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III.C Low-Cost Processing Research Technical Targets III.C.1 Low-Cost Manufacturing Project (JCI) Christopher Johnson, NETL Program Manager Subcontractor: Johnson Controls, Inc. YK Son, Principal Investigator Johnson Controls, Inc. 5757 N Green Bay Avenue Milwaukee, WI 53201 Phone: (414) 374-3709 E-mail: yk.son@jci.com Subrecipients: Maxwell Technologies, ENTEK Membranes Start Date: October 2011 Projected End Date: January 2015 Objectives Research, develop and demonstrate the advanced Li-ion cell manufacturing processes and techniques such as non-N-methyl-2- pyrrolidone (NMP) electrode, direct coating separator, and fast formation to reduce the existing Li-ion manufacturing costs by 50%. Maintain or exceed existing battery performance and requirements. Technical Barriers Dry processed electrode fabrication: A key challenge related to the preparation of solvent- free processed anode and cathode is achieving proper electrode thickness while producing desired active loading, porosity, pore size, and electrode structure. To overcome this challenge, new binders, powder mixing techniques, and new formulation are being developed to optimize active layer properties. Direct separator coating: There are multiple challenges for direct separator coating technology, such as producing a uniform microporous polymer film on the electrode surface and maintaining the rigidity of the microporous separator coating. Therefore, it requires investigating various polymers, solvents, inorganic materials including process conditions. Self discharge and calendar life Develop dry processed cathode and anode electrodes to meet the existing wet coated electrode performance. Develop direct coated separator to meet the existing poly-olefin separator performance. Develop the fast formation process to meet the existing baseline formation process performance while improving cell uniformity and maintaining detectability. Develop a 15Ah Li-ion cell that integrates all three advanced technologies to meet a baseline NMC/Graphite cell performance, durability and safety. Accomplishments Developed and proved out 15Ah NMC/Graphite baseline cell design with 155Wh/kg and 300Wh/l energy density. Developed lab scale pilot lines for dry electrode production and separator lamination for 3Ah integrated cell delivery. Developed 3Ah integrated cell design and process to incorporate dry processed electrodes and separator lamination technologies. Developed the activation process for fast formation. Developed interim cost model. Introduction Johnson Controls proposes to develop a portfolio of advanced manufacturing technologies to reduce the manufacturing cost of large format Li-ion cells by 50%. Three key technologies to be developed are: Non-NMP electrode, direct separator coating, and fast cell formation. The integration of these three advanced manufacturing technologies will achieve the targeted cost savings through the elimination of material, lower capital equipment expenses, and reduced energy and manufacturing costs. studies will be used to evaluate performance against these risks. FY 2013 Annual Progress Report 89 Energy Storage R&DPDF Image | Advanced Battery Development
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