Latex migration in battery slurries during drying

Light-Scattering Analysis of Drying Behavior in Suspension Droplets with Silica and Polystyrene Particles and a Hydrosoluble Polymer

The coffee-ring structure, which is the final drying pattern of a sessile suspension droplet, is a key factor in controlling the uniformity of the particulate deposits in various coatings. Two light-scattering methods, diffusing wave spectroscopy (DWS) and multispeckle DWS (MSDWS), were used to quantitatively distinguish temporal changes in particle mobility in evaporating suspension droplets containing micrometer-sized silica and polystyrene (PS) particles. The characteristic particle mobility was measured in terms of the mean square displacement in the early stage of drying, and the local particle dynamics around the edge and center regimes of the droplets during drying were analyzed using MSDWS. Hydroxyethyl cellulose (HEC), a hydrosoluble polymer, was added to the silica and PS suspensions to further investigate its role in suppressing or enhancing coffee-ring patterns based on particle-polymer interactions. Consequently, dried microstructures can be directly correlated with real-time drying dynamics, as well as the interactions between solutes by comprehensive light-scattering methods.

Effective Ultrasound Acoustic Measurement to Monitor the Lithium-Ion Battery Electrode Drying Process with Various Coating Thicknesses

The electrode drying process (DP) is a crucial step in the lithium-ion battery manufacturing chain and plays a fundamental role in governing the performance of the cells. The DP is extremely complex, with the dynamics and their implication in the production of electrodes generally being poorly understood. To date, there is limited discussion of these processes in the literature due to the limitation of the existing in situ metrology. Here, ultrasound acoustic measurements are demonstrated as a promising tool to monitor the physical evolution of the electrode coating in situ. These observations are validated by gravimetric analysis to show the feasibility of the technique to monitor the DP and identify the three different drying stages. A possible application of this technique is to adjust the drying rates based upon the ultrasound readings at different drying stages and to speed up the drying time. These findings prove that this measurement can be used as a cost-effective and simple tool to provide characteristic diagnostics of the electrode, which can be applied in large-scale coating manufacturing.

From Materials to Cell: State-of-the-Art and Prospective Technologies for Lithium-Ion Battery Electrode Processing

Electrode processing plays an important role in advancing lithium-ion battery technologies and has a significant impact on cell energy density, manufacturing cost, and throughput. Compared to the extensive research on materials development, however, there has been much less effort in this area. In this Review, we outline each step in the electrode processing of lithium-ion batteries from materials to cell assembly, summarize the recent progress in individual steps, deconvolute the interplays between those steps, discuss the underlying constraints, and share some prospective technologies. This Review aims to provide an overview of the whole process in lithium-ion battery fabrication from powder to cell formation and bridge the gap between academic development and industrial manufacturing.

Laser-based three-dimensional manufacturing technologies for rechargeable batteries

Laser three-dimensional (3D) manufacturing technologies have gained substantial attention to fabricate 3D structured electrochemical rechargeable batteries. Laser 3D manufacturing techniques offer excellent 3D microstructure controllability, good design flexibility, process simplicity, and high energy and cost efficiencies, which are beneficial for rechargeable battery cell manufacturing. In this review, notable progress in development of the rechargeable battery cells via laser 3D manufacturing techniques is introduced and discussed. The basic concepts and remarkable achievements of four representative laser 3D manufacturing techniques such as selective laser sintering (or melting) techniques, direct laser writing for graphene-based electrodes, laser-induced forward transfer technique and laser ablation subtractive manufacturing are highlighted. Finally, major challenges and prospects of the laser 3D manufacturing technologies for battery cell manufacturing will be provided.

In Situ Ultrasound Acoustic Measurement of the Lithium-Ion Battery Electrode Drying Process

The electrode drying process is a crucial step in the manufacturing of lithium-ion batteries and can significantly affect the performance of an electrode once stacked in a cell. High drying rates may induce binder migration, which is largely governed by the temperature. Additionally, elevated drying rates will result in a heterogeneous distribution of the soluble and dispersed binder throughout the electrode, potentially accumulating at the surface. The optimized drying rate during the electrode manufacturing process will promote balanced homogeneous binder distribution throughout the electrode film; however, there is a need to develop more informative in situ metrologies to better understand the dynamics of the drying process. Here, ultrasound acoustic-based techniques were developed as an in situ tool to study the electrode drying process using NMC622-based cathodes and graphite-based anodes. The drying dynamic evolution for cathodes dried at 40 and 60 °C and anodes dried at 60 °C were investigated, with the attenuation of the reflective acoustic signals used to indicate the evolution of the physical properties of the electrode-coating film. The drying-induced acoustic signal shifts were discussed critically and correlated to the reported three-stage drying mechanism, offering a new mode for investigating the dynamic drying process. Ultrasound acoustic-based measurements have been successfully shown to be a novel in situ metrology to acquire dynamic drying profiles of lithium-ion battery electrodes. The findings would potentially fulfil the research gaps between acquiring dynamic data continuously for a drying mechanism study and the existing research metrology, as most of the published drying mechanism research studies are based on simulated drying processes. It shows great potential for further development and understanding of the drying process to achieve a more controllable electrode manufacturing process.

Influence of the Polyacrylic Acid Binder Neutralization Degree on the Initial Electrochemical Behavior of a Silicon/Graphite Electrode

The role of the physicochemical properties of the water-soluble polyacrylic acid (PAA) binder in the electrochemical performance of highly loaded silicon/graphite 50/50 wt % negative electrodes has been examined as a function of the neutralization degree x in PAAH_1-xLi_x at the initial cycle in an electrolyte not containing ethylene carbonate. Electrode processing in the acidic PAAH binder at pH 2.5 leads to a deep copper corrosion, resulting in a significant electrode cohesion and adhesion to the current collector surface, but the strong binder rigidity may explain the big cracks occurring on the electrode surface at the first cycle. The nonuniform binder coating on the material surface leads to an important degradation of the electrolyte, explaining the lowest initial Coulombic efficiency and the lowest reversible capacity among the studied electrodes. When processed in neutral pH, the PAAH_0.22Li_0.78 binder forms a conformal artificial solid electrolyte interphase layer on the material surface, which minimizes the electrolyte reduction at the first cycle and then maximizes the initial Coulombic efficiency. However, the low mechanical resistance of the electrode and its strong cracking explain its low reversible capacity. Electrodes prepared at intermediate pH 4 combine the positive assets of electrodes prepared at acidic and neutral pH. They lead to the best initial performance with a notable areal capacity of 7.2 mA h cm^-2 and the highest initial Coulombic efficiency of around 90%, a value much larger than the usual range reported for silicon/graphite anodes. All data obtained with complementary characterization techniques were discussed as a function of the PAA polymeric chain molecular conformation, microstructure, and surface adsorption or grafting, emphasizing the tremendous role of the binder in the electrode initial performance.

Interplay between Interparticle Potential and Adsorption Structure in Nanoparticle Dispersions with Polymer Addition as Displayed by Small-Angle Scattering

The effect of polymer adsorption on the dispersion stability of particles is an important subject applicable to various manufacturing processes. In this study, small-angle scattering was used to examine the relationship between interparticle potential and polymer adsorption in dispersions of nanoparticles with an 81 Å radius containing two types of polymers. Small-angle X-ray scattering (SAXS) measurements in a silica/polyacrylamide (PAAm) system showed an increase in interparticle attractive interactions as PAAm concentration was increased. In a silica/poly(ethylene oxide) (PEO) system, the correlation between PEO concentration and interparticle potential strength became negligible at higher concentrations. Hence, the contrast variation small-angle neutron scattering (CV-SANS) method was employed to evaluate the interparticle potential and polymer adsorption simultaneously. CV-SANS revealed that PAAm was adsorbed to silica particles with a polymer shell layer thickness of 186 Å. The attractive potential observed in the absorbed layer region can be attributed to bridging PAAm molecules between the silica particles. By contrast, CV-SANS of the silica/PEO system indicated a low-polymer-concentration layer with a thickness of 34 Å around silica particles, indicating weak adsorption of PEO molecules. Negligible interaction between PEO and silica particles was assumed to be the origin of the depletion stabilization from excess polymer addition. Thus, quantitative analyses conducted using SAXS and CV-SANS measurements for the first time clearly demonstrated a difference in the adsorption structure of the polymer, which induces changes in the interaction potential between nanoparticles.

Evolution of Internal Stress in Heterogeneous Electrode Composite during the Drying Process

The mechanical behavior of electrode composite during the drying preparation has played a crucial role in the electrochemical performance of lithium-ion batteries (LIBs). Our work aimed at developing an integrated analysis method to study the component distribution, mechanical properties, and internal stress of composite coating in the process of electrode drying. The main influence factors of drying stress were thoroughly investigated. It was found that this present model could capture not only the heterogeneity effect of inactive ingredients but also the porosity-dependent viscoelasticity of electrode composite. Meanwhile, the calculated effective modulus and stress evolution upon drying time were in acceptable accord with the experimental data. Furthermore, the rapid solidification markedly increased the drying stress in electrodes and significantly impaired the tensile strength of electrode composite due to the highly gradient distributed constituents. However, the stress level at high drying temperature could be significantly reduced by an aqueous sodium alginate binder instead of poly(vinylidene fluoride). The obtained results will be a great help in efficiently manufacturing LIB electrodes with adequate mechanical integrity.

Classification of drying segregation states by a generalized diffusion model

During drying of binary colloidal mixtures, one colloidal particle component can segregate to the top surface. We investigate conditions where the segregation occurs through the analysis of a linearized diffusion model with Fick's law generalized for binary colloidal mixtures. The present model is the simplest representation that includes cross-diffusion between different particle components to describe the segregation. Using the analytical solutions of this model, we classify states in terms of which the particle component segregates for the following variables: the mixture ratio of particle components, diffusion coefficients, and drying rates. The obtained state diagrams suggest how to control the segregation by designing material and operation conditions.

Role of PVDF in Rheology and Microstructure of NCM Cathode Slurries for Lithium-Ion Battery

A binder plays a critical role in dispersion of coating liquids and the quality of coating. Poly(vinylidene fluoride) (PVDF) is widely used as a binder in cathode slurries; however, its role as a binder is still under debate. In this paper, we study the role of PVDF on the rheology of cathode battery slurries consisting of Li(Ni1/3Mn1/3Co1/3)O2 (NCM), carbon black (CB) and N-methyl-2-pyrrolidone (NMP). Rheology and microstructure of cathode slurries are systemically investigated with three model suspensions: CB/PVDF/NMP, NCM/PVDF/NMP and NCM/CB/PVDF/NMP. To highlight the role of PVDF in cathode slurries, we prepare the same model suspensions by replacing PVDF with PVP, and we compare the role of PVDF to PVP in the suspension rheology. We find that PVDF adsorbs neither onto NCM nor CB surface, which can be attributed to its poor affinity to NCM and CB. Rheological measurements suggest that PVDF mainly increases matrix viscosity in the suspension without affecting the microstructure formed by CB and NCM particles. In contrast to PVDF, PVP stabilizes the structure of CB and NCM in the model suspensions, as it is adsorbed on the CB surface. This study will provide a useful insight to fundamentally understand the rheology of cathode slurries.

Drying-induced back flow of colloidal suspensions confined in thin unidirectional drying cells

A clear back flow was observed in the thin unidirectional drying cell of a colloidal suspension. Flow around the colloidal-particle packing front was more complex than expected, even though a colloidal suspension was confined in a narrow space with a submillimeter-scale or shorter gap height. We propose that an increase in particle concentration around the packing front induces downward flow, which is the origin for back flow inside the cell. A mathematical model, which considered both a drying induced horizontal flow and a circulation flow caused by a concentration gradient of particles, showed a reasonable agreement with experimental data for the width of the back-flow region. The concentration gradient of particles was not negligible and it generated a rather complicated flow even in a thin drying liquid film.

Temporal evolution of concentration and microstructure of colloidal films during vertical drying: a lattice Boltzmann simulation study

We study the temporal and structural development of colloid films during vertical drying using the lattice Boltzmann (LB) simulation. The dispersed particles moving in Brownian motion have excluded volume and hydrodynamic interactions in the film. The concentrated colloidal film formed by solvent evaporation is modeled as an uniaxial compression of colloids with a planar moving interface. The simulation studies are carried out over a wide range of Péclet number (Pe), the relative ratio between the evaporation rate and the diffusion rate of colloids. The results clearly demonstrate a temporal variation of colloid concentration as the evaporation rate increases. In the case of high Pe, the increase of colloid concentration in the top layer creates structural features that can be distinguished along the height of the film, and eventually can induce a large tensile stress in the layer. However, surprisingly, the colloids are maximally crystallized in the case of moderate Pe. The LB simulation results are further compared with those from previous studies of the Brownian Dynamics (BD) simulation and the continuum model for the evaporation film. The LB and BD results match well both at low and high Pe limits. The qualitatively significant differences between LB and BD simulations at a moderate Pe indicate that hydrodynamic interactions (HIs) play an important role in this Pe. The presence of HIs induces a greater reduction of diffusion than under geometrical restriction alone, and the effect is conspicuous when particles are driven both by diffusion and by advection.

Positive and negative birefringence in packed films of binary spherical colloidal particles

We have investigated the birefringence in packed films of binary spherical colloidal particles. Particulate films were obtained by drying a mixed suspension of colloidal particles with two different diameters. We observed positive and negative birefringence depending on the diameters and volume ratios of the large and small particles. When the diameters of the large and small particles were similar, the films showed positive birefringence. However, negative birefringence or weakening of positive birefringence was observed in films with a large diameter ratio and an optimal volume fraction of large particles. The large particles were embedded in packed small particles in the negative and weakened positive birefringent films. We propose a packing structure in which a single shell layer of small particles formed around a large particle. Using this model, we estimated the required volume ratio of large particles, and it was in good agreement with the optimal volume fraction. The relation between the packing structure of the binary colloidal particles and the birefringence is discussed.

We have investigated the birefringence in packed films of binary spherical colloidal particles.

Direct Observation of Carboxymethyl Cellulose and Styrene-Butadiene Rubber Binder Distribution in Practical Graphite Anodes for Li-Ion Batteries

Despite the important role of carboxymethyl cellulose (CMC) and styrene-butadiene rubber (SBR) binders in graphite electrodes for Li-ion batteries, the direct analysis of these binders remains challenging, particularly at very low concentrations as in practical graphite anodes. In this paper, we report the systematic investigation of the physiochemical behavior of the CMC and SBR binders and direct observations of their distributions in practical graphite electrodes. The key to this unprecedented capability is combining the advantages of several analytic techniques, including laser-ablation laser-induced break-down spectroscopy, time of flight secondary ion mass spectrometry, and a surface and interfacial cutting analysis system. By correlating the vertical distribution with the adsorption behaviors of the CMC, our study reveals that the CMC migration toward the surface during the drying process depends on the degree of cross-linked binder-graphite network generation, which is determined by the surface property of graphite and CMC materials. The suggested analytical techniques enable the independent tracing of CMC and SBR, disclosing the different vertical distribution of SBR from that of the CMC binder in our practical graphite anodes. This achievement provides additional opportunity to analyze the correlation between the binder distribution and mechanical properties of the electrodes.

A critical and quantitative review of the stratification of particles during the drying of colloidal films

For a wide range of applications, films are deposited from colloidal particles suspended in a volatile liquid. There is burgeoning interest in stratifying colloidal particles into separate layers within the final dry film to impart properties at the surface different to the interior. Here, we outline the mechanisms by which colloidal mixtures can stratify during the drying process. The problem is considered here as a three-way competition between evaporation of the continuous liquid, sedimentation of particles, and their Brownian diffusion. In particle mixtures, the sedimentation of larger or denser particles offers one means of stratification. When the rate of evaporation is fast relative to diffusion, binary mixtures of large and small particles can stratify with small particles on the top, according to physical models and computer simulations. We compare experimental results found in the scientific literature to the predictions of several recent models in a quantitative way. Although there is not perfect agreement between them, some general trends emerge in the experiments, simulations and models. The stratification of small particles on the top of a film is favoured when the colloidal suspension is dilute but when both the concentration of the small particles and the solvent evaporation rate are sufficiently high. A higher particle size ratio also favours stratification by size. This review points to ways that microstructures can be designed and controlled in colloidal materials to achieve desired properties.

Effects of pH on the structure and mechanical properties of dried pH-responsive latex particles

Micrometer-sized monodisperse polystyrene (PS) particles carrying a pH-responsive poly[2-(diethylamino)ethyl methacrylate] (PDEA) colloidal stabilizer were synthesized via free radical dispersion polymerization. X-ray photoelectron spectroscopy and electrophoretic measurements verified that PDEA covered the PS particle surface. At pH 3.0 and 6.3, where the PDEA is protonated and cationically charged, the PDEA-PS particles were well dispersed in aqueous media thanks to the water soluble PDEA stabilizer and slowly sedimented due to gravity and enriched at the bottom of the glass vials. At pH 10.0, where the PDEA is non-protonated and neutral, the PDEA-PS particles weakly aggregated due to non-hydrated and collapsed PDEA. These PDEA-PS particles and aggregates sedimented to the bottom. The sediment height observed at pH 10.0 was higher than those observed at pH 3.0 and 6.3 in both wet and dry systems, which indicated that a larger porosity was formed at pH 10.0. Mechanical testing experiments confirmed that the fracture toughness of the dried materials decreased with an increase of pH. The fracture toughness was found to be correlated with the degree of particle ordering in the dried particulate materials: more ordered, dense packings lead to a higher fracture toughness compared to amorphous, less dense packings. Thus, we could tune fracture toughness and degree of particle ordering by controlling the pH.

The Impotence of Non-Brownian Particles on the Gel Transition of Colloidal Suspensions

The ability to predict transitions in the microstructure of mixed colloidal suspensions is of extreme interest and importance. The data presented here is specific to the case of battery electrode slurries whereby the carbon additive is reported to form strong colloidal gels. Using rheology, we have determined the effect of mixed particle systems on the critical gel transition ϕgel. More specifically, we show that the introduction of a high volume fraction of large non-Brownian particles has little to no effect on ϕgel. Although ϕgel is unchanged, the larger particles do change the shape of the linear viscoelasticity and the nonlinear yielding behavior. There are interesting similarities to the nonlinear behavior of the colloidal gels with trends observed for colloidal glasses. A comparison of experimental data and the prediction from theory shows that the equation presented by Poon et al. is able to quantitatively predict the transition from a fluid state to a gel state.

Phase behavior of colloid-polymer depletion mixtures with unary or binary depletants

Adding depletants to a colloidal suspension induces an attractive interparticle interaction that can be tuned to obtain desired structures or to probe phase behavior. When the depletant is not uniform in size, however, both the range and strength of the attraction become difficult to predict and hence control. We investigated the effects of depletant bidispersity on the non-equilibrium phase behavior of colloid-polymer mixtures. We added unary or binary mixtures of polystyrene as the depletant to suspensions of charged poly(methyl methacrylate) particles. The structure and dynamics of the particles were compared over three sets of samples with various mixtures of two different polystyrenes whose size varied by an order of magnitude. The structure and dynamics were nearly independent of depletant dispersity if the polymer concentration was represented as a sum of normalized concentrations of each species. Near the transition region between a fluid of clusters and an interconnected gel at intermediate volume fractions, partitioning of polymers in a binary mixture into colloid-rich and polymer-rich phase leads to a slightly different gelation pathway.