Battery Manufacturing Research Articles

Laser-Induced Regeneration of Spent LiMn2O4 Cathode Into High-Performance Ni-Doped LiMn2O4 Cathode.

The rapid increase in lithium-ion battery (LIB) production, fueled by the rise of electric vehicles, highlights significant challenges in managing end-of-life LIBs, particularly regarding environmental impact and waste management. Traditional recycling methods, such as pyrometallurgical and hydrometallurgical processes, are energy-intensive and consume substantial reagents. In this study, a laser-assisted regeneration method is introduced for LiMn2O4 (LMO) cathodes, enabling in situ Ni doping into spent LMO cathodes (r-LMO-Ni) to enhance electrochemical performance. Surface Ni-doping improves interfacial processes and reduces capacity loss at lower temperatures by creating a new interface with a lower charge transfer energy barrier. The r-LMO-Ni cathode surpasses pristine LMO cathodes, achieving a specific capacity of 112.95mA h g-1 at 1 C and retaining 95.1% of its capacity after 200 cycles at 0 °C. A techno-economic analysis supports the feasibility of this laser-assisted regeneration approach, offering an innovative pathway for upcycling spent cathodes and developing next-generation Mn-based cathodes.

Electric Vehicle Traction Battery Recycling Decision-Making Considering Blockchain Technology in the Context of Capacitance Level Differential Demand

In recent years, the rapid growth in electric vehicle ownership has resulted in a significant number of decommissioned traction batteries that will require recycling in the future. As consumer expectations for electric vehicle range continue to rise, the turnover of traction batteries has accelerated substantially. Consequently, there is an urgent need for electric vehicle manufacturers to establish an efficient, recyclable supply chain for the return of end-of-life (EOL) electric vehicle (EV) traction batteries. In this paper, we investigate the closed-loop recycling supply chain for retired power batteries in electric vehicle manufacturers, taking into account blockchain technology and the high range preferences in the electric vehicle market, which are influenced by varying demand for different levels of electric vehicle capacitance. Blockchain, as a distributed and decentralized technology, offers features such as consensus mechanisms, traceability, and security, which have been effectively applied across various fields. In this study, we construct four models involving EV battery manufacturers, EV retailers, and battery comprehensive utilization (BCU) enterprises participating in the recycling process. Through the analysis of a Stackelberg response model, we find that (1) single-channel recycling is less efficient than dual-channel recycling models, a difference driven by the diversity of recycling channels and the variability in recycling markets; (2) Recycling models incorporating blockchain technology demonstrate superior performance compared to those that do not utilize blockchain technology, particularly when the intensity of recycling competition is below 0.76; (3) Traction batteries integrated with blockchain technology exhibit higher recycling rates when the optimization index is below 0.96. Electric vehicle battery manufacturers must evaluate the benefits and costs of adopting blockchain technology; (4) With lower recycling incentive levels and EV range preferences, the single-channel recycling model yields better returns than the other three recycling models. EV manufacturers can enhance overall battery supply chain revenues by establishing varying incentive levels based on market demand for different capacitance levels.

Dense integration of chlorocatechols crosslinked polyphenylene sulfide solid-state separator for Li Metal-Free Batteries

Dry electrode film fabrication technology, known for its environmental friendliness and low energy consumption, is recognized as an effective industrial approach for producing highly dense solid-state electrolytes and pore-free separators. It holds promise for applying thin lithium metal and Li metal-free anodes in ultra-high energy density Li-ions batteries. However, the films produced by this method suffer from issues such as poor toughness, low strength, uneven thickness, and difficulties in rewinding, which limit its widespread adoption in the large-scale manufacturing of lithium batteries. In this study, we propose a hydrothermal process to introduce a chlorocatechol-based cross-linker onto the surface of highly crystalline polyphenylene sulfide (PPS) powder. By employing the dry electrode process, a PPS-based solid-state separator (PPS-SSS) is fabricated, featuring a thin profile (18±2 μm), a smoother surface, and a denser structure, significantly enhancing its mechanical properties. Moreover, the dense integration structure and chlorocatechol groups contribute to a higher Li+ transference number and more effectively inhibit the growth of Li dendrites. Li metal-free batteries, constructed with this separator, a Sn-plated Cu 10 μm foil anode, and a thick high-nickel cathode dry electrode, exhibit high discharge areal and specific capacities (5 mAh cm−2 and 200 mAh g−1, respectively) and pouch battery device energy density exceeding 440 Wh kg−1. Impressively, even in the presence of Cu or Fe powder contamination on the CuSn foil anode or cathode, this separator can still achieve uniform electric field distribution and lithium deposition, demonstrating good cycle stability.

Analisis Proses Produksi dan Perhitungan Harga Pokok Produksi pada UKM Batagor ESQ

The owner of the Small and Medium Enterprises (SMEs) Batagor ESQ is located in Bogor, in the implementation of financial records still needs help. One of the impacts of SMEs that have financial records is that they can know and control the expected level of business profits. In accordance with the name of the business, this SME carries out activities to produce and sell battery products. The purpose of this study is to analyze the production process and calculate the cost of production of Batagor ESQ SMEs. The research was carried out through interviews with the owners to get clear information. In addition, this research was also carried out by surveying the Batagor ESQ SMEs. The results of the research on the calculation of the Cost of Production (HPP) were obtained with a unit price of IDR 5.000. The results obtained from the application of the financial literacy concept turned out to be enough to increase their business, so that finances became more structured and clear. With a total revenue of IDR 70,000,000 and production costs of IDR 18,731,000 for a period of one month. The profit margin obtained by Batagor ESQ SMEs is 73.24%.

Data-driven macro-scale simulation for rapid electrolyte wetting in lithium-ion batteries

The electrolyte wetting process in lithium-ion battery manufacturing is a critical part of processes that affects battery performance and productivity. However, it is difficult to accurately measure and optimise this process with existing technologies. In this study, a three-dimensional macroscopic filling and wetting simulation model based on actual battery material parameters is constructed, which can simulate the wetting process of electrolyte in porous electrodes and separators. The model is employed to analyse effects of filling pressure pattern, boundary conditions and other process parameters on the wetting rate. The results demonstrate that the use of multilateral cyclic pressure filling can optimise the electrolyte wetting, which is in accordance with industry practice. Consequently, the study proceeds to investigate potential process optimisation strategies, including electrolyte selection and ambient temperature. These findings not only address limitations of traditional models, which employ simplified parameters, but also present a novel approach to enhance manufacturing efficiency and reduce cost of lithium batteries. This is of paramount importance for the sustainable development of lithium-ion battery industry.

Carbon footprint distributions of lithium-ion batteries and their materials

Lithium-ion batteries are pivotal in climate change mitigation. While their own carbon footprint raises concerns, existing studies are scattered, hard to compare and largely overlook the relevance of battery materials. Here, we go beyond traditional carbon footprint analysis and develop a cost-based approach, estimating emission curves for battery materials lithium, nickel and cobalt, based on mining cost data. Combining the emission curves with regionalised battery production announcements, we present carbon footprint distributions (5th, 50th, and 95th percentiles) for lithium-ion batteries with nickel-manganese-cobalt (NMC811, 8-1-1 ratio; 59, 74 and 115 kgCO2 kWh−1) and lithium-iron-phosphate (LFP; 54, 62, 69 kgCO2 kWh−1) cathodes. Our findings reveal the dominating impact of material sourcing over production location, with nickel and lithium identified as major contributors to the carbon footprint and its variance. This research moves the field forward by offering a nuanced understanding of battery carbon footprints, aiding in the design of decarbonisation policies and strategies.

Protective Role of Vitamin B6 Against Teratogenic Effects Induced by Lead in Chick Embryo.

Heavy metals like lead (Pb) have been used by humans for a very long time, but throughout the industrial revolution, their use expanded, increasing exposure to the metal. Lead, however, has no biological purpose in the human body and is hazardous when it gets into soft tissues and organs. Lead is still used in a variety of industries, including battery manufacturing and car maintenance, despite efforts to limit its usage. This study investigates the teratogenic and morphometric effects of lead on chick embryos and the potential ameliorative effects of vitamin B6. Two hundred fertilized eggs from the golden black chicken were divided into four groups: control, lead acetate, vitamin B6, and lead + vitamin B6. On the 14th day, embryos were analyzed. Significant reductions in body weight and size were observed in the lead-exposed group (33.93 ± 1.27 g) compared to the control (41.12 ± 0.97 g). Pronounced deformities included rudimentary beaks, protruding eyes, tridactyl limbs, hydrocephaly, and neck deformities. Appendicular deformities like phocomelia, amelia, and abnormal phalanges growth were also noted. Vitamin B6 demonstrated therapeutic benefits, significantly improving mean embryo weight in the Lead + Vitamin B6 group (42.37 ± 0.99 g). The lead-exposed group showed a reduction in maxilla length (3.61 ± 1.30 mm) compared to the Lead + Vitamin B6 group (7.57 ± 0.79 mm). This group also showed reduced severity of muscular dystrophy and bone thinning, with signs of recovery in beak and bone sizes. The study highlights vitamin B6's beneficial impact in mitigating lead's toxic effects on chick embryonic development.

A Diagnostic Approach to Improving the Energy Efficiency of Production Processes—2E-DAmIcS Methodology

This article presents the issue of energy waste in manufacturing processes, focusing on reducing unnecessary energy consumption and CO2 emissions. A significant challenge in modern production is identifying and minimizing energy waste, which not only increases operational costs but also contributes to environmental degradation. An improvement methodology referred to as 2E-DAmIcS is proposed. A distinguishing feature of the methodology is a risk map of energy waste in the production process. Application of the methodology is demonstrated using the example of a lead–acid battery production process. It is shown that even small but well-diagnosed changes to the process make it possible to significantly reduce energy consumption. The proposed methodology offers practical tools for managers and decision-makers in various industries to systematically identify and minimize energy waste. It highlights the importance of cross-disciplinary collaboration among specialists in technology, energy consumption, and statistical analysis to optimize energy use. By applying this approach, companies can achieve both financial savings and environmental benefits, contributing to more sustainable production practices.

Deep learning based emulator for predicting voltage behaviour in lithium ion batteries

This study presents a data-driven battery emulator using long short-term memory deep learning models to predict the charge–discharge behaviour of lithium-ion batteries (LIBs). This study aimed to reduce the economic costs and time associated with the fabrication of large-scale automotive prototype batteries by emulating their performance using smaller laboratory-produced batteries. Two types of datasets were targeted: simulation data from the Dualfoil model and experimental data from liquid-based LIBs. These datasets were used to accurately predict the voltage profiles from the arbitrary inputs of various galvanostatic charge–discharge schedules. The results demonstrated high prediction accuracy, with the coefficient of determination scores reaching 0.98 and 0.97 for test datasets obtained from the simulation and experiments, respectively. The study also confirmed the significance of state-of-charge descriptors and inferred that a robust model performance could be achieved with as few as five charge–discharge training datasets. This study concludes that data-driven emulation using machine learning can significantly accelerate the battery development process, providing a powerful tool for reducing the time and economic costs associated with the production of large-scale prototype batteries.

Gravure-Printed Anodes Based on Hard Carbon for Sodium-Ion Batteries

Printed batteries are increasingly being investigated for feeding small, wearable devices more and more involved in our daily lives, promoting the study of printing technologies. Among these, gravure is very attractive as a low-cost and low-waste production method for functional layers in different fields, such as energy, sensors, and biomedical, because it is easy to scale up industrially. Thanks to our research, the feasibility of gravure printing was recently proved for rechargeable lithium-ion batteries (LiBs) manufacturing. Such studies allowed the production of high-quality electrodes involving different active materials with high stability, reproducibility, and good performance. Going beyond lithium-based storage devices, our attention was devoted on the possibility of employing highly sustainable gravure printing for sodium-ion batteries (NaBs) manufacturing, following the trendy interest in sodium, which is more abundant, economical, and ecofriendly than lithium. Here a study on gravure printed anodes for sodium-ion batteries based on hard carbon as an active material is presented and discussed. Thanks to our methodology centered on the capillary number, a high printing quality anodic layer was produced providing typical electrochemical behavior and good performance. Such results are very innovative and relevant in the field of sodium-ion batteries and further demonstrate the high potential of gravure in printed battery manufacturing.

Enhanced Decision Support for Multi-Objective Factory Layout Optimization: Integrating Human Well-Being and System Performance Analysis

This paper presents a decision support approach to enable decision-makers to identify no-preference solutions in multi-objective optimization for factory layout planning. Using a set of trade-off solutions for a battery production assembly station, a decision support method is introduced to select three solutions that balance all conflicting objectives, namely, the solution closest to the ideal point, the solution furthest from the nadir point, and the one that is best performing along the ideal nadir vector. To further support decision-making, additional analyses of system performance and worker well-being metrics are integrated. This approach emphasizes balancing operational efficiency with human-centric design, aligning with human factors and ergonomics (HFE) principles and Industry 4.0–5.0. The findings demonstrate that objective decision support based on Pareto front analysis can effectively guide stakeholders in selecting optimal solutions that enhance both system performance and worker well-being. Future work could explore applying this framework with alternative multi-objective optimization algorithms.

Developing an Ontology on Battery Production and Characterization with the Help of Key Use Cases from Battery Research

Materials science research faces challenges due to diverse and evolving measurements, materials, and methods. Managing research data in a way that is understandable, comparable, and reproducible is essential for high data quality, particularly for data science and machine learning applications. In Li‐ion batteries research data storage concepts and structures vary widely between institutions and researchers, leading to difficulties in data comparison and understanding. To address the issue of data structuring, battery production and characterization ontology (BPCO) is developed. The ontology builds on existing ontologies like the Platform MaterialDigital core ontology and quantities, units, dimensions, and types ontology to model standard battery production processes, characterization methods, and materials. The BPCO is based on a workflow structure to be accessible to nonexperts and, unlike highly specialized existing ontologies, models the whole production process removing the need for separate data structures and enabling the identification of dependencies between parameters. This work builds upon a previously published paper in which the taxonomy and fundamental strategies for ontology development are established. The article presents the developed ontology and its use for structuring research data in three key use cases, that is, different experiments performed to validate the ontology's capabilities, provide feedback, and ensure its applicability.

Evaluating Pressure‐dependent Discharge Behavior of Foil Versus In situ Plated Lithium Metal Anodes in Solid‐State Batteries

AbstractAnode‐free manufacturing of solid‐state batteries (SSBs) shows promise to maximize energy density by eliminating excess lithium (Li) and simplifying battery production. However, high reversibility during discharge (stripping of Li) is necessary for long‐lifetime SSBs with a limited Li reservoir. Further, the plastic flow of Li changes depending on the Li thickness, leading to possible differences in discharge performance under stack pressure. This work investigates the pressure‐dependent discharge performance of anode‐free manufactured SSBs with in situ plated Li and compares the performance to that of conventional thick Li foil cells. Distinct stripping behavior is observed at low pressures (0–1 MPa), where Li diffusivity and initial interfacial contact may control accessible capacity, compared to high pressures (3–10 MPa) where mechanical deformation of Li likely governs stripping behavior. Analysis of impedance spectra collected during stripping shows that additional stack pressure delays the formation of deep, as opposed to lateral, voids in the Li anode. These results provide insights to guide the transition from thick Li foil anodes to anode‐free manufactured SSBs.

Green method for preparation NaVO2 from vanadium-chromium slag based on Na2CO3 roasting and water leaching

An effective and environment-friendly method for preparing NaVO2, which can be used as an energy storage material, from Na2CO3 roasted vanadium-chromium slag was proposed using water as the leaching medium. Vanadium-chromium slag with 30 % Na2CO3 was heated in air and argon atmospheres from 30 °C to 1000 °C, respectively. The results show that vanadium compounds converted to NaVO3 while chromium compounds to Na2CrO4 under air. NaVO3 and Na2CrO4 were water-soluble making the separation of vanadium and chromium complicated. NaVO3 and Na2CrO4 were water-soluble making the separation of vanadium and chromium complicated. Heating vanadium-chromium slag in an argon atmosphere caused Fe2VO4 to react with Na2CO3, forming NaVO2 and NaFeO2 below 1000 °C. However, chromium compounds unreacted in argon. NaFeO2 was insoluble, while NaVO2 was water-soluble with a leaching efficiency exceeding 70 %. Notably, the characteristic peak of V(III) in NaVO2 was first found to be −532.00 ppm by the liquid 51V NMR spectrum. This method represents a novel, green strategy for the resource utilization of vanadium-chromium slag, involving Na2CO3 roasting in an argon atmosphere to produce NaVO2. It offers a promising approach to reduce the cost of NaVO2 battery production and support its commercialization.

Identification of critical moisture exposure for nickel-rich cathode active materials in lithium-ion battery production

Nickel-rich cathode materials are crucial for improving lithium-ion battery performance due to their potential for high energy densities. However, their sensitivity to humidity demands cost- and energy-intensive dry room production environments. This study examined the storage stability of a surface-treated nickel-rich cathode (≈ 91 mol% nickel) under industry-relevant scenarios to assess the required atmospheres and the impact of short moisture exposure on material and cell performance. Calendered and non-calendered cathodes were produced in a dry room with a dew point of −60 °C and then exposed to dew points of up to −20 °C and ambient atmosphere (dew point ≈ 5 °C). Analysis showed that calendered electrodes were more susceptible to carbonate formation at higher dew points. Cycling tests of single-layer full-pouch cells indicated that carbonate impurities, predominantly present on electrodes stored in ambient conditions, reduced energy efficiency during formation but did not significantly affect long-term performance. These findings suggest that less stringent dry room requirements could reduce production costs and energy consumption for high-performance lithium-ion battery cells.

Molecular Crowding Solid Polymer Electrolytes for Lithium Metal Battery by In Situ Polymerization

AbstractSolid‐state polymer electrolytes (SPEs) require high ionic conductivity and dense contact with the electrodes for high‐performance lithium‐metal solid‐state batteries. However, massive challenges such as poor ionic migration ability, low antioxidant ability, and lithium dendrite formation still remain unresolved. These issues severely restrict its practical applications. Herein, a new type of solid‐state polymer electrolyte with a molecular crowding feature is rationally designed by in situ polymerization of a precursor containing poly (ethylene glycol) diacrylate (PEGDA) and 1,2‐dimethoxyethane (DME). Noticeably, the prepared SPE expands the electrochemical window to 4.7 V with a high lithium‐ion transfer number of 0.55 and a superior ionic conductivity of 3.6 mS cm−1 at room temperature. As a result, the lithium symmetrical batteries achieve stable cycles with more than 3000 h with no lithium dendrites at a current density of 0.5 mA cm−2. Importantly, this design provides dense contact of solid‐state polymer electrolytes with the porous cathode and lithium anode, allowing the assembled winding‐type solid‐state pouch cells with outstanding cycling stability of 81.7% retention for more than 340 cycles at room temperature. It shows excellent adaption to widely practical technology with large‐scale battery production, offering a new solution for the future development of solid‐state polymer lithium‐metal batteries.

An Evolutionary Game Analysis of China’s Power Battery Export Strategies Under Carbon Barriers

With the continuous evolution of international trade, the global market has been steadily expanding while also facing increasing challenges, particularly in relation to the introduction of environmental policies such as carbon barriers. Our research explores how China’s power battery manufacturers can adapt their export strategies to the EU’s carbon barrier policies. Additionally, we examine the roles of government regulations, research institutions, and manufacturers in either facilitating or hindering compliance with carbon reduction objectives. Using evolutionary game theory, we construct models involving government entities, manufacturers, and research institutions to systematically analyze market evolution, strategic interactions, and outcomes among these stakeholders. Our analysis focuses on understanding the competitive dynamics faced by exporting countries under stringent environmental policies and provides strategic insights to guide export strategies. Taking the EU’s carbon barrier policy as a case study, we explore Chinese battery manufacturers’ adaptive strategies and decision-making processes as they respond to shifting market demands and regulatory environments. The findings not only offer valuable insights into exporting countries but also provide policymakers with information on international trade and industrial policy design. Furthermore, we validate our model through numerical simulations and conduct sensitivity analyses on key parameters. The results underscore the importance of governmental adoption of punitive and incentive policies, revealing their substantial impact on stakeholder behavior. Additionally, the study highlights how participants’ pre-cooperation losses and post-cooperation gains influence participation rates and the speed at which stakeholder consensus is reached. By offering a novel approach with which to address carbon barrier challenges, this research contributes valuable perspectives on environmental regulations’ strategic and policy implications in global trade.

Review of Economic, Technical and Environmental Aspects of Electric Vehicles

Electric vehicles (EVs) have seen significant advancements and mainstream adoption, prompting in-depth analysis of their economic, technical, and environmental impacts. Economically, while EVs offer lower operational costs than internal combustion engine vehicles, challenges remain, particularly for urban users reliant on public charging stations and the potential implementation of new road taxes to offset declining fuel tax revenues. Technically, electric motors in EVs have fewer moving parts, but battery management and cybersecurity complexities pose new risks. Transitioning from Nickel-Manganese-Cobalt (NMC) to Lithium-Iron-Phosphate (LFP) batteries reflects efforts to enhance thermal stability and mitigate fire hazards. Environmentally, lithium extraction for batteries has profound ecological impacts, including for water consumption and pollution. Battery production and the carbon footprint of the entire lifecycle remain pressing concerns, with battery recycling and second-life applications as crucial mitigation strategies. Smart integration of EVs with the energy infrastructure introduces challenges like grid stability and opportunities, such as smart, intelligent, innovative charging solutions and vehicle-to-grid (V2G) technology. Future research should develop economic models to forecast long-term impacts, advance battery technology, enhance cybersecurity, and conduct comprehensive environmental assessments to optimise the benefits of electromobility, addressing the multidimensional challenges and opportunities presented by EVs.

Cooperation and Production Strategy of Power Battery for New Energy Vehicles Under Carbon Cap-and-Trade Policy

Considering the supply chain composed of a power battery supplier and a new energy vehicle manufacturer, under the carbon cap-and-trade policy, this paper studies the different cooperation modes between the manufacturer and the supplier as well as their strategies for green technology and power battery production. Three game models are constructed and solved, respectively, under the collaboration mode of wholesale purchasing, patent-licensed manufacturing, and own R&D + Wholesale purchasing. The equilibrium analysis is carried out. Finally, the influence of relevant parameters is explored through numerical simulation. It is found that (1) the manufacturer’s choice of optimal battery production strategy is influenced by the input cost of green technology, the production cost of power battery, the carbon trading price, and the free carbon quota allocated by the government; (2) the cost coefficient of technological innovation affects negatively the optimal decision-making of the supply chain members, the market demand, and the optimal profit, and it has no impact when the cost coefficient reaches a certain value; (3) carbon cap-and-trade policy can, to a certain extent, incentivize suppliers and manufacturers to carry out technological innovation to reduce carbon emissions in the production process, but we cannot ignore the negative impacts of excessively high carbon trading price on the level of emission reduction and the market demand; and (4) the government should reasonably control the carbon price and carbon quota. The above conclusion will provide reference suggestions for new energy vehicle manufacturers and related suppliers.

Sustainable optimisation of SMEs closed-loop supply chain for lithium battery manufacturing

Maintaining the sustainability of small and medium-sized enterprises (SMEs) supply chain has positive impact on society. Under the ripple effect, the vulnerability of the SMEs supply chain and the collaboration uncertainty of participants have potentially negative impact on the sustainability that cannot be ignored. We consider the closed-loop SMEs supply chain network design based on the risk propagation to improve the triple sustainability. The basis of the simulation model structure is a bi-level multi-objective mixed-integer linear programming model that aims to maximise triple sustainability, and an improved dynamic non-dominated genetic algorithm (DNSGA2) is designed to solve the problem. An SMEs supply chain for closed-loop manufacturing of lithium batteries in China was considered. The results show that the centralised SMEs supply chain preform better when the supply-demand imbalance, and the distributed network structure is preform better in maintaining sustainability when manufacturer capacity imbalances. Supply chain managers should develop more flexible strategies based on the structure of downstream demand, increasing upstream manufacturers' participation to enhance their viability and improve the sustainability of the supply chain.