By Dr. Michael Rohde
In a previous story, I explored the critical pain points in lithium-ion battery cell production, focusing on the “magic triangle” of slurry formulation: dispersion, process conditions and carbon black properties. Let’s dive deeper into why achieving homogeneous slurries and defect-free coatings is such a challenge.
Why is formulating the perfect slurry is so challenging in lithium-ion battery cell production?
Formulating the perfect slurry is far from straightforward. It involves various ingredients, each with unique sizes, surface properties and amounts. Dispersing these ingredients might sound simple, but it’s actually a science. Dispersing goes beyond just mixing or blending. Even a well-executed dispersing process is often far from achieving maximum dispersion. It’s about achieving uniformity at a level that ensures consistency and stability, which is much more complex than simply blending the components together.
What makes the science of mixing so complex in lithium-ion battery cell production?
Many labs have mixing equipment, but determining the optimal speed, duration, device geometry and geometry of the blades for the best results is often a mystery. The system’s complexity, driven
by numerous parameters, makes a comprehensive design of experiments approach impractical due to budget and timeline constraints. As a result, many empirical studies are conducted, relying on existing “working” procedures with some adjustments.
Time constraints and iterations
Development groups often face tight project timelines, making it challenging to optimize the system fully. Even after 10 to 15 iterations, performance might converge to a local maximum rather than a total maximum, without anyone realizing it. The only way to overcome these challenges is through collaboration, learning from experts and suppliers. This approach saves significant time, energy and costs.
Easy as cake? Not really
Think about preparing a cream cake. Pastry chefs have perfected their craft, but our first attempts often fall short in appearance, stability and taste. Only with support, training and process knowledge do we improve and, eventually, some secret ingredients are revealed.
Why is Orion S.A. uniquely qualified to make battery materials?
At Orion S.A., with more than 160 years of experience with carbon black, we understand the critical role this material plays in impacting rheology, while also incorporating various matrices in slurry formulation. Our global team is here to support you with engineered conductive carbon blacks, process optimizations, and deep technical insights that enable you to achieve high-performance electrodes and reduce scrap rates. Let’s connect and discuss how we can tackle these challenges together.
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Dr. Michael Rohde is the director of Global Marketing for Batteries at Orion S.A. He earned a doctorate in chemistry from the University of Freiburg and an MBA from the Frankfurt School of Finance and Management.
