With X.Cellify DC, Dürr is presenting a process that produces electrodes from a dry powder mixture and thus dispenses with drying ovens and solvents. It is based on the Activated Dry Electrode process from partner LiCAP Technologies. X.Cellify DC reproduces all steps of the dry coating process - from dosing, film formation and compaction to lamination onto the collector foil. The proof of concept confirms the scalability for gigawatt-scale applications, initially for lithium-ion batteries, and in the future also for solid-state batteries.
Energy savings and low waste
According to Dürr, the process significantly reduces the space required for production compared to conventional wet coating and lowers energy consumption by eliminating the need for drying. A key feature is the free-standing film, which is guided during the process steps without a carrier film. If it does not meet the specifications, it can be completely returned to the material cycle, thus avoiding rejects.
Film formation and web guiding
The film is formed using calendering technology from Dürr subsidiary Ingecal: first, a horizontal calender forms the powder into a film, then further rolling stages compress it to a defined density and porosity. Only in the final step is the film laminated onto both sides of the collector foil. The special web guide reduces the force required during lamination and prevents deformation of the film, which improves further processing during notching and stacking.
On the way to pilot projects
In X.Cellify DC, Dürr combines its system integration with precision calendering technology and LiCAP's dry electrode technology. The company is looking for partners for industrial pilot projects to test the process in real production environments.