The energy transition to sustainable technologies confronts us with great challenges but although brings fascinating opportunities. Among these opportunities lies the battery technology, which is considered the heart of electromobility and renewable energy storage. A strategic focus on the future of battery production is essential for progress in these areas and for national value creation.
One leading research center in this field is the Zentrum für Sonnenenergie- und Wasserstoff-Forschung Baden-Württemberg (ZSW) in Ulm. The ZSW has been involved in battery production and process research for many years, with the aim of improving the efficiency and performance of batteries and their production.
The research spectrum of the ZSW in Ulm is unique. ZSW offers all process steps for the development and production of lithium-ion cells in various standard formats. These include 18650 and 21700 round cells, single and multiple stacked pouch cells, and prismatic PHEV-2 cells. Battery manufacturing includes prototype and sample production, from lab scale to near industrial production on the Research Production Line (FPL).
The manufacture of a battery is a multi-step process that requires a high level of expertise and precision. Battery manufacturing is an interdisciplinary field where materials science, electrochemistry, and engineering come together to produce efficient and powerful batteries. But what exactly happens during the production of a battery?
The initial stage of producing a battery is selecting the appropriate materials. Active materials hold a central role in every battery as they facilitate the chemical reactions that store and discharge energy. Yet, merely having active materials does not ensure that the battery will be of good quality. The battery's output and lifespan are considerably influenced by the interaction between the active materials and other components, particularly the electrolyte.
Particle design (also known as particle morphology) and additive selection are crucial factors in producing electrodes. The morphology of the particles determines how effectively chemical reactions can take place within the battery, while additives influence the battery's performance and lifespan. Creating electrodes, therefore, demands a high level of expertise and meticulous control of all variables.
This is then followed by cell design and the actual manufacturing process. Factors such as the quality and speed of the manufacturing process, as well as costs, are crucial. The design of the cell dictates how its components - including electrodes and electrolytes - are assembled to create a working unit. The manufacturing process quality significantly influences the end product's quality, while its speed determines the production rate, which, in turn, affects costs.
Finally, any new material or component utilised in battery manufacturing must undergo qualification and verification in sample runs prior to commercial production. This guarantees that the new material or component will function safely and proficiently, meeting the industry's rigorous standards.
Attaining a high-performance, long-lasting, cost-effective battery is dependent on meticulous planning and precise execution of every step in the manufacturing process. This necessitates a thorough comprehension of all process steps in actual production conditions.
The battery industry has made considerable strides in recent years, mainly due to the evolution of pioneering materials. Advanced materials improve battery efficiency, safety and longevity, reducing costs and conserving resources.
Scientists at the ZSW in Ulm are working on the formulation of innovative material compositions on a laboratory scale and on the development of suitable processing methods to transfer these materials to the scale of industrial battery production. By specifically optimizing the material composition and processing methods, we are able to maximize the outstanding properties of the materials through innovative formulations and thus increase efficiency.
The advantages of innovative material classes become apparent when they are processed into electrodes and complete cells. At the ZSW, the study of the properties and interactions with other cell components is therefore an important area of work, with which we can determine a deeper understanding of the function and its potential applications.
The selection and processing of innovative materials and the resulting electrode and cell properties are carefully analyzed and tested. At the ZSW in Ulm, there are extensive analytical facilities and highly experienced personnel available for this purpose.
The use of new materials also poses new challenges for the production process. For example, the replacement of the organic solvent NMP (N-methyl-2-pyrrolidone), which is harmful to health and the environment, by water requires the use of alternative, water-compatible binders and a new processing method for anode coating. The ZSW in Ulm is up to these challenges and is able to develop innovative solutions. This work is crucial for realizing the full potential of the new materials and developing the next generation of high-performance batteries.
Producing Li-ion cells requires unique electrodes for different applications. To meet these different requirements, ZSW uses specific methods and techniques for electrode development. All the equipment and expertise needed to produce customised electrodes is available at the ZSW in Ulm.
For instance, thinner coatings with a low active mass fraction are typically applied to electrodes for high-power cells because of the greater need for conductivity additives. Conversely, electrodes for high energy applications normally have thicker coatings with minimized amounts of additives in the formula.
The porosity of the electrode is also a vital factor. It determines the kinetics of the charging and discharging process, the energy density, as well as the adhesion and stability.
ZSW's battery manufacturing facilities in Ulm are world-class in terms of diversity and technologies. The institute is able to develop and manufacture various cell formats, including single-layer pouch cells, 18650 and 21700 round cells, as well as pouch cells and prismatic PHEV-2 cells up to 80 Ah. As a result, customised solutions can be offered for a wide range of applications.
At ZSW in Ulm, Germany, in addition to electrode and cell development, we offer our industrial customers a wide range of services related to the battery cell manufacturing process. We ensure that every step of battery production is carried out with the utmost care and precision to meet our customers' requirements. The staff is always available for questions and further information.
