MANUFACTURING CATHODES VIA DRY-PROCESSING FOR LITHIUM-ION BATTERIES

Runming Tao, Bryan Steinhoff, Yang Tse Cheng, Jianlin Li

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

Abstract

Conventional lithium-ion battery (LIB) electrodes are prepared through a wet slurry process with n-methyl pyrrolidone solvent, especially for cathodes. The wet slurry process encounters several disadvantages such as binder migration, electrode cracking in thick electrodes, energy intense heat-dry NMP solvent removal, and costly NMP recovery. The cost and energy consumption of coating and drying of electrode are about 11.5 % and >46 % in LIB manufacturing, respectively. Thereby, it is essential to develop a facile roll-to-roll solvent-free LIB electrode processing for reducing the cost and energy consumption. Recently, the Maxwell-type dry processing (DP) shines new lights on LIB manufacturing, which mainly bases on dry mixing (DM) of electrode component powder followed by calendering into electrode films and laminating onto current collectors, realizing the rapid manufacturing of LIB electrodes in a powder-to-film manner for industries. This report shares some recent progress on the DP from our group. We aim to further advance the manufacturing science of DP by correlating the processing conditions with electrode properties and performance. Particularly, we investigate the effect of DM, and compression on the polytetrafluoroethylene (PTFE) binder fiberization, porosity, mechanical properties, electrical conductivity and electrochemical behaviors of electrodes. The DM study suggests that PTFE fiberization heavily relies on the degree of DM. Insufficient DM results in poor PTFE fiberization while outrageous DM damages the formed PTFE fibers. Both negatively affect the mechanical behaviors of the electrodes and their rate capability. However, moderate DM is highly beneficial. In addition, our study of the porosity impact reveals that LiNi0.8Mn0.1Co0.1O2 (NMC) secondary particles can be broken into primary particles due to compression, especially at low porosity. Those fractured NMC secondary particles exhibit lower modulus. We propose that a moderate porosity of around 32% favors the electronic conductivity, charge transfer impedance and rate capability. The study of the cathodic electrolyte interphase layer of PTFE-based DPed electrode confirms that side reactions of PTFE binder due to the formation of LiF in LiClO4-based electrolyte.

Original languageEnglish
Title of host publicationManufacturing Equipment and Automation; Manufacturing Processes; Manufacturing Systems; Nano/Micro/Meso Manufacturing; Quality and Reliability
ISBN (Electronic)9780791888117
DOIs
StatePublished - 2024
EventASME 2024 19th International Manufacturing Science and Engineering Conference, MSEC 2024 - Knoxville, United States
Duration: Jun 17 2024Jun 21 2024

Publication series

NameProceedings of ASME 2024 19th International Manufacturing Science and Engineering Conference, MSEC 2024
Volume2

Conference

ConferenceASME 2024 19th International Manufacturing Science and Engineering Conference, MSEC 2024
Country/TerritoryUnited States
CityKnoxville
Period6/17/246/21/24

Bibliographical note

Publisher Copyright:
Copyright © 2024 by Argonne National Laboratory and The United States Government.

Keywords

  • Dry mixing
  • Dry processing
  • Energy density
  • Lithium-ion batteries
  • Porosity
  • Sustainable manufacturing

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering

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