Making batteries from a candle constituent? Lower costs and zero environmental pollution

□ Daegu Gyeongbuk Institute of Science and Technology (DGIST, President Lee Kunwoo) has announced that a research team led by Professor Kim Jinsoo of the Department of Energy System Engineering has developed a novel dry-electrode binder technology using paraffin, the main component of candles. This technology overcomes the limitations of the dry-electrode process, which has long been considered a major challenge in battery manufacturing, and reduces costs while eliminating environmental pollution.

□ Currently, the global battery industry is accelerating its transition from the conventional wet-electrode process to the dry-electrode process to improve energy efficiency and reduce environmental impact. The wet process involves mixing battery materials with an organic solvent to form a slurry, which is then coated and dried in a large oven. This process results in high energy consumption, carbon emissions, and high operating costs. Furthermore, production of thick film electrodes is limited by uneven material migration during solvent drying.

□ In contrast, the dry process involves compressing battery materials in a particulate state to form electrodes, and it can dramatically reduce costs and carbon emissions compared to the conventional wet process. In January 2026, Tesla announced plans to begin mass-producing 4,680 battery cells by applying the dry-electrode process to both cathodes and anodes. LG Energy Solution is also fiercely competing to secure a technology lead. It has announced plans to commercialize dry-electrode technology by 2028 and is building a pilot line.

□ However, the polytetrafluoroethylene (PTFE) binder material for dry electrodes has been limited by its high cost, environmental regulation issues regarding per- and polyfluoroalkyl substances (PFAS), and the need for an additional wet-coating for the adhesive layer due to low adhesion.

□ A research team led by Professor Kim Jinsoo of the Department of Energy System Engineering at the DGIST has proposed a groundbreaking solution that defies conventional wisdom. They have introduced paraffin, the main material in common candles, into battery manufacturing. Recognizing that the main components of Parafilm^® M, a laboratory-grade sealing film, are paraffin and polyethylene, the research team successfully applied it as a novel binder for dry electrodes in batteries.

□ Parafilm^® M fixes the active material at a low temperature of 60°C, enabling the manufacture of dry electrodes without the need for an additional wet adhesive layer on the current collector. Furthermore, compared to PTFE binders, it can reduce the cost by 95% and lower the global warming potential (GWP) to a level of 1/2,200, making it advantageous for achieving carbon neutrality. The research team confirmed that the Parafilm binder is distributed uniformly inside the electrode, resulting in excellent ion transfer characteristics. Additionally, the parafilm has demonstrated excellent stability, showing no oxidation or reduction even under a wide-voltage environment. Furthermore, on the basis of the NCM811 cathode material, the team confirmed stable lifespan characteristics with no performance degradation after 1,000 charge-discharge cycles.

□ The research team verified the commercial viability of parafilm-based dry-electrode technology by fabricating 3 cm × 4 cm pouch cells and using a twin-screw continuous extrusion process. Having secured the patent rights, the team plans to transfer the proprietary technology to relevant demand companies.

□ “The parafilm-based binder we developed is a key proprietary technology that can maximize the economic efficiency and environmental friendliness of dry processes,” said Professor Kim Jinsoo of DGIST. “We will contribute to enhancing South Korea’s leadership in the battery industry by supplying sustainable battery-manufacturing technologies.”

□ This research was conducted with support from the National Research Council of Science and Technology’s Creative Convergence Research Program and the DGIST Startup Fund. Researchers Kim Min-kyeong, Yoo Tae-kyun, and Jang Seong-bin participated as first authors, and the paper was published in the December 2025 issue of the prestigious journal Nature Communications.