Does micro-level manufacturing affect the energy density of EV batteries?

Besides the cell manufacturing, “macro”-level manufacturing from cell to battery system could affect the final energy density and the total cost, especially for the EV battery system. The energy density of the EV battery system increased from less than 100 to ∼200 Wh/kg during the past decade (Löbberding et al., 2020).

How can battery manufacturing improve energy density?

The new manufacturing technologies such as high-efficiency mixing, solvent-free deposition, and fast formation could be the key to achieve this target. Besides the upgrading of battery materials, the potential of increasing the energy density from the manufacturing end starts to make an impact.

What is battery manufacturing process?

Figure 1 introduces the current state-of-the-art battery manufacturing process, which includes three major parts: electrode preparation, cell assembly, and battery electrochemistry activation. First, the active material (AM), conductive additive, and binder are mixed to form a uniform slurry with the solvent.

How can the battery industry reduce energy costs?

The industry aims to achieve this by using both cobalt- and nickel-free materials, standardizing cells and integrating them directly into the battery pack. New manufacturing processes could also contribute to reducing costs, both by leveraging energy and equipment costs and by standardizing the factory itself.

Can new battery materials reduce the cost of a battery?

Although the invention of new battery materials leads to a significant decrease in the battery cost, the US DOE ultimate target of $80/kWh is still a challenge (U.S. Department Of Energy, 2020). The new manufacturing technologies such as high-efficiency mixing, solvent-free deposition, and fast formation could be the key to achieve this target.

How can new manufacturing processes reduce battery costs?

New manufacturing processes could also contribute to reducing costs, both by leveraging energy and equipment costs and by standardizing the factory itself. Low battery cost could also be achieved by localizing factories to more advantageous production sites.