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III.C.4 Materials for Low Cost Lithium Ion Batteries Tabacchi – NETL, Carlson – Optodot conventional assembly equipment to precisely interleave the electrodes with free standing separators. Approach Optodot will characterize the performance and cost of the inactive components and assembly process of current baseline cells. Starting with a thinner ceramic separator layer for this project, Optodot and its subcontractors will overcoat this separator with conventional anode and cathode layers. Optodot will design and develop thinner and lower cost current collector layers for the anode and cathode electrodes before coating a second anode or cathode layer. Optodot is also developing a cell termination and casing system for use in making and demonstrating high performance 2 Ah cells. With its subcontractors, Optodot is working to develop a lower cost and more thermally stable electrolyte that functions well with the much thinner ceramic separator and coated battery stack. Optodot and its subcontractors will demonstrate and document the acceptable performance and overall cost reduction of these improved inactive components for lithium ion batteries and of the simpler and faster coating and assembly processes. A cost analysis report will document the cell cost reduction achieved compared to the cost of current baseline cells. Results The capability of overcoating the electrodes onto an 8 micron thick ceramic separator layer without penetration of the pigments of the electrode into the separator and without damage to the electrode/separator coated stack during calendering was demonstrated in FY2012. This 8 micron ceramic separator is 40% porous with a narrow pore size distribution centered at 30 nm. The use of an 8 micron nanoporous ceramic separator as the layer on which the electrodes and current collector layers are coated to form anode and cathode coated stacks provides significant cell cost savings of 20-25% of the inactive components of the cell, using the ANL battery cost model. The cost savings are derived from the use of the much thinner separator, a reduction in the usage of the electrolyte due to the thinner separator, and cell cost reduction in $/kWh from the much thinner separator that allows more active material to be used in the cell. The ceramic separator layers and the release substrates of this project have excellent stability to the heat and stress of the electrode coating process, as demonstrated during the machine coating of the electrodes and subsequent calendering of the electrode/separator stacks. Safety- and cell performance- related features of the ceramic separator layer include dimensional stability of less than 0.5% shrinkage at 220°C, much greater compression strength than plastic separators, excellent thermal conductivity and heat dissipation, excellent cycling rate capability and low resistance from the much thinner ceramic separator, and non-flammability. Metal current collector layers and edge connections are being incorporated into the electrode/separator coated stacks to produce the full anode and cathode coated stacks. Considerable progress was made in developing a low cost proprietary process for coating 3 micron copper metal layers as the anode current collector layer with an electrical conductivity of about 0.5 ohms/square. The estimated cost savings for this copper current collector layer is about 40% with a large weight savings compared to the existing copper foils used as the substrate for coating the anodes. Figure III - 91 shows cross-sections of anode and cathode coated stacks of this project. Small cells made with these coated stacks showed good cycling and high and low temperature performance. Figure III - 91: Anode electrode stack and cathode electrode stack The new separator and current collector layers of this project are generic and compatible for use with various anode, cathode, and electrolyte materials as improved cell materials become available. Since the much thinner ceramic separator provides more flexibility and latitude in the selection of Energy Storage R&D 100 FY 2013 Annual Progress ReportPDF Image | Advanced Battery Development
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