Fluorine-free binder-based dry thick battery electrodes with Parafilm® M for sustainable and efficient battery manufacturing

Fluorine-free binder-based dry thick battery electrodes with Parafilm® M for sustainable and efficient battery manufacturing | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Article Fluorine-free binder-based dry thick battery electrodes with Parafilm® M for sustainable and efficient battery manufacturing Jinsoo Kim, Min Kyung Kim, Taegyun Yu, Sungbin Jang, Juho Lee, and 26 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-5544657/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 16 Dec, 2025 Read the published version in Nature Communications → Version 1 posted You are reading this latest preprint version Abstract Dry electrodes are being actively developed for sustainable and efficient battery manufacturing. Currently, polytetrafluoroethylene (PTFE) binders dominate dry processes, yet their production contributes to significant CO2 emissions, and concerns persist regarding their high fluorine content, especially considering evolving per- and polyfluoroalkyl substances (PFAS) restrictions. Moreover, the poor adhesion of bare current collectors necessitates a wet coating-based primer layer, which dilutes its main objectives. This study introduces an alternative dry processing concept based on a thermoplastic fluorine-free binder with low environmental impact and high productivity. Parafilm® M (hereafter Parafilm), a well-known laboratory sealing film formulated with low-cost paraffin and polyethylene (PE), is a mixture of primarily saturated linear hydrocarbons, which are the most stable chemical species owing to its C-H covalent bonds and the wide gap between highest occupied molecular orbital (HOMO) and lowest unoccupied molecular orbital (LUMO) energies. It also has a low glass transition temperature (Tg), allowing facile cohesion of the active materials to be interconnected by mild pressing activation without wet-coated primer layers. This dry electrode binder provides substantial electrochemical properties based on both NCM811 cathodes over 5 mAh cm−2 for 700 cycles. Furthermore, the binder mechanics were maintained at the elevated temperature over Tg with its cheesy nature rather than liquefied melting. This integrated approach bridges the gap between materials and processes, paving the way for sustainable advancements in battery electrode manufacturing. Physical sciences/Energy science and technology/Energy storage/Batteries Physical sciences/Materials science/Materials for energy and catalysis/Batteries Physical sciences/Chemistry/Electrochemistry/Batteries Full Text Additional Declarations Yes there is potential Competing Interest. Jinsoo Kim is named as an inventor on application of PCT (PCT/KR2024/017344) and patent of Republic of Korea (10-2024-0067630, 10-2024-0074946) filed by Korea Institute of Energy Research that covers these and related classes of paraffin-based dry electrode binders, as well as aspects of their use in electrochemical devices. Supplementary Files VideoS1PTFEelectrode.mp4 Scorching test of PTFE-based electrode VideoS2PVDFelectrode.mp4 Scorching test of PVDF-based electrode VideoS3Parafilmelectrode.mp4 Scorching test of Parafilm-based electrode VideoS4screwmixer1st.mp4 Dry twin-screw mixing of Parafilm-based electrode powder (1st iteration) VideoS5screwmixer2nd.mp4 Dry twin-screw mixing of Parafilm-based electrode powder (2nd iteration) VideoS6screwmixer3rd.mp4 Dry twin-screw mixing of Parafilm-based electrode powder (3rd iteration) ParafilmdryelectrodeSIvfplaintext.pdf Supplementary Fig. 1~18 Supplementary Table 1~8 Cite Share Download PDF Status: Published Journal Publication published 16 Dec, 2025 Read the published version in Nature Communications → Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-5544657","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Article","associatedPublications":[],"authors":[{"id":388063080,"identity":"e85e9fd7-d0cd-4250-a0bb-3eb78096a77b","order_by":0,"name":"Jinsoo 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Currently, polytetrafluoroethylene (PTFE) binders dominate dry processes, yet their production contributes to significant CO2 emissions, and concerns persist regarding their high fluorine content, especially considering evolving per- and polyfluoroalkyl substances (PFAS) restrictions. Moreover, the poor adhesion of bare current collectors necessitates a wet coating-based primer layer, which dilutes its main objectives. This study introduces an alternative dry processing concept based on a thermoplastic fluorine-free binder with low environmental impact and high productivity. Parafilm® M (hereafter Parafilm), a well-known laboratory sealing film formulated with low-cost paraffin and polyethylene (PE), is a mixture of primarily saturated linear hydrocarbons, which are the most stable chemical species owing to its C-H covalent bonds and the wide gap between highest occupied molecular orbital (HOMO) and lowest unoccupied molecular orbital (LUMO) energies. It also has a low glass transition temperature (Tg), allowing facile cohesion of the active materials to be interconnected by mild pressing activation without wet-coated primer layers. This dry electrode binder provides substantial electrochemical properties based on both NCM811 cathodes over 5 mAh cm−2 for 700 cycles. Furthermore, the binder mechanics were maintained at the elevated temperature over Tg with its cheesy nature rather than liquefied melting. 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