Fluorine-Free Strategies for Sustainable Battery Manufacturing: Materials, Processes, and Prospects

To decarbonize the battery value chain and comply with per- and polyfluoroalkyl substances regulations, a “fluorine-free” strategy is crucial, replacing fluorine-based electrolytes, binders, and processes. This review assesses the impacts of removing fluorine in lithium-ion battery production. Our review shows that using aqueous binders or dry coating process, can cut n-methyl-2-pyrrolidone and polyvinylidene fluoride generation toxicity and process energy by over 40%. Life cycle assessments indicate that a fully fluorine-free process can reduce CO2 emissions by 30–45%, water usage by 40%, and hydrogen fluoride emissions entirely, thereby meeting the 2028 EU battery regulation carbon cap. Projections suggest over 15% of global cell production will adopt fluorine-free systems by 2030. We also address remaining technical challenges such as interface stability and recycling-friendly design, emphasizing the need for integrated research and regulatory demonstrations.