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Cell Manufacturing Issues - Electrode Manufacturing Is Difficult Every step in battery production presents challenges, but some, like coating, drying, and slitting carry a significantly higher risk of defects. The heat map illustrates these critical areas, highlighting their likelihood of defects. Produces most scrap during ramp-up
MAJOR DEFECTS THAT CAN OCCUR DURING COATING AND DRYING OF ELECTRODES
Contamination occurs leading to cell failure (most relevant for mass production)
agglomerates
pinholes
contamination
inhomogeneous coating load
heavy edges
DESCRIPTION
BULK DEFECTS
closely packed clusters of the solid components
tiny holes or missing spots in the electrode coating
impurities of foreign substances
Inhomogeneous coating application
poor optimization of the slot die on the cross-web profile
EFFECT
SURFACE DEFECTS
mechanical failure of the separator; localized impedance rise and capacity loss
can affect cell performance due to localized regions where capacity balancing issues occur, potential Li plating
can cause fast battery degradation and internal short circuit (ISC), lead to hi-pot failure (2)
heterogeneous porosity of electrodes; capacity balancing issues within cell, potential Li plating
uneven calendaring, leading to electrode wrinkles, leading to cell failure
Sources: Mastering Ramp-up of Battery Production, Fraunhofer (Both Figures but with internal edits*); (2) High-Potential Failure Analysis, Sotto; Detecting the foreign matter defect in lithium-ion batteries[...], Pan et al.
Extracted from the PDF; charts and images may read imperfectly.
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