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III.A.4 Advanced High-Performance Batteries for PEV Applications Arsenault – USABC, Judes – JCI Electrode Processing Optimization. The two approaches studied for solvent reduction through improved electrode processing methods are shown in Figure III - 12. Dry compound mixing yielded material which met solvent reduction targets, but cell testing has shown high resistance and poor calendar life behavior. This is attributed to the excessive shear undergone by the material during compounding. This process is no longer being considered for high solids mixing. Figure III - 12: High solids mixing approaches using dry compounding (left) and paste mix (right) methods A second method being tested to achieve the high solids targets is paste mixing. With this method, materials are combined with a portion of the solvent in an in-line compound mixer to achieve the work needed for the initial combination of materials to contribute to reduced solvent demand. The internal workings of this pre-blending equipment are shown in Figure III - 13. Following initial trials, equipment was rented and installed in the JCI Pilot line for further testing of electrode processing and resulting cell evaluation. Initial electrodes produced, shown in Figure III - 13, appear promising for achieving good uniformity with calendaring to the high density targets for improved energy density. Electrode quality after calendaring is a significant accomplishment not realized with previous trials. A solvent reduction of 13% was achieved, still below the 18% target. However, optimization work continues. Figure III - 13: Paste mixing equipment and electrodes An alternate (higher risk/higher reward) process incorporating aqueous binder (allowing total solvent elimination) was pursued for the positive. This offers a significant cost reduction opportunity by avoiding the need to capture the evaporated NMP solvent from the electrode process. The application of water-based binder for the cathode has shown minimal adverse impact in cell testing. Primary efforts have focused on quantifying the potential corrosion effects of the water-based cathode slurries as this corrosion can have detrimental effects on life and cell resistance. Evaluations indicate no impact on stability of the water-based slurry with 30 minutes of contact with aluminum foil, well beyond the normal processing time before electrode drying. Scaled up mixing and electrode processing is scheduled for February 2014. Electrode Design Optimization. Different approaches were tested to optimize electrode design. Higher electrode loading was proven not to be efficient. Electrode densification delivered more capacity, and better power and life. A new conductive carbon has improved electrode processing and cell performance. The anode optimization has been applied in the mid- program cells. Increased Voltage Limit. Accelerated testing began with prismatic cells at upper voltages of 4.1, 4.2 and 4.3V. The 4.2 V group showed acceptable power and energy fade. The first generation (baseline) 4.3 V tests were stopped due to poor results. Chemistry stabilization improvements have demonstrated life at 4.2V that meets EOL targets. 4.2V has been selected as the standard upper voltage limit. A few electrolyte additives tested at 4.3V imparted some stability improvement. Overall, however, capacity saw a crossover with cells at 4.2V. To maximize cell energy utilization, the usable SOC window was widened from 95%-25% to 95%-15% SOC. The cycle life of baseline cells has shown excellent performance, even with the expanded SOC window (see Figure III - 14). Energy Storage R&D 42 FY 2013 Annual Progress ReportPDF Image | Advanced Battery Development
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