process development and optimization for li-ion battery production process development and...
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![Page 1: Process development and optimization for Li-ion battery production Process development and optimization for Li-ion battery production electrode manufacturing slurry mixing, coating,](https://reader036.vdocuments.us/reader036/viewer/2022070705/5e9092f0e5535e3e8340a716/html5/thumbnails/1.jpg)
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Process development and optimization for
Li-ion battery production
Mareike Wolter, Diana Leiva, Marco Fritsch, Stefan Börner
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© Fraunhofer IKTS - 2 -
Fraunhofer IKTS in profile - Research fields
Structural ceramics Functional ceramics
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Ceramic Expertise Battery Expertise
Battery research at Fraunhofer IKTS
Material
Technology
Electrode Battery Cell
Manufacturing
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Process development and optimization for Li-ion battery
production
electrode
manufacturingslurry mixing,
coating, drying
+ -Li-Ion IKTS
raw
materialspowder
electrode foil
'.
slitting/ cutting
joint tabs,
terminalssealing
EoL conditioningformation
aging
EoL testing
cell assemblystacking
calendering
electrolyte
filling
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Process development and optimization for Li-ion battery
production
� Optimum battery performance and
lifetime relies on optimized battery
production
� Process optimization is the main tool to
reach cost targets
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© Coatema, Hirano
Electrode manufacturing
� State of the art coating technology developed for small
consumer cells
� Automotive application requires
4x lifetime
10x cycle number
20x larger electrode areas
� significant higher requirements on production processes
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mixing
coating
calendering
slitting
stacking/ winding
connecting electrodes/
packaging
electrolyte filling/
sealing
form
ation / aging
clean / dry room
environment
battery performance /life
time
battery failures
� Relevance of process steps regarding battery quality
Process development and optimization for Li-ion battery
production
![Page 8: Process development and optimization for Li-ion battery production Process development and optimization for Li-ion battery production electrode manufacturing slurry mixing, coating,](https://reader036.vdocuments.us/reader036/viewer/2022070705/5e9092f0e5535e3e8340a716/html5/thumbnails/8.jpg)
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mixing
coating
calendering
slitting
stacking/ winding
connecting electrodes/
packaging
electrolyte filling/
sealing
form
ation / aging
clean / dry room
environment
battery performance /life
time
battery failures
� Relevance of process steps regarding battery quality
Process development and optimization for Li-ion battery
production
![Page 9: Process development and optimization for Li-ion battery production Process development and optimization for Li-ion battery production electrode manufacturing slurry mixing, coating,](https://reader036.vdocuments.us/reader036/viewer/2022070705/5e9092f0e5535e3e8340a716/html5/thumbnails/9.jpg)
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Understanding process parameters I
Electrode geometry
� Significant influence on energy and power
characteristics
� Formation of electrically conductive network
� crucial for thicker high
ED-electrodes and high C-rates
0
1
2
3
0 2 4 6 8
Capacity / mAh/cm²
Current density / mA/cm²
Capacity NCA/C cells
� typical high
power/high energy
characteristic
discharge
chargeVoltage
dropthick electrode
thin electrode
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110
120
130
140
0 1 2 3Capacity / mAh/g
Current density / mA/cm²
68 N/mm88 N/mm218 N/mm667 N/mm
Understanding process parameters II
Rate Rate Rate Rate capabilitycapabilitycapabilitycapability ofofofof LFP/C LFP/C LFP/C LFP/C cellscellscellscells
� Calender force is used to adjust
electrode porosity
� Porosity has significant influence on rate
capability
� Calendering enhances
electrical inter particle and particle
to current collector resistance
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Understanding process parameters III
0%
20%
40%
60%
80%
100%
120%
0 50 100 150 200
Capacity retention / %
Cycle
68 N/mm 218 N/mm
667 N/mm dR 68
dR 218 dR 667
AgingAgingAgingAging ofofofof LFP/C LFP/C LFP/C LFP/C cellscellscellscells
� Calender force is used to adjust
electrode porosity
� Porosity has significant influence on rate
capability
� Calendering enhances
electrical inter particle and particle
to current collector resistance
� Higher adhesion & cohesion of active
layer to electrode
� Optimized capacity retention
2C-Cycle test at 60°C
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mixing
coating
calendering
slitting
stacking/ winding
connecting electrodes/
packaging
electrolyte filling/
sealing
form
ation / aging
clean / dry room
environment
battery performance /life
time
battery failures
equipment investments
operating costs
� Relevance of process steps regarding battery quality and costs
Process development and optimization for Li-ion battery
production
![Page 13: Process development and optimization for Li-ion battery production Process development and optimization for Li-ion battery production electrode manufacturing slurry mixing, coating,](https://reader036.vdocuments.us/reader036/viewer/2022070705/5e9092f0e5535e3e8340a716/html5/thumbnails/13.jpg)
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mixing
coating
calendering
slitting
stacking/ winding
connecting electrodes/
packaging
electrolyte filling/
sealing
form
ation / aging
clean / dry room
environment
battery performance /life
time
battery failures
equipment investments
operating costs
� Relevance of process steps regarding battery quality and costs
Process development and optimization for Li-ion battery
production
![Page 14: Process development and optimization for Li-ion battery production Process development and optimization for Li-ion battery production electrode manufacturing slurry mixing, coating,](https://reader036.vdocuments.us/reader036/viewer/2022070705/5e9092f0e5535e3e8340a716/html5/thumbnails/14.jpg)
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Investigating process optimization I
Drum mill Dispenser
Planetary mixer
Intensive mixer
Mixing at lab scale
� Material and recipe development
Mixing at pilot line scale
� Investigation of mixing parameters and technologies
� Optimization mixing time
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Investigating process optimization II
Coating at pilot line scale
� Process stability, defects
Coating at lab scale
� Effect of slurry properties regarding coating quality
� Development of coating technologies
Doctor blade
Slot die
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Summary
� IKTS is working along the entire process chain of LIB electrode manufacture and
characterization
� Process development and optimization for Li-ion battery production results in a
series of complex processes with many parameters and diverse optimization goals
� DoE
� Depending on development goal work has to be done on lab or pilot line scale
� Never forget the strong interaction between technology and product properties!
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Thank you for your attention!
Special thanks to: � the European Regional Development
Fund (ERDF) and the Free State of
Saxony for funding of this work
� our Co-workers in the project LiFab