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Frontiers of Engineering Reports on Leading-Edge Engineering from the 2014 Symposium (2015) / Chapter Skim
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Lithium Ion Batteries and Their Manufacturing Challenges--Claus Daniel
Pages 45-50

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From page 45...
... Electrodes are coated on a metal current collector foil in a composite structure of active material, binders, and conductive additives, requiring careful control of colloidal chemistry, adhesion, and solidification. But the added inactive materials and the cell packaging reduce energy density.
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From page 46...
... When packaged in real devices, however, much inactive material mass is added and the energy density tends to drop to 100 Wh/kg on the pack level. To push for higher energy density, researchers have sought higher capacity and higher voltage -- and found them in lithium- and manganese-rich transition metal oxides.
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From page 47...
... COST CHALLENGES IN MANUFACTURING LITHIUM ION BATTERIES The costs of lithium ion batteries are much higher than the automotive market will bear for full penetration of electric vehicles and a cost-neutral product compared to cars run by internal combustion engines. The US Department of Energy cost target for all electric vehicle batteries is $125/kWh of usable energy (DOE 2013)
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From page 48...
... Thicker electrodes and a tremendous reduction in inactive materials will improve energy density at lower cost, reduce direct costs, and possibly enable much shorter and less energy intensive battery formation cycling. CONCLUSION Lithium ion batteries have tremendous potential for enabling partial to full electrification of the automotive fleet, diversifying energy sources for transportation, and supporting large-scale energy storage for a higher penetration of inter
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From page 49...
... In addition to reducing costs, research can enhance knowledge of molecular processes and transport issues in order to optimize the design and use of available energy in batteries and increase their life time. As shown in this paper, an increase in energy content and capacity in active electrode materials and a reduction of indirect materials in production are two ways to impact cost.
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From page 50...
... 2015. Prospects for reducing the cost of lithium ion electrode processing and cell formation steps.
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Key Terms

  • ion batteries
  • energy density
  • current collector
  • cost reduction
  • lithium ions

  • battery cells
  • flammable vapors
  • cells lithium
  • ion battery
  • surface energy

  • available energy
  • inactive materials
  • electrode manufacturing
  • collector foil
  • surface tension

  • active materials
  • metal current
  • crystal structure
  • active material
  • pack level

  • conductive additives
  • processing equipment
  • manufacturing lithium
  • ion electrode
  • lithium cobalt

  • balanced lithium
  • energy cost
  • conclusion lithium
  • battery manufacturing
  • corona plasma


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