer Research Institution for Battery Cell Production (Fraunhofer FFB). The new line will be installed in one of the innovation modules inside the FFB PreFab facility, supporting ongoing research into next-generation lithium-ion battery production for electric vehicles (EVs) and stationary storage.
Advancing dry electrode manufacturing
Fraunhofer’s program focuses on reducing battery-cell production costs while improving sustainability compared with conventional wet-coating methods. Instead of using solvent-based slurries, the dry-coating approach begins with solvent-free powder mixing.
The premixed material is fed directly into a roll gap to form a uniform electrode layer, which is then applied to aluminum or copper current collectors.
BREYER’s IONDry 600 system continuously conveys this dry premix into the roll gap and coats both sides of the electrode track before the material is wound. A newly developed dosing system ensures precise powder distribution and consistent feed control.
The rotating rolls generate a homogeneous film with thickness controlled by roll speed, while an electrohydraulic system regulates the roll gap with high accuracy. Multiple roll gaps enable simultaneous production of top and bottom electrode layers, which are laminated onto the current collector to form a final composite.
Engineering features
- Solvent-free operation: Eliminates chemical solvents and associated drying steps, lowering energy demand and environmental impact.
- Reduced operating cost: No large-scale drying ovens required, decreasing process time and energy consumption.
- Precision gap control: Force and distance-regulated roll-gap adjustment for high-accuracy coating.
- Higher throughput goals: System designed for coating speeds of at least 20 m/min at a 400-mm coating width.
- Inline sensing: Integrated sensors enable real-time monitoring and closed-loop optimization of coating quality.
Dry-coating technologies such as this represent an emerging alternative to traditional slurry coating, offering higher sustainability, lower energy use, and potentially lower capital cost, all critical factors as EV manufacturers scale lithium-ion production.
With delivery of the IONDry 600, BREYER supports Fraunhofer FFB’s broader research mission to develop advanced, scalable manufacturing methods that can help accelerate the EVs and energy-storage systems.
Filed Under: Batteries, R&D, Technology News