The patent landscape for dry electrode processing technologies has evolved significantly over the past two decades, driven by the demand for more efficient, cost-effective, and environmentally friendly battery manufacturing methods. Dry electrode processing eliminates the need for solvent-based slurry casting, reducing energy consumption, production time, and harmful emissions. This review examines key patent holders, technological trends, geographical distributions, and freedom-to-operate considerations in this field.

Key patent holders in dry electrode processing include established battery manufacturers, automotive companies, and specialized technology firms. Tesla, through its acquisition of Maxwell Technologies, holds a substantial portfolio of patents related to dry electrode manufacturing. Maxwell’s patented dry coating technology involves fibrillizing polytetrafluoroethylene (PTFE) as a binder to create self-supporting electrode films without solvents. Other major players include Toyota, which has developed dry processes for solid-state batteries, and Bosch, with patents covering dry powder deposition methods. Startups such as Sila Nanotechnologies and QuantumScape have also filed patents addressing dry processing for advanced anode and solid-state electrolytes.

Geographically, the majority of dry electrode processing patents originate from the United States, Japan, South Korea, and Europe. The U.S. leads in patent filings, largely due to the activity of Tesla and Maxwell Technologies. Japan follows closely, with companies like Toyota and Panasonic contributing to the development of dry electrode methods for lithium-ion and solid-state batteries. South Korea’s Samsung SDI and LG Chem have also filed numerous patents, particularly in dry processing for high-energy-density electrodes. Europe shows a growing interest, with German companies like Bosch and BASF focusing on scalable dry coating techniques.

The evolution of dry processing claims in patents reflects a shift from early conceptual designs to advanced, scalable manufacturing solutions. Early patents from the 2000s primarily described basic dry powder mixing and pressing methods. Over time, innovations emerged in binder fibrillation, powder dispersion, and roll-to-roll compatibility. More recent patents focus on improving electrode adhesion, uniformity, and throughput. A notable trend is the integration of dry processing with next-generation battery technologies, such as solid-state and silicon-dominant anodes. For example, several patents now claim dry methods for applying sulfide solid electrolytes or silicon-carbon composites without solvents.

Significant innovations in dry electrode processing include the development of electrostatic spray deposition and laser-assisted drying techniques. Electrostatic spray deposition enables precise control over electrode thickness and morphology, while laser drying enhances the bonding between active materials and current collectors. Another breakthrough is the use of dry calendering to improve electrode density and mechanical integrity. These advancements address critical challenges in traditional slurry-based methods, such as cracking, delamination, and non-uniform coating.

Freedom-to-operate considerations are crucial for companies entering the dry electrode processing space. The dense patent landscape means new entrants must carefully navigate existing intellectual property to avoid infringement. Key areas with high patent density include binder-free electrode fabrication, dry powder mixing equipment, and in-line quality control systems. Companies should conduct thorough patent searches to identify potential barriers and explore licensing opportunities. For example, Tesla’s acquisition of Maxwell Technologies has made certain dry electrode patents inaccessible without negotiation. Alternatively, firms can focus on developing novel approaches, such as hybrid dry-wet processes or alternative binder systems, to circumvent existing claims.

The competitive landscape suggests that collaboration and cross-licensing may become increasingly important as dry electrode technology matures. Established players with large patent portfolios may leverage their IP to form partnerships with material suppliers or equipment manufacturers. Meanwhile, startups with niche innovations could attract investment or acquisition interest from larger corporations seeking to expand their dry processing capabilities.

In summary, the patent landscape for dry electrode processing is characterized by rapid innovation, with key players investing heavily in scalable and sustainable manufacturing methods. The geographical distribution of patents highlights the dominance of the U.S., Japan, and South Korea, while emerging technologies like solid-state batteries drive further IP development. Companies entering this space must carefully assess freedom-to-operate risks and consider strategic partnerships to navigate the complex IP environment. As dry electrode processing gains traction in commercial battery production, ongoing advancements in materials, equipment, and process optimization will continue to shape the patent landscape.