Search NASA⌕ Search

SEARCH · Search NASA

Results for “Electrode manufacturing”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Water-Based Electrode Manufacturing and Direct Recycling of Lithium-Ion Battery Electrodes—A Green and Sustainable Manufacturing System

It is critical to develop a low-cost and environmentally friendly system to manufacture and recycle lithium-ion batteries (LIBs) as the demand on LIBs keeps increasing dramatically. Conventional LIB cathodes are manufactured using N-methyl-2-pyrrolidone as the solvent, which is expensive, highly toxic, flammable, and energy intensive to produce and recover. Ideally, a close-loop industrial supply chain should be built, in which the batteries are manufactured, market harvested, and recycled with minimal external toxic solvent through the whole system. This work demonstrates a green and more sustainable manufacturing method for LIBs where no hazardous organic solvent is used during electrode manufacturing and recycling. The electrodes fabricated via water-based processing demonstrate comparable rate performance and cycle life to the ones from conventional solvent-based processing. Utilization of a water-soluble binder enables recovering the cathode compound from spent electrodes using water, which is successfully regenerated to deliver comparable electrochemical performance to the pristine one.

25 ENERGY STORAGE↗
DOE OSTI2019

Electrode manufacturing for lithium-ion batteries—Analysis of current and next generation processing

As modern energy storage needs become more demanding, the manufacturing of lithium-ion batteries (LIBs) represents a sizable area of growth of the technology. Specifically, wet processing of electrodes has matured such that it is a commonly employed industrial technique. Despite its widespread acceptance, wet processing of electrodes faces a number of problems, including expensive and dangerous solvent recovery, cut-off waste, coating inconsistencies, and microstructural defects due to the solvent drying process. This review considers each of these issues and discusses which electrode slurry properties should be considered when optimizing wet slurry fabrication. Simultaneously, methods to replace traditional wet processing of electrodes are being extensively researched. Some of these novel electrode manufacturing techniques prioritize solvent minimization, while others emphasize boosting energy and power density by thickening the electrode and, subsequently, creating an organized pore structure to permit faster ion diffusion. This review contemplates the advantages and disadvantages of each of these approaches and provides a comprehensive outlook on the future of electrode manufacturing.

25 ENERGY STORAGE↗
DOE OSTI2022

Methods for manufacturing electrodes including fluoropolymer-based solid electrolyte interface layers

Methods for manufacturing electrodes include applying a fluoropolymer film to a lithium-based host material, defluorinating the fluoropolymer film by heating to produce a lithium electrode having a solid electrolyte interface (SEI) layer including defluorinated fluoropolymers and at least about 5 wt. % LiF. The fluoropolymers can include one or more of fluorinated ethylenepropylene, perfluoroalkoxy alkanes, vinylidenefluoride, and copolymers of perfluoromethylvinylether and tetrafluoroethylene. The fluoropolymers can include one or more fluorinated monomers, including hexafluoropropylene, tetrafluoroethylene, ethylene-tetrafluoroethylene, perfluoroethers, and vinylidene fluoride. The —CF 3 functional groups of the defluorinated fluoropolymers can be about 3 wt. % to about 10 wt. % of the SEI layer. The SEI layer can include about 30 wt. % to about 50 wt. % LiF. The method can include assembling a battery cell by disposing a battery separator between a cathode and the electrode, and disposing the battery separator, the cathode, and the electrode in an electrolyte.

Xiao, Xingcheng↗
DOE OSTI2024

Enable superior performance of ultra-high loading electrodes through the cost-efficient solvent-free electrode manufacturing technology

This research explores an innovative solvent-free method for fabricating ultra-high loading NMC811 and graphite electrodes (~6mAh∙cm -2 ), showcasing remarkable electrochemical performance enhancements compared to the electrodes prepared by the conventional slurry-casting method. Here, the optimized microstructure with dry-printed (DP) electrodes enhanced electrolyte penetration and minimized lithium-ion diffusion tortuosity resulting in improved rate performance at high current rates. Additionally, this innovative electrode manufacturing approach enables more uniform CEI and SEI formation and growth, which effectively doubles the cycle life of single-layer pouch cells with DP electrodes. Beyond the performance enhancements, this method also offers a notable 29.2 % overall cost advantages, potentially revolutionizing future battery manufacturing. The findings presented in this work underscore the potential of solvent-free manufacturing technology as a high-loading capable and cost-efficient path for advanced battery production.

25 ENERGY STORAGE↗
DOE OSTI2016

Effect of electrode manufacturing defects on electrochemical performance of lithium-ion batteries: Cognizance of the battery failure sources

During LIB electrode manufacturing, it is difficult to avoid the certain defects that diminish LIB performance and shorten the life span of the batteries. This study provides a systematic investigation correlating the different plausible defects (agglomeration/blisters, pinholes/divots, metal particle contamination, and non-uniform coating) in a LiNi 0.5 Mn 0.3 Co 0.2 O 2 positive electrode with its electrochemical performance. Additionally, an infrared thermography technique was demonstrated as a nondestructive tool to detect these defects. The findings show that cathode agglomerates aggravated cycle efficiency, and resulted in faster capacity fading at high current density. Electrode pinholes showed substantially lower discharge capacities at higher current densities than baseline NMC 532 electrodes. Metal particle contaminants have an extremely negative effect on performance, at higher C-rates. The electrodes with more coated and uncoated interfaces (non-uniform coatings) showed poor cycle life compared with electrodes with fewer coated and uncoated interfaces. Further, microstructural investigation provided evidence of presence of carbon-rich region in the agglomerated region and uneven electrode coating thickness in the coated and uncoated interfacial regions that may lead to the inferior electrochemical performance. In conclusion, this study provides the importance of monitoring and early detection of the electrode defects during LIB manufacturing processes to minimize the cell rejection rate after fabrication and testing.

25 ENERGY STORAGE↗
DOE OSTI2023

Advanced electrode manufacturing to enable low cost PEM electrolysis

A critical challenge for the implementation of proton exchange membrane (PEM)-based water electrolyzers for the H2@Scale vision is the capital cost, which is largely driven by related factors of overdesign and highly manual legacy manufacturing methods. Typical electrolyzer cells have an order of magnitude higher membrane thickness and catalyst loading vs. fuel cells, in part because the manufacturing methods being used are not capable of producing uniform and reliable electrodes on thin membranes with low loading. Advanced electrode manufacturing is therefore the key enabler to reduce the cost of the electrolyzer stack, particularly roll-to-roll (R2R) manufacturing of catalyst coated layers (CCLs) and catalyst coated membranes (CCMs). The electrolyzer manufacturing process still relies on traditional sheet-to-sheet (S2S) processes, which requires intensive labor to make parts to meet the specification requirements. This project leverages fuel cell expertise (GM) with Proton’s knowledge of electrolyzer components to develop the electrocatalyst ink formulations and coating processes using slot die (ORNL) and gravure (NREL) coatings, with proof of concept at the pilot-scale (Kodak).

08 HYDROGEN↗
DOE OSTI2024

Solvents and slurries comprising a poly(carboxylic acid) binder for silicon electrode manufacture

An silicon-containing electrode is formed by coating a silicon-containing slurry onto a conductive current collector. The slurry comprises a binder solution comprising a poly(carboxylic acid) binder dissolved in a mixed solvent system comprising an amide solvent of Formula I, as described herein, and a second solvent which can be water and/or an organic solvent. The binder preferably comprises poly(acrylic acid). The mixed solvent system comprises about 10 to about 99 vol % of the amide solvent of Formula I. The binder solution is utilized as a solvent for a slurry of silicon-containing particles for preparing the silicon-containing electrode. The slurries comprising the mixed solvent system have higher viscosity and are more stable than slurries containing the same concentrations of silicon particles, carbon particles, and binder in water as the sole solvent.

Zhang, Lu↗
DOE OSTI2024

Viability of Additively Manufactured Electrodes for Lithium-Ion Batteries

As the global economy becomes increasingly electrified, the demand for batteries and energy storage is expected to rise significantly, particularly in the transportation and electricity sectors. Lithium-ion batteries (LIBs) are currently the most advanced and widely used technology in this field. Traditionally, LIBs are manufactured using simple 2D planar geometries to maximize production efficiency and minimize costs. However, this approach limits energy density due to the restricted design flexibility of the electrodes. Additive manufacturing (AM) offers a promising solution to enhance the energy density and efficiency of LIBs by enabling the design of architectures that reduce diffusive losses and allow for a greater amount of active material to be incorporated within the same device footprint, thereby minimizing the use of inactive materials. Different AM techniques come with their own set of limitations, including printing speed, material compatibility, and scale, which must be considered when designing electrodes. Scalable and cost-effective methods are particularly important for electric vehicle batteries, while achieving higher energy densities in microbatteries is crucial for the miniaturization of wearable electronics and medical devices. Here, in this study, we simulate various 3D porous electrode designs for LIBs using graphite and nickel manganese cobalt oxide (NMC) electrodes. These designs are selected to represent structures that could be produced using different AM techniques, such as direct ink writing, fused deposition modeling, and stereolithography. Our results indicate that at higher charging rates and increased areal mass loading, 3D structures can outperform traditional 2D electrodes, although the benefits may diminish with more complex designs that are harder to manufacture. The observed gains in energy density are attributed to improved electrode utilization and reduced diffusive energy losses. This comprehensive analysis of structure–performance relationships will provide valuable insights to guide future research on 3D designs, material selection, and AM techniques for additively manufactured battery electrodes.

25 ENERGY STORAGE↗
DOE OSTI2020

Electrodeposition for Low-Cost, Water-Based Electrode Manufacturing. Research Performance Progress Report, Jan. 1, 2016 - Dec. 31, 2019

The viability of electrocoat to fabricate battery electrodes at commercially relevant formulations has been demonstrated using both bench-scale equipment and a small pilot-scale roll-to-roll system (mini-coater). Through this, we show that an electrodeposited lithium-ion battery electrode coating system and manufacturing process is capable of reducing cell costs. Specifically, >60% decrease in capital costs is expected when transitioning from slot-die to electrocoat-based coating systems due to the removal of a solvent recovery system. In addition, a 50% reduction in operating costs in also expected as we enable 2-coat/2-cure processing of cathode electrodes.

25 ENERGY STORAGE↗
DOE OSTI2020

Perspectives on the relationship between materials chemistry and roll-to-roll electrode manufacturing for high-energy lithium-ion batteries

As lithium-ion battery (LIB) active material and cell manufacturing costs continue to drop with wider adoption of electric vehicles, electrode and cell processing costs remain too high in terms of reaching the ultimate U.S. Department of Energy (DOE) cell cost target of $80/kWh. This paper primarily covers major materials chemistry advancements made over the last 10 years at Oak Ridge National Laboratory (ORNL) in the space of advanced manufacturing science for LIBs with the aim of simultaneously meeting the ultimate cost target, 500 Wh/kg gravimetric energy density, 10-15-min fast charge times, and 1000 deep discharge cycles. Aqeous electrode processing with a variety of active anode and cathode materials is now a standard procedure at the DOE Battery Manufacturing R&D Facility at ORNL (BMF), including the latest processes developed for Ni-rich cathodes. New results on cobalt-free LiNi 0.8 Fe 0.1 Al 0.1 O 2 (NFA 811) are also included and discussed in an electrode processing advantage context. In addition, colloidal processing advancements have been made for Si/C composite anodes for achieving >600 mA h/g capacities. Optimization of electrode coating parameters and drying protocols have been completed, which has elucidated how key processing variables need to be changed when parameters such as slurry solids loading, solvent type, and wet electrode thickness are changed. ORNL has also increased the line speeds at which thick cathodes can be processed using ultra-fast electron beam (EB) curing and substantially decreased formation cycling times to <1 day. Finally, key details of these advancements are discussed in the context of materials chemistry and process-property-performance relationships.

25 ENERGY STORAGE↗
DOE OSTI2023

Roll-to-roll solvent-free manufactured electrodes for fast-charging batteries

In response to the growing demand for lithium-ion batteries (LIBs), we demonstrate a solvent-free manufacturing technology that can avoid toxic organic solvents and form unique electrode structures to overcome the bottlenecks in low costs and fast charging. The lower tortuosity achieved by the open pores in the dry-printed (DP) electrode allows for a shorter Li+ diffusion pathway, which leads to better rate performance. The DP pouch cells exhibit higher capacity retention of 78% and 69% at 3C and 4C, respectively, compared with 67% and 52% for the slurry cast (SL) cells at the same rates. Moreover, the coating layer on the surface of active materials prevents the excess side reaction between active materials and electrolytes, which prolongs the cycle life of the DP cells. This manufacturing process is a roll-to-roll system with immense potential to be scaled up, providing a more efficient and economical way for battery manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Co-Extrusion (CoEx) for Cost Reduction of Advanced High-Energy-and-Power Battery Electrode Manufacturing

Co-Extrusion (CoEx) is a deposition technology developed at PARC that uses engineered fluidic channels to cause multiple streams of dissimilar fluids to impart shape to one another. Here, we describe the use of CoEx to produce structured cathode electrode films to improve electrochemical performance of thick electrode films. CoEx enables us to create structured electrode films that have periodic regions of enhanced ionic conductivity, enabling higher utilization of thicker cathode films at high discharge rates. While increasing electrode thickness is a known method for increasing energy density of battery electrodes, this increase in energy density typically also results in reduced power density. This project, a collaboration between the Palo Alto Research Center, Oak Ridge National Laboratories, and Ford Motor Company, seeks to first validate the benefits of CoEx at the coin cell level, before performing the necessary R&D effort to scale production up to large (10+ Ah) pouch cells that will show increased energy density without a reduction in power density. We used conventional battery materials (commercially available NMC, PVDF, carbon black, and graphite) to produce structured electrodes via CoEx and compared them to thick and thin conventionally produced (unstructured) battery electrodes. CoEx electrodes show improved high rate performance compared to unstructured electrodes, resulting in higher energy density pouch cells compared to the baseline electrode of 7 and 11% in volumetric and gravimetric energy density, respectively. These electrodes also showed substantially improved electrochemical performance at high discharge rates compared to thick conventional electrodes.

25 ENERGY STORAGE↗
DOE OSTI2022

Solvents and slurries comprising a poly(carboxylic acid) binder for silicon electrode manufacture

A binder solution for manufacturing silicon-based anodes useful for lithium-ion electrochemical cells is described herein. The binder solution comprises a poly(carboxylic acid) binder dissolved in a mixed solvent system comprising an amide solvent of Formula I, as described herein, and a second solvent which can be water and/or an organic solvent. The binder preferably comprises poly(acrylic acid). The mixed solvent system comprises about 10 to about 99 vol % of the amide solvent of Formula I. The binder solution is utilized as a solvent for a slurry of silicon-containing particles for preparing a silicon-containing electrode. The slurries made with the mixed solvent systems have higher viscosity and are more stable than slurries containing the same concentrations of silicon particle, carbon particles, and binder in water as the sole solvent.

Zhang, Lu↗
DOE OSTI2021

Additively manufactured electrodes for plasma and power-flow studies in high-power transmission lines on the 1-MA MAIZE facility

Power-flow studies on the 30-MA, 100-ns Z facility at Sandia National Laboratories have shown that plasmas in the facility’s magnetically insulated transmission lines (MITLs) and double post-hole convolute can result in a loss of current delivered to the load. To study power-flow physics on the 1-MA, 100-ns MAIZE facility at the University of Michigan, planar MITL loads and planar post-hole convolute loads have been developed that extend into the lines of sight for various imaging diagnostics on MAIZE. These loads use 3D-printed dielectric support structures lined with thin foils of either aluminum or stainless steel. Here, the metal foils serve as the current-carrying power-flow surfaces, which generate plasma during the current pulse. The foil thickness (50 µm) and widths (11.5–16 mm) are selected to ensure a sufficient linear current density (0.5–0.7 MA/cm) for plasma formation. Laser backlighting (532 nm) and visible-light self-emission imaging capture the overall plasma evolution in the anode–cathode gaps, including the gap closure velocities (1–4 cm/μs).

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

High Throughput Solvent-free Manufacturing of Battery Electrodes

The project goal is to develop and demonstrate an advanced solvent-free lithium-ion battery electrode process through proposed Advanced Dry Electrode Process (ADEP) equipment, which is expected to exhibit a better binder fibrillization and high throughput and suitable for high performance electrode manufacturing, and commonize the anode and cathode dry processing equipment, supply chain and operation for lithium-ion battery OEMs for replacing the solvent-based slurry casting. Our proposed approach will facilitate low-cost battery production by addressing the following gaps in present dry electrode processing: • Extend the dry electrode fabrication process to lithium-ion battery anode manufacturing • Increase the active material content for anodes and cathodes • Intensify the process through improved mixing, powder rheology and surface modifications • Enable processing of next-generation electrode materials that are not stable to solvent or ambient air exposure. The project objectives include the development of anode-compatible binder and binder fibrillization promoter for low irreversible capacity loss, low electrode binder content yet higher film mechanical strength, and the optimization of solvent-free anode and cathode process for low cost (>60% electrode cost reduction), high performance (10% increase in energy density without sacrificing cycle life) and high throughput to enable next generation lithium-ion battery electrode production. Solvent-free electrode manufacturing will also enable next-generation cell designs based on prelithiated anodes or solid-state electrolytes.

25 ENERGY STORAGE↗