Technical Performance and Energy Intensity of the Electrode-Separator Composite Manufacturing Process

Abstract

Energy storage is one of the key technological factors that determine the success of a sustainable future. Especially green mobility concepts for electric or hybrid electric vehicles highly depend upon storage technologies with high energy density and light-weight materials. At the same time, innovative production processes should be conceived that ensure energy and resource efficient manufacturing of these energy storage devices. This paper focuses on the technical as well as dynamic energetic performance analysis and evaluation of an innovative electrode-separator composite manufacturing process of lithium-ion batteries for automotive applications. The technical performance indicators such as battery capacity and the energy intensity of the manufacturing process are highly dependent upon process parameters, machine and product design. Hence, in-depth process knowledge must be acquired to understand interdependencies between all system components. Thus, the manufacturing process is analysed in terms of its dynamics, and correlations between process parameters, process energy demand and final product properties are assessed. The resulting knowledge is important for the subsequent design of large-scale products and processes involved design, as well as for characterisation of the manufacturing process for life cycle inventory databases or life cycle costing calculations.

Analyzing Bending Stresses on Lithium‐Ion Battery Cathodes induced by the Assembly Process

“…The manufacturing step that creates the inner layer structure (electrode–separator composite, ESC) influences the battery geometry and properties significantly. Several procedures are implemented in industry, of which the most prominent are stacking, folding, prismatic winding, and cylindrical winding (Figure ) . All these manufacturing principles have in common that mechanical stress (tension, compression and bending) is applied to electrodes and separators.…”

“…[4] Them anufacturing step that creates the inner layer structure (electrode-separatorc omposite,E SC) influences the battery geometry and properties significantly.S everal procedures are implemented in industry,o fw hich the most prominent are stacking, folding, prismatic winding, and cylindrical winding (Figure 1). [5,6] All these manufacturing principles have in commont hat mechanical stress (tension, compression and bending) is applied to electrodes and separators.T his is important to notice,b ecause mechanical stress affects the adherence between coating and substrate. The final consequence is that this stress increases the capacity fade during the cycle life and decreases life time.…”

The Role of Pilot Lines in Bridging the Gap Between Fundamental Research and Industrial Production for Lithium‐Ion Battery Cells Relevant to Sustainable Electromobility: A Review

“…In addition, highest product safety is absolutely essential; hence, automated in‐line and on‐line data acquisition including evaluation (preferable in real time), as well as automated defect recognition (ADR) must be realized. [ 15–17 ] Quality control through all manufacturing steps is indispensable for an early detection of defects and prevention of waste in the following steps. [ 18 ] In general, the sensitivity to scrap costs increases the later a process takes place in the manufacturing chain, as more value has been added in previous steps.…”

Production Research as Key Factor for Successful Establishment of Battery Production on the Example of Large‐Scale Automotive Cells Containing Nickel‐Rich LiNi0.8Mn0.1Co0.1O2 Electrodes

“…However, skills acquisition for the mass production of large‐scale LIBs in European countries (in this work, with special focus on Germany) is rather young, as this technology was historically developed and well implemented in Asia . Special challenges are provided by the highly interdisciplinary character of this topic, as expertise from material science, electrochemistry, as well as electrical, mechanical, and process engineering is required . Furthermore, inline and eventually online data acquisition, its analysis, and visualization must be realized in an automated, preferable in real time, manner.…”