乾式電極專利分析及技術趨勢

• 儘管乾法電極具有降低揮發性有機化合物 (VOC)、縮短製程時間、提高能量密度等諸多優勢，但特斯拉等大公司已掌握關鍵專利，這使得後來者難以在不突出自身差異化的情況下引入該技術。
• 因此，在引進新製程或進行新材料研發時，必須對現有專利進行技術評估，並在設計階段確定策略方向。

本報告探討了乾電極市場，並提供了多方面的分析，包括實施過程中的實際考慮、合作研究策略以及潛在應用。

目錄

第1章 乾電極技術概要

• 乾電極開發背景
• 乾法和濕式製程的區別
• 乾電極製造工藝

第2章 乾電極的PTFE黏合劑的利用

• PTFE（聚四氟乙烯）的化學/物理特性
• PTFE纖維的機理
• 與傳統PVDF黏合劑的比較

第3章 Tesla的乾電極專利的現狀

• Maxwell超級電容器核心乾式製程技術
• Maxwell Technologies的專利組合
  • Maxwell Technologies乾電極專利檢索結果
  • Maxwell 專利組合分析
  • 專利趨勢：依國家、年份
  • 專利趨勢：依年份與技術主題
  • 申請佔有率：按國家和技術主題
• 特斯拉收購 Maxwell 及重要專利的繼承

第四章：Maxwell（特斯拉）乾電極專利的特性與優勢

• 關鍵權利要求的技術結構
• 技術差異化因素與開發限制
  • 對實際工業應用的影響
• 已公佈專利中的技術描述範例
• 從乾電極到鋰離子電池的轉變

第5章 乾法工藝及其詳細要素

• 粉末混合（活性材料、導電劑、PTFE）階段
• 預壓階段
• 輥壓和層壓
• 後處理（熱處理、額外壓延等）
• 製程複雜性與品質控制 (QC) 要素：依階段

第6章 PTFE 特性與製程參數之間的技術相關性分析

• PTFE 黏合劑含量與製程參數之間的相互作用
• 壓力、溫度和電極厚度對 PTFE 纖維化的影響
• 黏合劑纖維化方法與技術差異化因素

第七章：Maxwell（特斯拉）專利組合維護趨勢及其對產業的影響

• Maxwell/特斯拉早期專利的到期日（約2026)
• 透過額外申請擴展技術組合的策略
• 專利到期的影響
• Maxwell/Tesla 持有的有效專利概覽

第八章：差異化策略與對策

• 產業因應策略
  • 替代黏合劑材料
  • 製程參數變化
  • 半乾法或混合製程的引入
  • 授權或合作解決方案
  • 客製化製程設計

第九章：乾電極技術為何成為主流

• 基本優勢（無溶劑技術的重要性）
• 廣泛的應用範圍和成熟的量產能力
• 應用於下一代科技的潛力電池（全固態、矽陽極等）

附錄

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