MATERIALS USED IN BATTERIES

MOL-52226 Functional materials

GROUP 5

HAMZA

MADAN

SANTHOSH KUMAR

YASHWANTH

CONTENT

Introduction

Primary batteries and applications

Secondary batteries and applications

Case study on processing of Li ion battery

Conclusion

INTRODUCTION

Alessandro volt invented the first battery in 1745

In 1898 the first commercial available are sold in united stated by

the Colombia Dry cell

Through ‘Wilhelm konig’, while doing his archeological studies in

1938 he found some clay pots with iron rods encased with copper

built in 200 BC itself

DEFINITION

“Battery consist of electrochemical

cells which convert chemical energy in

to electrical energy”

Primary Batteries

Non-Rechargeable

Power source for electronic devices

and so on.

Convenient and simple to use

Good shelf life

Reasonable energy

Power density

Reliability, when stored in moderate

temperature improves shelf life

Primary Batteries

System Characteristics Applications

Zinc-carbon

(Leclanché), Zinc/MnO2

Common, low-cost primary battery; available in a

variety of sizes

Flashlight, portable radios, toys, novelties, instruments

Magnesium (Mg/MnO2) High-capacity primary battery; long shelf life Formerly used for military receiver-transmitters, and aircraft

emergency transmitters (EPIRBs)

Mercury (Zn/HgO) Highest capacity (by volume) of conventional types;

flat discharge; good shelf life

Hearing aids, medical devices (pacemakers), photography,

detectors, military equipment, but in limited use at present

due to environmental hazard of mercury

Mer-cad (Cd/HgO) Long shelf life; good low- and high-temperature

performance; low energy density

Special applications requiring operation under extreme

temperature conditions and long life; in limited use

Alkaline

(Zn/alkaline/MnO2)

Most popular general-purpose battery; good low-

temperature and high-rate performance; low cost

Most popular primary battery; used in a variety of

portable battery operated equipment

Lithium/ soluble

cathode

High energy density; long shelf life; good

performance over wide temperature range

Wide range of applications requiring high energy density,

long shelf life, e.g., from utility meters to military electronics

applications

Lithium/ solid cathode High energy density; good rate capability and low-

temperature performance; long shelf life;

competitive cost

Replacement for conventional button and cylindrical cell

applications, such as digital cameras

Lithium/ solid

electrolyte

Extremely long shelf life; low-power battery Medical electronics

Table 1: Characteristics and applications [1]

Magnesium Batteries

Twice the service life or capacity of zinc battery

Disadvantages – voltage delay and parasitic corrosion

Potential > 2.8V, but 1.1V is achieved

Battery chemistry, Mg + 2 MnO2 + H2O Mn2O3 + Mg (OH) 2

Figure represents

Magnesium batteries

[2]

Zinc Carbon batteries

Leclanché and zinc chloride systems

low cost, ready availability, and acceptable performance

Electrolyte – Ammonium chloride and zinc chloride

Carbions with Mg2O- Conductivity

Specific capacity- 75-35 A h/kg

Basic chemistry Zn + 2MnO2 ZnO.Mn2O3

Figure represents Zinc-Carbon

batteries

[3]

Secondary Batteries

Rechargeable batteries

Many applications such as ignition automotive and portable

devices

Two categories of applications

1)Energy storage device

2)Discharged and recharged after use

Secondary Batteries [4]System Characteristics Applications

LEAD-ACID:

Automotive Popular, low-cost secondary battery, low

specific-energy, high-rate, and low-

temperature performance; maintenance-

free designs

Automotive SLI, golf carts, lawn mowers, tractors, aircraft,

marine, micro-hybrid vehicles

Traction (motive power) Designed for deep 6-9 h discharge,

cycling service

Industrial trucks, materials handling, electric and hybrid

electric vehicles, special types for submarine power

Stationary Designed for standby float service, long

life, VRLA designs

Emergency power, utilities, telephone, UPS, load levelling,

energy storage, emergency lighting

Portable Sealed, maintenance-free, low cost, good

float capability, moderate cycle life

Portable tools, small appliances and devices, portable

electronic equipment

NICKEL-CADMIUM:

Industrial and FNC Good high-rate, low-temperature

capability, flat voltage, excellent cycle life

Aircraft batteries, industrial and emergency power

applications, communication equipment

Portable Sealed, maintenance-free, good high-rate

low-temperature performance, good

cycle life

Consumer electronics, portable tools, pagers, appliances,

photographic equipment, standby power, memory

backup

NICKEL-METAL

HYDRIDE

Sealed, maintenance-free, higher

capacity than nickel-cadmium batteries;

high energy density and power

Consumer electronics and other portable applications;

hybrid electric vehicles

LITHIUM-ION High specific energy and energy density,

long cycle life; high-power capability

Portable and consumer electronic equipment, electric

vehicles (EVs, HEVs, PHEVs), space applications, electrical

energy storage

Nickel Cadmium batteries

Nickel oxy hydroxide as positive electrode and Cadmium plate is negative

electrode

Circuit voltage difference is nearly 1.29 V

Electrolyte used is KOH (31% by weight) or NaOH, LiOH is added to improve

life cycle and high temperature operations.

The major advantages are they have a long life line, excellent long - term

storage, and flat discharge profile.

Disadvantages are the energy density is low and they are expensive than

lead-acid batteries and also contains cadmium which is hazardous

There are two types of cells Vented and Recombinant

Chemistry involved

Positive electrode:

2NiOOH + 2H2O + 2e- ⇋ 2Ni(OH)2 + 2(OH)-

Negative electrode:

Cd + 2(OH)- ⇋ Cd(OH)2 + 2e-

Overall reaction:

2NiOOH + 2H2O + Cd ⇋ 2Ni(OH)2 + Cd(OH)2

Due to faster discharge rate or over charging the O2 is generated from which the

following reaction undergoes in Recombinant cells

Cd + H2O + ½ O2 Cd(OH)2

Construction of battery

Considering Aircraft battery design consists of steel case containing

identical, individual cells connected in series

And the end of the cells of the series are connected to receptacle located on the outside of the case

[5] [6]

Lithium Ion Batteries

Li ions exchange between the positive and negative electrodes

The major advantages are they are sealed and no maintenance is required, they have long life cycle, they have long shelf life, and low self-discharge rate. High power discharge rate capability

The major disadvantages are that, they degrade at high temperatures, capacity loss and potential for thermal runway when charged, possible venting and possible thermal runway when crushed, and may become unsafe when rapid charge at low temperature (< 0 0C).

higher specific energy (up to 240 Wh/kg)

energy density (up to 640 Wh/L)

self-discharge rate is around 2-8% per month

The working temperature range is at 0 to 45 0C

Single cell Operating Voltage between 2.5 and 4.3 V

[7]

Chemistry involved

Positive Electrode:

LiMO2 ⇋ Li1-x MO2 + x Li+ + x e-

Negative Electrode:

C + y Li+ + ye- ⇋ LiyC

Over all reaction:

LiMO2 + x/y C ⇋ x/y LiyC + Li1-xMO2

Battery materials

There are wide range of cathodic, anodic and electrolyte materials

Anodic materials are lithium, graphite, lithium-alloying materials (Lithium

titanate, Li4/3Ti5/3O4), intermetallic, Tin or silicon

Electrolytes include salts (aqueous) and organic solvents(non - aqueous) (They should be conductive)

Salt electrolytes are LiAsF6, LiPF6, LiSO3CF3, and LiN(SO2CF3)2

Organic solvents are EC = ethylene carbonate, PC = propylene carbonate, DMC = dimethyl carbonate, DEC = diethyl carbonate, DME = dimethylether, AN =

acetonitrile, THF = tetrahydrofuran, γ-BL = γ-butyrolactoneEC, ethyldiglyme, triglyme, tetraglyme, sulfolane,and Freon

Battery materials [7]

Material

Specific

capacity

mAh/g

Comments

LiCoO2 155 Still the most common. Co is expensive.

LiNi1-x-yMnxCoyO2 (NMC) 140-180Safer and less expensive than LiCoO2. Capacity depends on

upper voltage cut-off.

LiNi0.8Co0.15Al0.05O2 200 About as safe as LiCoO2, high capacity.

LiMn2O4 100-120Inexpensive, safer than LiCoO2, poor high temperature stability

(but improving with R&D).

LiFePO4 160Synthesis in inert gas leads to process cost. Very safe. Low

volumetric energy.

Li[Li1/9Ni1/3Mn5/9]O2 275 High specific capacity, R&D scale, low rate capability.

LiNi0.5Mn1.5O4 130 Requires an electrolyte that is stable at a high voltage.

IMPORTANCE OF BATTERIES

Battery Manufacturing Process[11]

Mixer

Mixing of Electrode Materials

Anode: Carbon/Graphite

Cathode: Lithium Metal Oxide (with conductive binding agent)

No Dissolution and breakup of

Particles

homogeneous distribution of components

Coating

Copper Coating on Anode

Aluminum Coating on Cathode

Coting thickness variance should be in tolerance of 1 to 2 µm

Coating thickness must be

homogeneous

Compressing

Drying of Solvent at 150 C in

drying tunnel

Reducing porosity by compression

No cracking should take place in material surface

Homogeneous material

properties should be maintained

Drying

After compression to pass

electrode through drying process is optional.

Purpose is to reduce

residual humidity in drying chamber with air humidity

of ~ 0.5%

Slitter /Cutter/ Puncher

Highly precise cutting by means

of laser cutting tolls

No burr formation on edges

Fraying of edges and material

particles on surface

Assembling

Stacking of cells in housing

Contacting of electrodes

Housing is sealed partially later on for filling of electrolyte

Positioning of cells should be

very much accurate ~0.1mm

Stacking speed shouldn’t be maintained regarding

production targets

Filling

Electrolyte Filling

Complete sealing of

housing

Cleaning cell in dry room

Filling should be

homogeneous and rapid

Toxic reaction may take place with air humidity

Formation / Ageing

Activation by means of

charging discharging routines

Gradually increasing voltage

Storage for 2 to 4 weeks

leading towards high cost and time expenditures

Increased risk of fire

After formation battery’s

operability should be confirmed

Grading

Grading is done on the basis of discharge,

resistance and capacitance measuring

Cells in batteries should have identical characteristics

Packaging

Sorting cells by grades

Packaging materials specifications

Special requirements

Measures to be taken for transportation

Conclusion

Primary and secondary batteries.

Lead Acid batteries, Nickel batteries, Silver Batteries, Alkaline

Manganese batteries, Carbon-zinc and so on.

Different battery mechanism is studied

Materials used for the production of cathode and anode is studied.

Electrode material preparation is explained in the manufacturing

process.

REFERENCES

[1] Thomas Reddy. "Chapter 8 - An Introduction to Primary Batteries". Linden's Handbook of Batteries, FourthEdition.McGraw-Hill, © 2011. Books24x7. Web. Apr. 7, 2015. http://common.books24x7.com/toc.aspx?bookid=35916

[2] Thomas Reddy. "Chapter 10 - Magnesium and Aluminium Batteries". Linden's Handbook of Batteries, Fourth Edition.McGraw-Hill. © 2011. Books24x7. http://common.books24x7.com/toc.aspx?bookid=35916 (accessed April 8, 2015)

[3] Thomas Reddy. "Chapter 9 - Zinc-Carbon Batteries—Leclanché and Zinc Chloride Cell Systems". Linden's Handbook ofBatteries, Fourth Edition. McGraw-Hill, © 2011.Books24x7.Web. Apr.7, 2015.http://common.books24x7.com/toc.aspx?bookid=35916

[4] Thomas Reddy. "Chapter 15 - An Introduction to Secondary Batteries". Linden's Handbook of Batteries, FourthEdition. McGraw-Hill, © 2011. Books24x7. Web. Apr. 9, 2015.http://common.books24x7.com/toc.aspx?bookid=35916

[5] D. Vutetakis, “Batteries,” in Digital Avionics Handbook, Third Edition, CRC Press, 2014, pp. 419–442.

[6] Thomas Reddy. "Chapter 19 - Industrial and Aerospace Nickel-Cadmium Batteries". Linden's Handbook of Batteries, Fourth Edition. McGraw-Hill, © 2011. Books24x7. Web. Apr. 9, 2015. http://common.books24x7.com/toc.aspx?bookid=35916

[7] Thomas Reddy. "Chapter 26 - Lithium-Ion Batteries”. Linden’s Handbook of Batteries, Fourth Edition. McGraw-Hill, © 2011. Books24x7. Web. Apr. 9, 2015 http://common.books24x7.com/toc.aspx?bookid=35916

[8] A. Manthiram, “Smart Battery Materials,” in Smart Materials, CRC Press, 2008.

[9] D. Vutetakis, “Batteries,” in Digital Avionics Handbook, Third Edition, CRC Press, 2014, pp. 419–442.

[10] Z. Bakenov and I. Taniguchi, “Cathode Materials for Lithium-Ion Batteries,” in Lithium-Ion Batteries, CRC Press, 2011, pp. 51–96.

[11] http://www.industry.siemens.com/topics/global/en/battery-manufacturing/process/pages/default.aspx

THANK YOU