Advanced Low-Cost Electrostatic Deposition-Based Dry Electrode Manufacturing Technology

Electrostatic Deposition (ESD) based Dry Battery Electrode (DBE) manufacturing technique provides exciting potential to overcome the challenges to manufacturing cost and high energy density in conventional Li-ion battery manufacturing. To address this, simultaneous doublesided coating ability is highly desirable in a dry battery manufacturing process. In this proposal, a technical solution is proposed to enable an ESD-based dry manufacturing process and equipment for simultaneous double-sided coating and electrode production in roll-to-roll processes at competitive web-speeds. The primary technical objective for this project is to demonstrate proof-of-concept of simultaneous double-sided coating using ESD. To achieve this primary objective, the approach taken by AMB will be to design and fabricate a prototype ESD coating system, conduct a preliminary study of the coating process conditions and parameters in a vertical coating configuration, and finally evaluate the electrochemical performances of the fabricated electrodes. The findings from this project are expected to greatly impact the ESD-based dry battery manufacturing technology. During Phase I, AM Batteries will (1) develop the vertical coating configuration design, build prototype equipment and (2) carry out preliminary feasibility studies for the double-side coated electrode manufacturing process. We will then evaluate the electrostatic charging and deposition technique to achieve highly uniform and smooth coating on both sides of the current collector. The manufactured double side coated electrodes will be characterized for mechanical, electrical, and electrochemical performance by the in-house characterization tools. The AMB solvent free technology has the potential to reduce overall cell costs by 7-10% with additional savings (~5%) from thicker electrodes, reduced CO2 tax, and reduced labor requirements. For example, for a 5GWh LIB (Lithium-ion Battery) plant, AMB technology can lower the total plant energy usage by 47%, corresponding to $34M reduction of annual energy OPEX, and reduce the electrode coating equipment CAPEX by 41%, corresponding to a $27M one-time CAPEX reduction. Furthermore, there are opportunities to reduce the cell material cost by as much as 24%, due to thick electrode coating and higher energy density. The proposed double-sided coating ability is expected to reduce the equipment space by more than 25% and an approximately 25% throughput increase in comparison with the current horizontal singlesided ESD-based DBE coating process.