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research-article

Simulation of Micro-/Nano-powder Mixing Characteristics for Dry Spray Additive Manufacturing of Li-ion Battery Electrodes

[+] Author and Article Information
Brandon Ludwig

Mechanical and Aerospace Engineering, Missouri University of Science and Technology, 400 West 13th Street, Rolla, MO 65409
bjlzq7@mst.edu

Heng Pan

Mechanical and Aerospace Engineering, Missouri University of Science and Technology, 400 West 13th Street, Rolla, MO 65409
hp5c7@mst.edu

Jin Liu

Mechanical Engineering, Worchester Polytech Institute, 100 Institute Road, Worchester, MA 01609
hp5c7@mst.edu

Yangtao Liu

Mechanical Engineering, Worchester Polytech Institute, 100 Institute Road, Worchester, MA 01609
yliu24@wpi.edu

Zhangfeng Zheng

Mechanical Engineering, Worchester Polytech Institute, 100 Institute Road, Worchester, MA 01609
zzheng@WPI.EDU

Yan Wang

Mechanical Engineering, Worchester Polytech Institute, 100 Institute Road, Worchester, MA 01609
yanwang@WPI.EDU

1Corresponding author.

ASME doi:10.1115/1.4037769 History: Received June 15, 2017; Revised August 21, 2017

Abstract

A new dry spraying additive manufacturing method for Li-ion batteries has been developed to replace the conventional slurry-casting technique for manufacturing Li-ion battery electrodes. A dry spray manufacturing process can allow for the elimination of the time and energy intensive slurry drying process needed due to the use solvents to make the electrodes. Previous studies into the new manufacturing method have shown successful fabrication of electrodes which have strong electrochemical and mechanical performance. Li-ion battery electrodes typically consist of three basic materials: active material, binder particle additives, and conductive particle additives. In this paper, a Discrete Element Method simulation was developed and used to study the mixing characteristics of dry electrode powder materials. Due to the size of the particles being in the sub-micron to micron size range, the mixing characteristics are heavily dependent on van der Waals adhesive forces between the particles. Therefore, the effect the Li-ion battery electrode material surface energy has on the mixing characteristics was studied. Contour plots based on the DEM simulation results where the surface energy components of selected material types are changed were used to predict the mixing characteristics of different particle systems. For the cases studied, it is found that experimental mixing results are representative of the results of the DEM simulations.

Copyright (c) 2017 by ASME
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