Lithium-based batteries are rechargeable and power our daily lives from consumer electronics to medical equipment, power tools, electric vehicles, and even national defense. They enable electrification of transportation and provide stationary grid storage, which the US Department of Energy considers critical to developing the clean-energy economy.
The US EPA reports that the greenhouse gas emissions associated with an electric vehicle over its lifetime are typically lower than those from an average gasoline-powered vehicle, even when accounting for manufacturing. The organization notes that “over the lifetime of the vehicle, total greenhouse gas (GHG) emissions associated with manufacturing, charging, and driving an Electric Vehicle are typically lower than the total GHGs associated with a gasoline car. That’s because EVs have zero tailpipe emissions and are typically responsible for significantly fewer GHGs during operation.”
The International Energy Agency reports that the demand for electric cars is booming, with sales expected to leap 35% this year after a record-breaking 2022. The report also predicts that cars are just the first wave: electric buses and trucks will follow soon, and that the “encouraging trends are also having positive knock-on effects for battery production….”
The Agency notes that “In emerging and developing economies, the most dynamic area of electric mobility is two- or three-wheel vehicles, which outnumber cars. For example, over half of India’s three-wheeler registrations in 2022 were electric, demonstrating their growing popularity. In many developing economies, two- or three-wheelers offer an affordable way to get access to mobility, meaning their electrification is important to support sustainable development.”
The significance of battery technology lies in its potential to transform the energy landscape, reducing our reliance on fossil fuels and enabling a more sustainable future. However, as the demand for batteries continues to grow, so does the need for efficient manufacturing processes to produce high-quality batteries at a low cost.
Analytical technologies play a critical role in battery manufacturing, from sourcing raw materials to producing the final product. These technologies enable manufacturers to monitor and optimize their processes, ensuring they make batteries that meet the desired specifications.
Research, Development, and Manufacturing for Reducing Wastage
Efficient research, development, and manufacturing processes are essential for reducing wastage in battery production. Analytical technologies can help achieve this goal by providing manufacturers with real-time data on their manufacturing processes, enabling them to identify inefficiencies and make informed decisions about improving them.
Some of the most commonly used analytical technologies in battery manufacturing include:
- X-ray diffraction (XRD) and X-ray fluorescence (XRF) for analyzing the chemical composition of raw materials and finished products
- Scanning electron microscopy (SEM) for visualizing the structure of materials at the micro and nanoscale
- Infrared (IR) spectroscopy for detecting chemical bonds and functional groups in materials
- Raman spectroscopy for analyzing the vibrational modes of molecules in materials
- FTIR analysis to perform research or quality control to help optimize lithium battery alternatives (e.g., Li–S, Li–O2, Na-ion) and electrolyte formulations, or catalytic systems
These technologies provide manufacturers with real-time data on their batteries’ composition, structure, and performance, allowing them to make informed decisions about improving their manufacturing processes.
“Gauging” Battery Success
Online gauging solutions are a prime example of analytical technologies that can be used to achieve more efficient manufacturing. These solutions provide In-line measurement and control which helps battery manufacturers to cost-effectively produce safer, better performing batteries. The real-time measurements of various parameters such as thickness, weight, and density during the manufacturing process allows manufacturers to monitor and adjust their production processes in real-time. This helps ensure that their batteries meet the desired specifications, as well as minimize wastage and optimize the use of raw materials.
Electrode coatings that are uniform and defect-free play a defining role in delivering reliable batteries of superior quality. Uneven coating of the aluminum or copper substrates compromises characteristics such as charge density, recharge time, and operational lifetime and can lead directly to safety concerns. Detecting defects and non-uniformities early enables cost-effective remedial action and is the key to making better batteries more efficiently. As performance targets rise, battery manufacturers are looking to reliably detect increasingly small defects, intensifying the need for effective in-line measurement.
Calendering ensures consistent compression of the coated electrode, delivering homogeneous thickness and particle size. It helps to control the porosity of the coating, improving electrical contact and adhesiveness, along with other critical parameters. Total electrode thickness measurements are crucial during this final step to avoid excessive compression and deliver electrodes of consistent dimensional accuracy.
Increasingly sophisticated multilayer separator films are a critical component of high-performance lithium-ion batteries. Separator film properties impact characteristics such as self-discharge rate and safety, providing in-built thermal shutdown and protecting against thermal runaway. Properties ranging from porosity to tensile strength are controlled to deliver desirable performance. Consistent thickness is crucial to optimize battery performance and life, and a primary focus during manufacture.
Overall, the role of analytical technologies in battery manufacturing, including thickness and basis weight measurement, is becoming increasingly important as demand for batteries continues to grow. By providing manufacturers with the tools they need to optimize their production processes, reduce wastage, and improve the quality and consistency of their products, these technologies are helping to drive innovation and sustainability in the industry and are playing a big part in moving to a Clean-Energy Economy because if the batteries don’t work well, no one will want to move to an electric vehicle or renewable energy solution.
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