Abstract
The demand for batteries for energy storage is growing with the rapid increase in photovoltaics (PV) and wind energy installation as well as electric vehicle (EV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV). Electrochemical batteries have emerged as the preferred choice for most of the consumer product applications. Cost reduction of batteries will accelerate the growth in all of these sectors. Lithium-ion (Li-ion) and solid-state batteries are showing promise through their downward price and upward performance trends. We may achieve further performance improvement and cost reduction for Li-ion and solid-state batteries through reduction of the variation in physical and electrical properties. These properties can be improved and made uniform by considering the electrical model of batteries and adopting novel manufacturing approaches. Using quantum-photo effect, the incorporation of ultra-violet (UV) assisted photo-thermal processing can reduce metal surface roughness. Using in-situ measurements, advanced process control (APC) can help ensure uniformity among the constituent electrochemical cells. Industrial internet of things (IIoT) can streamline the production flow. In this article, we have examined the issue of electrochemical battery manufacturing of Li-ion and solid-state type from cell-level to battery-level process variability, and proposed potential areas where improvements in the manufacturing process can be made. By incorporating these practices in the manufacturing process we expect reduced cost of energy management system, improved reliability and yield gain with the net saving of manufacturing cost being at least 20%.
Highlights
Energy storage has evolved at a rapid rate in the last couple of decades
There is room for improvement in controlling the process variations observed in battery manufacturing
We have emphasized that the variation from cell‐to‐cell is crucial for energy storage application
Summary
Energy storage has evolved at a rapid rate in the last couple of decades. Battery storage was mostly used for starting engines, few emergency backup and portable devices, toys, etc. Due to the rise of consumer electronics and the convenience of recharging, nickel metal hydride (NiMH) and nickel cadmium (NiCd) batteries gained mainstream popularity. The arrival of lithium-based batteries changed the scenario by offering higher energy efficiency and density, in addition to its longer shelf life, fast charge and discharge, etc. Though it was reported that lithium-ion (Li-ion) batteries have slight memory effect [2], it is less prominent than NiCd and NiMH batteries. Li-ion batteries have high gravimetric (Wh/kg), high volumetric (Wh/L), high cycle life, and high energy efficiency, etc. Li-ion batteries have high gravimetric (Wh/kg), high volumetric (Wh/L), high cycle life, and high energy efficiency, etc. [3]
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