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III.C.4 Innovative Manufacturing and Materials for Low Cost Lithium Ion Batteries (Optodot) John G. Tabacchi, NETL Project Manager Subcontractor: Optodot Corporation Steven A. Carlson, Program Manager 100 TradeCenter, Suite G-700 Woburn, MA 01801 Phone: (617) 513-6313; Fax: (781) 569-5201 E-mail: scarlson@optodot.com mailto:cashtiani@ENERDEL.com Subcontractors: Madico Inc., Woburn, MA Dow Kokam, LLC, Lee’s Summit, MO University of Rhode Island (URI), Kingston, RI Ashland Inc., Wayne, NJ Start Date: October 1, 2011 Projected End Date: September 30, 2014 Objectives Demonstrate technology that reduces the cell or battery inactive component weight, volume, and/or cost by at least 20% (goal of at least 40%), while maintaining overall cell or battery performance. Design, develop, optimize and improve the separator, current collectors, electrolyte, termination materials, and cell casing used for manufacturing lithium ion batteries. Develop a simpler and faster battery coating and assembly process. Technical Barriers At least a two-fold reduction in the cost of manufacturing lithium-ion batteries is needed for widespread adoption of electric vehicles. Even though improvements in the battery anode and cathode materials will provide significant cost reduction, it is difficult to achieve this overall two-fold level of cost reduction from incremental improvements of the current generation of battery inactive components and of battery coating and assembly processes. Technical Targets Develop a high performance cell that reduces the combined cost of the battery inactive components of separator, current collectors, electrolyte, termination materials, and casing by at least 20%. Demonstrate a manufacturing process based on new inactive components that provides high performance cells while reducing the coating and assembly cost by at least 20%. Accomplishments Developed new versions of 8 micron thick ceramic separator layers with an all- nanoporous design and a very narrow pore size distribution with a 30 nm average pore diameter. Using the Argonne National Lab(ANL) battery cost model, cost savings from the 8 micron ceramic separator component including the reduced usage of electrolyte were estimated to be greater than 20% for the inactive components of the cell. This estimated saving meets the cost reduction objectives of this project from the thinner ceramic separator alone. 3 micron thick copper and aluminum current collector layers were coated onto anode/separator and cathode/separator coated stacks, respectively, and showed good cycling and conductivity. A low cost proprietary process was developed for coating the 3 micron thick copper current collection layer. Introduction FY 2013 Annual Progress Report 99 Energy Storage R&D Optodot has proposed to develop a new set of battery inactive components and a new battery coating and assembly process. These innovative materials and manufacturing process are based on the use of a thinner, safer, and lower cost ceramic separator. The proposed work comprises development of advanced ceramic separator, current collector, and electrolyte materials and of advanced battery stack coating and current collection methods. A new system of edge termination and cell casing will be developed for use with these coated anode and cathode stacks. The thinner ceramic separator enables the use of lower cost and more thermally stable electrolytes. Wider and higher speed industrial coaters will be utilized to make the coated battery electrode stacks to obtain the cost benefits of at least a five-fold increase in coating output. The new battery manufacturing process eliminates the expensivePDF Image | Advanced Battery Development
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