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III.C.2 Ultraviolet Curable Binder Lithium Ion Battery Project (Miltec UV) John Tabacchi, NETL Manager Contractor: Miltec UV International, LLC Primary Contact: Gary E. Voelker, Project Director Dr. John Arnold, Principal Investigator 146 Log Canoe Circle Stevensville, MD 21666 Phone: (410) 604-2900; Fax: (410) 604-2906 E-mail: gvoelker@miltec.com,jarnold@miltec.com Start Date: October 1, 2011 Projected End Date: October 1, 2014 Progress and Current Status Introduction The objective of this project is to reduce lithium ion battery electrode manufacturing costs by 50% by replacing thermal drying of solvent-based binders with ultraviolet (UV) or electron beam (EB) curable binders. The project goal is to demonstrate that battery cells made from UV or EB cured electrode coatings perform equal to or greater than equivalent cells made from solvent based binders. Previously identified UV and EB curable binders and associated curing technology will be shown to reduce the time required to cure electrode coatings from tens of minutes to less than one second. This revolutionary approach can result in dramatic increases in process speeds and significantly reduced capital costs (a factor of 10 to 20) and operating costs, reduced energy requirements and reduced environmental concerns and costs due to the virtual elimination of volatile organic solvents and associated solvent dryers and recovery systems. Multiple lithium ion battery cells will be fabricated using various approaches to UV and EB curing technology; performance of the cells will be evaluated; and analytical testing will be used to further improve the performance of the cells. Eventual cells made with UV/EB curable binders will be submitted to the DOE for independent testing and performance verification. Commercialization of UV/EB technology will lead to greater market penetration of HEVs, PHEVs and EVs as well as significantly reducing the environmental intrusion associated with the manufacturing processes. During FY 2013, Miltec UV researchers formulated UV curable binders (patents pending) and used them to successfully make lithium ion battery anode and cathode coatings. These coatings have been applied at thicknesses up to 100 microns and successfully cured at speeds up to 200 feet per minute (FPM). Electrode coatings have been made which retained physical integrity after being immersed in pure electrolyte at elevated temperatures for extended periods. Coin cells have been made using UV curable binder anodes and cathodes and tested. The initial charge/discharge and first 50 cycles for two such coin cells are shown later in this section. The long term cycling performance of full cells made with a conventional anode and UV curable binder cathodes are shown below. Anodes have also been fabricated using UV curable binder and tested in half cells. The initial charge/discharge results for one such test is shown below. These efforts culminated in the delivery of 18 Interim cells made with UV curable binder anodes and cathodes with the goal of having performance equal to or greater than conventional cells. A slot die coater and reel to reel conveyor have been installed on a Miltec UV multiple lamp UV curing system. The system is capable of accommodating a 10” current collector foil and an 8” coating width and is capable of coating and curing at speeds up to 200 fpm. Interim Cell Evaluation and Test. The major part of the efforts during FY2013 has focused on research and development to improve and verify the adhesion, chemical stability, and other qualities of selected UV and EB curable binders leading to the delivery of 18 Interim cells for independent evaluation. These efforts are described below. Figure III - 79 shows the initial charge discharge performance for a baseline cell. Figure III - 80 shows the initial charge/discharge performance of a half cell made with a cathode using UV curable binder and Figure III - 81 the cycling performance to 50 cycles. The active material is NMC and the coating is 87% NMC, 5% Carbon, 8% Binder (by weight); cured at 100 FPM; and 50 microns coating thickness. Full cells using these same UV curable binder coatings have completed long term cycling and the results of one full coin cell are shown in Figure III - 82. The initial charge and discharge tests for a UV cured anode are shown in Figure III - 83. FY 2013 Annual Progress Report 93 Energy Storage R&DPDF Image | Advanced Battery Development
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