A novel high-throughput extrusion-lamination process for lithium-ion battery manufacture

Completed

Other Power and Storage Technologies(Energy storage)

Basic and strategic applied research

PHYSICAL SCIENCES AND MATHEMATICS (Physics)

Not Cross-cutting

Professor I Ward
Physics and Astronomy
University of Leeds

Standard

EPSRC

05 January 2012

04 July 2013

18 months

£124,021

Materials sciences

Yorkshire & Humberside

Non Theme Specific

Professor I Ward, Physics and Astronomy, University of Leeds

Dr K Mattsson, Physics and Astronomy, University of Leeds

This programme of research is to develop and demonstrate the feasibility of producing a completely new high performance solid state battery suitable for scaling into applications such as electric vehicles, consumer electronics and green energy.Conventional technologyIn the typical conventional Li-ion technology the two electrode foils are kept apart physically by a porous film and the whole battery is enclosed in a rigid container into which the highly flammable liquid electrolyte is injected. This is a batch process of two or more stages.Most research into Li-ion batteries focuses on the electrodes especially to increase capacity; these are then incorporated in the conventional battery fabrication method. Little research is undertaken into the electrolyte and separators and even less on developing more cost effective fabrication methods and alternatives processing routes.Advantages of the Leeds technologyThe Leeds polymer gel electrolyte and extrusion lamination technology differs from the conventional in that the electrolyte acts as both separator and ion conductor. The highly conducting polymer gel electrolytes possess excellent mechanical toughness and electrochemical stability. The laminated gel electrolyte binds the cell together from within, can be produced on continuous single process, requires no rigid container, and is flexible and formable. Instead of separate components of electrolyte, binder and separator these electrolytes can act as all three.The development of a thermoreversible gel electrolyte enables melt extrusion of the gel and continuous production of battery cells at high extrusion rates of at least 10m/minute. The elimination of the expensive porous film separator and the high speed extrusion lamination process significantly reduce the cost of battery production.The programme of researchThe Leeds process has been developed and demonstrated for a number of years. It is now poised to take the technology forward to develop the process for the reliable production of multilayer laminates which can be immediately incorporated into batteries.The development of the process will require a study of the formation of gels at the fast extrusion rates that are required for commercially viable processing.Future commercial developmentsThis programme will demonstrate that the technology can produce mainstream cost effective Li-ion batteries with enhanced safety and high specific capacity

27/01/12