Proposal for UV and EB Curable Binder Technology for Lithium Ion Batteries and Ultracapacitors

One of the major cost elements of todays Lithium Ion Batteries and Ultracapacitors is the cost of manufacturing the electrodes. A significant reduction in cost is a major goal of the DOE Vehicle Technologies Program. Reducing the cost of these storage devices could accelerate the use of HEV, PHEV, and EV vehicles in the U.S. transportation sector. One of the major contributors to the manufacturing cost of these electrodes is the large amount of capital invested in the drying ovens, and the time and energy required to operate them. UV and EB curable binders have been identified that have the potential to be used to replace the specialized nonreactive thermoplastic polymers and solvent based systems and their drying ovens presently being used to bind the coating material to the current collectors of anodes and cathodes. The objective of this project is to confirm the ability to use these binders to produce anodes and cathodes of Lithium Ion Batteries and Ultracapacitor electrodes at speeds of 200 feet per minute; a tenfold increase over todays typical system. The use of UV or EB curable binders will also significantly reduce the capital cost, operating cost, energy cost and reduce the environmental concerns of manufacturing electrodes. The potential exists that the electrode performance could also be enhanced by application of this technology.Commercial Applications and Other Benefits: In future applications, this process could be used in Lithium ion battery and Ultracapacitor manufacturing lines throughout the world. Commercialization of the technology would lead to greater market penetration of HEVs, PHEVs and EVs as well as significantly reduce the environmental intrusion associated with the manufacturing processes.