干式电极专利分析及技术趋势

• 儘管干法电极具有降低挥发性有机化合物 (VOC)、缩短製程时间、提高能量密度等诸多优势，但特斯拉等大公司已掌握关键专利，这使得后来者难以在不突出自身差异化的情况下引入该技术。
• 因此，在引进新製程或进行新材料研发时，必须对现有专利进行技术评估，并在设计阶段确定策略方向。

本报告探讨了干电极市场，并提供了多方面的分析，包括实施过程中的实际考虑、合作研究策略以及潜在应用。

目录

第1章 干电极技术概要

• 干电极开发背景
• 干法和湿式製程的区别
• 干电极製造工艺

第2章 干电极的PTFE黏合剂的利用

• PTFE（聚四氟乙烯）的化学/物理特性
• PTFE纤维的机理
• 与传统PVDF黏合剂的比较

第3章 Tesla的干电极专利的现状

• Maxwell超级电容器核心干式製程技术
• Maxwell Technologies的专利组合
  • Maxwell Technologies干电极专利检索结果
  • Maxwell 专利组合分析
  • 专利趋势：依国家、年份
  • 专利趋势：依年份与技术主题
  • 申请占有率：按国家和技术主题
• 特斯拉收购 Maxwell 及重要专利的继承

第四章：Maxwell（特斯拉）干电极专利的特性与优势

• 关键权利要求的技术结构
• 技术差异化因素与开发限制
  • 对实际工业应用的影响
• 已公布专利中的技术描述范例
• 从干电极到锂离子电池的转变

第5章 干法工艺及其详细要素

• 粉末混合（活性材料、导电剂、PTFE）阶段
• 预压阶段
• 辊压和层压
• 后处理（热处理、额外压延等）
• 製程复杂性与品质控制 (QC) 要素：依阶段

第6章 PTFE 特性与製程参数之间的技术相关性分析

• PTFE 黏合剂含量与製程参数之间的相互作用
• 压力、温度和电极厚度对 PTFE 纤维化的影响
• 黏合剂纤维化方法与技术差异化因素

第七章：Maxwell（特斯拉）专利组合维护趋势及其对产业的影响

• Maxwell/特斯拉早期专利的到期日（约2026)
• 透过额外申请扩展技术组合的策略
• 专利到期的影响
• Maxwell/Tesla 持有的有效专利概览

第八章：差异化策略与对策

• 产业因应策略
  • 替代黏合剂材料
  • 製程参数变化
  • 半干法或混合製程的引入
  • 授权或合作解决方案
  • 客製化製程设计

第九章：干电极技术为何成为主流

• 基本优势（无溶剂技术的重要性）
• 广泛的应用范围和成熟的量产能力
• 应用于下一代科技的潜力电池（全固态、硅阳极等）

附录

SNE Research's newly released report, "<2025> Dry-process Electrode Patents Analysis & Technology Trends", offers a differentiated perspective on the dry electrode process, which is rapidly emerging as an "innovative technology" within the secondary battery industry.

Rather than simply presenting dry electrode as a promising technology, this report provides a multi-dimensional analysis that includes practical considerations for implementation, collaboration strategies, and potential applications.

• While dry electrode offers compelling benefits such as VOC reduction, shorter processing time, and higher energy density, the fact that leading companies like Tesla have secured key patents makes it difficult for latecomers to introduce the technology without differentiation.
• Therefore, when introducing the process or pursuing R&D on new materials, it is essential to technically assess existing patents and establish strategic direction at the design stage.

This report aims to reduce uncertainty in business execution by systematically organizing the core elements of related patents and key considerations for industrial application.

Key strengths of this report:

1. In-depth guide on patent strategy for dry electrode technology

• The report provides a multi-faceted analysis of major international patents covering core technologies in dry electrode processes such as solvent-free manufacturing and PTFE binder fibrillation, offering actionable design directions and collaboration options for latecomers.
• OEMs, battery manufacturers, and materials suppliers can use this report to assess practical technical questions such as whether modifying specific process parameters can lead to meaningful differentiation, and what to consider when applying the technology under different binder types, temperatures, or pressures.

2. Analysis of over 240 key patent cases and presentation of strategic portfolios

• The report analyzes more than 240 dry electrode-related patents applicable across a wide range of technologies, from supercapacitors to solid-state batteries. Rather than simply listing the patents, it identifies the specific process components addressed by each patent (e.g., binder fibrillation, post-treatment, roll pressing) and clarifies their technical context.
• In particular, for high-potential application areas such as high-nickel cathodes, silicon anodes, and solid-state batteries, the report provides a strategic portfolio focused on technical approaches and potential collaboration or utilization paths. This enables not only materials and equipment suppliers but also securities firms and investors to understand the value and commercial applicability of each technology from multiple perspectives.

3. Integrated analysis from market, technical, and legal perspectives

• The report goes beyond technical characteristics and advantages of dry electrode processes (such as cost savings and line efficiency improvements) to address global regulatory trends (e.g., VOC reduction), pilot line cases at OEM and battery manufacturers, and benefits in safety and energy density.
• It also explores key legal and strategic considerations such as patent publication timing and claim evolution, follow-up applications (e.g., CIP, divisional), and counter-strategy development by latecomers. These insights help stakeholders better manage risks and establish forward-looking technology roadmaps.
• As a result, OEMs, battery and material companies, investors, and research institutions can tailor their R&D, investment, and business strategies to enhance long-term competitiveness.

Who should read this report?

1. Automakers, OEMs, and battery manufacturers

• This report is valuable for companies considering the adoption of dry electrode processes, which offer practical benefits such as reduced CAPEX and OPEX, simplified production lines, and higher energy density. It also provides strategic insights for designing processes while taking into account potential overlap with existing patents.

2. Materials and equipment suppliers

• For companies supplying binders such as PTFE, PVDF, and FEP, conductive additives like carbon nanotubes and graphene, or equipment such as mixers and roll presses, this report helps identify how technical requirements are linked to patent claims in dry processing. It can also guide efforts to establish meaningful technological differentiation.

3. Investment firms and securities companies

• The report supports investment decisions, stock analysis, and partnership or M&A strategies by offering a grounded view of the market potential, patent barriers, and long-term value of dry electrode technologies compared to conventional wet processes.

4. Research institutes and R&D organizations

• By understanding pilot project cases in industry and analyzing patent portfolios, researchers can explore follow-up directions for next-generation battery R&D, including solid-state batteries, silicon anodes, and high-nickel cathodes.

Table of Contents

1. Dry Electrode Technology Overview

• 1.1. Background of Dry Electrode Development
• 1.2. Differences Between Dry and Wet Processes
• 1.3. Dry Electrode Manufacturing Process

2. Application of PTFE Binder in Dry Electrodes

• 2.1. Chemical and Physical Properties of PTFE (Polytetrafluoroethylene)
• 2.2. Fibrous Mechanism of PTFE
• 2.3. Comparison with Conventional PVDF Binders

3. Tesla's Dry Electrode Patents Status

• 3.1. Maxwell's Core Dry Process Technology for Ultracapacitors
• 3.2. Maxwell Technologies Patent Portfolio
  • 3.2.1. Search Results for Maxwell Technologies' Dry Electrode Patents
  • 3.2.2. Analysis of Maxwell's Patent Portfolio
  • 3.2.3. Patent Activity Trends by Country and Year
  • 3.2.4. Patent Activity Trends by Year and Technical Theme
  • 3.2.5. Filing Share by Country and Technical Theme
    • 3.2.5.1. Major Countries Overall (US, CN, EP, JP, KR, PCT)
    • 3.2.5.2. US
    • 3.2.5.3. CN
    • 3.2.5.4. EP
    • 3.2.5.5. JP
    • 3.2.5.6. KR
• 3.3. Tesla's Acquisition of Maxwell and Inheritance of Key Patents

4. Characteristics and Strengths of Maxwell (Tesla)'s Dry Electrode Patents

• 4.1. Technical Configuration of Key Claims
• 4.2. Technical Differentiators and Development Constraints
  • 4.2.1. Impact in Real-World Industrial Applications
• 4.3. Examples of Technical Descriptions in Published Patents
• 4.4. Transition of Dry Electrodes to Lithium-Ion Batteries

5. Dry Process and Its Detailed Factors

• 5.1. Powder Mixing (Active Material, Conductive Agent, PTFE) Stage
• 5.2. Pre-Pressing Stage
• 5.3. Roll Pressing and Lamination
• 5.4. Post-Treatment (Thermal Treatment, Additional Calendaring, etc.)
• 5.5. Process Complexity and Quality Control (QC) Factors by Stage

6. Analysis of Technical Correlation Between PTFE Properties and Process Parameters

• 6.1. Interaction Between PTFE Binder Content and Process Parameters
• 6.2. Effects of Pressure, Temperature, and Electrode Thickness on PTFE Fibrillation
• 6.3. Binder Fibrillation Methods and Technical Differentiators

7. Maintenance Trends of Maxwell (Tesla) Patent Portfolio and Its Industry Impact

• 7.1. Expiration Timeline of Early Maxwell/Tesla Patents (Around 2026)
• 7.2. Strategy for Expanding the Technology Portfolio Through Follow-Up Filings
• 7.3. Impact of Patent Expiration
• 7.4. Overview of Alive Patents Held by Maxwell/Tesla

8. Differentiation Strategies and Countermeasures

• 8.1. Industry Response Strategies
  • 8.1.1. Alternative Binder Materials
  • 8.1.2. Modifications of Process Parameters
  • 8.1.3. Introduction of Semi-Dry or Hybrid Processes
  • 8.1.4. Settlements Through Licensing or Collaboration
  • 8.1.5. Customized Process Design

9. Why Dry Electrode Technology Dominates

• 9.1. Foundational Advantage (Significance of Solvent-Free Adoption)
• 9.2. Broad Claim Scope and Proven Mass Production Capability
• 9.3. Applicability to Next-Generation Batteries (All-Solid-State, Silicon Anode, etc.)

Appendix

Appendix 1. Analysis of Representative Patent Families

• A 1.1. Representative Patent Families
• A 1.2. Core Inventions
• A 1.3. Examples of Differentiating Patent Claims
• A 1.4. Implications

Appendix 2. Application of Dry Electrodes to Cathodes and Anodes and Patent Implications

• A 2.1. Cathode Applications (NCM, NCA, LFP)
• A 2.2. Anode Applications (Graphite, Silicon Composite)
• A 2.3. Comparison of Application Difficulty Between Cathode and Anode
• A 2.4. Conclusion and Outlook

Appendix 3. Expansion of Dry Electrode Technology to All-Solid-State and Next-Gen. Batteries

• A 3.1. Significance of Dry Processing in All-Solid-State Batteries
• A 3.2. Synergy Between Dry Process and Transition from Lithium-Ion to All-Solid-State Batteries
• A 3.3. Conclusion

Appendix 4. Glossary