The electrification of transportation worldwide has led to an increased demand for better batteries that can charge faster and travel farther. Most electric vehicles (EVs) today are powered by lithium-ion (Li-ion) batteries, making it crucial to find ways to manufacture these batteries that are safer, more sustainable, and more energy-dense to meet growing demand. Palani Shanmugam, Product Manager – Advanced Metrology, Thermo Fisher Scientific explains
According to the International Energy Agency (IEA), electric car sales have been the primary driver of battery demand in recent years and show no signs of slowing down. Early leaders in electrode and battery cell manufacturing have worked to scale up production by duplicating existing lines, but this has often come at the expense of yield. The number of product recalls due to battery failures has also increased as EVs enter the global market, highlighting that traditional quality control methods in electrode production are struggling to meet the industry’s demands. To improve electrode coating quality and process yield, manufacturers should consider next-generation process metrology tools, such as the Thermo Scientific™ LInspector™ Edge In-line Mass Profilometer, which sets a new benchmark for electrode coating quality assurance (QA) and quality control (QC).
Overcoming Quality Challenges in Electrode Coating
Maintaining the quality of battery components throughout the manufacturing process is essential, as even small defects can have serious implications for the safety and performance of the battery. Electrode coating is a critical step in battery manufacturing, involving the deposition of a slurry of active material onto a metal foil substrate, followed by a drying process. The precision of this coating process directly impacts the performance, safety, and reliability of finished battery cells. Despite advancements in production technology, battery manufacturers still experience significant yield losses at this stage.
Traditional QA/QC methods rely on single-point sensors and post-production destructive testing, which only measure a small percentage of the electrode—typically two to four percent—in real time. This causes delays in the data needed for battery manufacturers to meet high-quality standards, ensure uniformity, and optimise yield.
The Advantages of Mass Profilometry for Battery Manufacturers
Mass profilometry represents a paradigm shift in in-line metrology for battery electrode production. This innovative technology allows for real-time analysis of mass loading across the entire electrode, providing a comprehensive view of the coating process at full production speeds. Mass profilometry can measure 100 percent of the coated electrode in real time, offering complete edge-to-edge loading uniformity profile data that enables line operators to monitor and control the coating stations with precision. This data is invaluable for process engineers, who can use it to optimize process parameters and design studies that ultimately lead to higher yields and better-quality batteries.
Several key benefits of mass profilometry should be considered when ramping up production to meet current and future demand. The technology offers enhanced detection of non-uniformities and defects, improved anode and cathode mass balancing, reduced scrap and downtime, comprehensive data for traceability and failure analysis, and faster process quantification and development.
Using mass profilometry to detect small defects and dimensional errors in electrode coating helps operators visualize and address non-uniformities, such as scratches or high edges, in real time. Traditional single-point sensors have been unable to provide this granular level of detail. Early detection of defects allows manufacturers to address problems before they lead to yield loss, reducing scrap rates and minimizing downtime. Maintaining an optimal anode-to-cathode ratio is also critically important for increased battery cell performance, and mass profilometry ensures precise balancing and consistent quality across the entire production run.
Lastly, mass profilometry provides a complete dataset that allows for traceability and failure analysis. When manufacturers can track and analyze process deviations, they can maintain the high standards of quality and safety required by the industry. This data also speeds up the process of qualifying new production runs, enabling operators to quickly achieve target parameters during startup phases.
Adopting Mass Profilometry to Meet Growing Demand for Better Batteries
As demand for batteries continues to grow, battery manufacturers need tools to ensure that the batteries they produce are safe, reliable, and high-performance. Introducing innovative technologies like mass profilometry offers a competitive advantage with enhanced speed, precision, and data-driven insights. With real-time, comprehensive measurement data, this technology helps manufacturers overcome the limitations of traditional quality control methods and create overall efficiencies in battery electrode production.
For more information go to thermofisher.com/LInspectorEdge
