In the production process chain of lithium-ion battery cells, the filling process is eminent for the final product quality and costs. The filling consists of several dosing steps of electrolyte liquid into the cell and the subsequent (intermediate) wetting of the cell components. The quantity of electrolyte filled not only has an impact on the wetting rate of electrodes and separator but also limits the capacity of the cell and influences the battery lifetime. However, too much electrolyte is dead weight, results in a lower energy density and unnecessarily increases the costs of the battery. To ensure low costs in production and at the same time high quality of the cells, the optimal amount of electrolyte is studied in this paper. Based on experimental data from electrochemical impedance spectroscopy, the filling process, the formation process as well as a lifetime test, the interdependencies between electrolyte quantity, wetting rate, capacity, energy density and lifetime are presented for large-format cells.

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The high demand for an efficient energy supply for various applications facilitates the development of innovative storage technologies like all-solid-state batteries in addition to novel production technologies. Compared to the conventional manufacturing process, additive manufacturing (AM) is a promising technology used for the rapid and cost-effective production of battery components containing separators. However, AM technologies like laser-based powder bed fusion of polymers (PBF-LB/P) have been neglected so far. The present research aims to fill this research gap and outline a novel approach for processing polymers like polyethylene oxide (PEO) and polyvinylidene fluoride (PVDF) into separators using PBF-LB/P. Optimal process parameters for manufacturing PVDF and PEO with PBF-LB/P to generate homogeneous and dense layers represent the key findings of this paper and provide a deeper process understanding. The first proof of concept for producing separator layers by PBF-LB/P in a scalable process is demonstrated as a result. K E Y W O R D Sadditive manufacturing, all-solid-state battery, laser-based powder bed fusion of plastics, PVDF powder, separator

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