Material and process development for the efficient production of the large-format bipolar battery EMBATT
For the anticipated mass market adoption of electric vehicles to occur, it is necessary to reduce the production costs of battery systems to less than 200 euros/kWh. Product safety and energy densities of more than 450 Wh/l are required to ensure ranges suitable for everyday use.
The “EMBATT2.0” consortium is focusing on an approach that, in contrast to established lithium-ion battery systems, uses large-area bipolar battery stacks as the central storage element. Adopting the established process for fuel cell production, individual cells were stacked and connected in series to create bipolar electric assemblies. Such a structure bypasses complex cell packaging and supplies stack voltages that are determined by the number of stacked individual cells. This greatly simplifies the connection technology, since the electrode carrier films themselves act as large-area cell connectors and the low internal resistance makes it possible to realize very large electrode areas. The EMBATT concept thus transfers the high energy density at the cell level directly into the battery system and eliminates the module structure as an intermediate level.
Work focused on the development of LiNi0.5Mn1.5O4 (LNMO) cathode material with a defined primary particle size and formed crystal surfaces that can be produced at low cost. Furthermore, an anisotropically electrically conductive polymer film as arrester with electrical conductivity in the direction of the surface normal was developed as part of the project, as well as a polymer electrolyte based on polymer ionic liquids, which has a defined ionic conductivity.
As a specialist in particle design, Glatt was entrusted with the task of developing efficient and economical process solutions for the synthesis of novel LNMO systems as high-performance active battery materials. With the aid of Glatt Powder Synthesis, raw materials were produced that met the required specifications like particle size, phase formation, or capacity and were suitable for mass-market adoption (scalability, manufacturing costs).
The structure of LMNO-powder can easily be modified by changing the stoichiometry and process parameters. Copyright: IKTS
Published article: Comparison of Electrochemical Degradation for Spray Dried and Pulse Gas Dried LiNi0.5Mn1.5O4
To commercialize next-generation cathode materials a lot of different synthesis methods need to be researched and evaluated regarding the attainable electrochemical properties of the materials on one hand, and the scalability of the process on the other. For the high voltage LiNi0.5Mn1.5O4 cathode material especially the degradation of the material during cycling needs to be investigated for different scales and techniques. LiNi0.5Mn1.5O4 (LNMO) was synthesized using two different methods in different scales: lab-scaled spray drying and pilot-scaled gas pulse drying.
» published in: Journal of The Electrochemical Society, 166 (13) A2860-A2869 (2019)
Both scientific-university partners and industry partners participated in the “EMBATT2.0” research project. The coordination was carried out by Glatt Ingenieurtechnik GmbH.
- IAV GmbH,
- Fraunhofer Institut für Keramische Technologien und Systeme (IKTS)
- Leibniz-Institut für Polymerforschung Dresden e.V.
- Isocoll Chemie GmbH, Butylkautschukwerk
- KMS Technology Center GmbH
- Litarion GmbH
- thyssenkrupp System Engineering GmbH
- ULT AG
Project management agency: Jülich PTJ
The joint project “EMBATT2.0” was funded by the German Federal Ministry of Education and Research (BMBF) and pursued within the funding program “Research for Sustainable Development (FONA3)”.
Duration 2016 – 2019
Funding code: 03XP0068A
Further information on this topic and related topics can also be found in the following publications: