Advanced Materials Processing for Lithium Ion Battery Applications

Introduction The introduction of large-scale lithium secondary battery technology for new energy storage applications requires significant investment in production facilities in changing from old to new chemistries and for reducing production cost and energy intensity. In addition, there will be required changes in process methodologies and quality control in shifting emphasis from small-scale consumer electronics to large-scale automotive and grid storage applications. Oak Ridge National Laboratory (ORNL) is meeting these challenges by developing advanced component processing methodology, low-cost electrode processing, non-destructive evaluation, and material diagnostics. The major objective of our research group is to investigate, improve, and scale electrode and materials processing methodology to manufacture high performance lithium secondary batteries in industrial quantities with key industrial partners. Achieving this objective will result in widespread commercialization of lithium secondary battery technology and establishment of a secure domestic supply chain. Manufacturers currently lack a full understanding of effects of material processing parameters and electrode formulation (i.e. colloidal chemistry and dispersion techniques) on battery performance [1,2]. ORNL is conducting research on electrode coating technology that both reduces material processing cost and improves cell performance. Using ORNL’s expertise in process technology and quality control, the Lab is assisting industry in developing lowcost, water-based methods of producing electrodes and in enabling successful implementation of cells meeting performance needs and cost targets. Major results from several industrial partnerships will be discussed including advanced materials characterization and electrode processing parameter studies with Dow Kokam, solidstate cathode processing with Planar Energy Devices, and polymer-ceramic composite separator thermomechanical property characterization with Porous Power Technologies. ORNL is also characterizing materials and components with its world-class facilities that will complement the manufacturing science, as well as developing important diagnostic methods to elucidate high-voltage/energy cathode performance.