Introduction:

Lithium-based batteries have a special potential because they are flexible and variable when
used for energy storage. Today they are already the dominant energy storage system for
small mobile devices and their superior energy and power density show great potential for
use in large systems like eg. cars.

There is no single lithium battery. With the variety of materials and electrochemical couples
available, it is possible to design battery cells specific to their applications in terms of
voltage, state of charge use, lifetime needs, and safety. Selection of specific electrochemical
couples also facilitates the design of power and energy ratios and available energy.

Integration in a large format cell requires optimized roll-to-roll electrode manufacturing and
use of active materials. Electrodes are coated on a metal current collector foil in a
composite structure of active material, binders, and conductive additives, requiring careful
control of colloidal chemistry, adhesion, and solidification. But the added inactive materials
and the cell packaging reduce energy density. Moreover, degree of porosity and compaction
in the electrode can affect battery performance.

Types:
There are two types of lithium batteries. One is only Lithium battery & another one is
Lithium ion battery. One can think easily these are same type but for the surprise, Lithium
battery is not rechargeable. On the other hand, Lithium ion battery can be recharged
hundreds of times.

Application:
 Consumer Electronics (Mobile Phones, Tablet PCs, Digital Cameras, Laptops)
 Hybrid Vehicles / Electric Vehicles (EV)
 Electric Grid Storage (ESS)
 UPS for Data Centers
 Forklifts
 Telecom
 Medical Devices
 Power Tools
 Electric Bikes, Wheel Chairs
 Battery Characterization Laboratory (R&D)
Lithium ion batteries and their manufacturing process:
Lithium battery technology is changing dramatically. New materials and chemistries are
tested every day to try to reduce costs and meet the growing demand. It is critical that
advanced engineering, battery innovation, and high performance battery production take
place in specially designed ultra-low humidity dry rooms. Research with high energy battery
chemistries involving lithium-ion, lithium iron phosphate, graphene, and solid state must be
contained in stable environments with less than 1 percent humidity due to chemical
sensitivity to moisture.

A reaction with lithium and water is exothermic (generates heat) and forms lithium
hydroxide and hydrogen. The heat from the reaction can ultimately lead to burning and
potential explosion. In addition to the important safety considerations, minimizing moisture
content with ultra-low dew point air supply is necessary to achieve high levels of product
yield, quality control, energy efficiency, cycle life and storage capacity. Since flammable
solvents are often also used in these dry rooms, an exhaust system is important for the
removal of solvent vapors.

Each dry room application is unique. With the advent of consumer electronics, electric
vehicles, solar power, and grid storage applications, there is a significant variety of battery
production processes. In addition to the chemistry variations, many other factors are
considered when determining the dehumidification capacity needed for a dry room. The
dehumidification system must be custom designed with enough drying capacity to be able
to maintain the dry room at the specified condition. Most battery manufacturers require
that a room’s humidity/average moisture level be maintained as low as -40°C dew point
(0.5% Relative Humidity at 72°F) and sometimes even lower.

Even moisture from human bodies has a relatively big effect on the very low humidity levels
that have to be adhered to in such high-tech facilities. This is a big technical challenge — one
that very few suppliers of dehumidification systems can tackle.

Dehumidification Design Factors:

 Dry room size
 Type of chemistry and process
 Moisture infiltration
 Personnel activity in the dry room
 Airlocks for material and personnel movement

Case study of Munturs @ MEET:

This Munters MDU system is specially designed to control moisture levels at -50°C dewpoint
with 12 persons working in the room. The MDU system supplies an air flow of 30,000 m3/h,
creating an air-exchange rate at 120/hour. (Exhaust air 1,650 m3/h). The supply air is
distributed into the dry room via a ceiling of perforated sheets to achieve laminar flow
conditions. The return air intakes are integrated in the wall panels 0,5 m above the floor.
The desiccant wheel is individually designed with a unique low dew point purge sector for
heat recovery and a special cooling sector ensuring an efficient dehumidification
performance at a very low energy consumption. This closed loop reduces the moisture load
as no outside air will be required for
cooling down the rotor material. Hereby the energy consumption is reduced considerably
and the life time of rotor and sealings is prolonged. A special team at Munters are designing
low dew point solutions for lithium battery manufacturers, providing individual solutions for
the demanding processes. Thanks to many years of experience and the continuous
development of rotor materials, purge sectors and energy efficient components, Munters is
able to supply systems meeting the strongest demands from battery manufacturers all over
the world.

Battery Manufacturing Challenges:

• Achieving ultra-low dew point conditions (-30° to -55°C or -22° to - 67°F dew point) in the
dry room with RH 0.5%
• Maintaining consistent conditions through personnel changes ( ACPH more than 50)
• Maintaining consistent conditions while equipment operates and heat loads fluctuate
• Maintaining consistent conditions through seasonal ambient conditions
• Ensuring stable positive pressure
• Minimizing equipment footprint and energy consumption
• Flammable solvents are also used in the dry rooms, an exhaust system is also needed for
the removal of solvent vapor.

Battery Processes Requiring Low Dew Point Conditions:

• Slurry Mixing
• Electrode Coating/Drying
• Electrode Stamping/Punching
• Electrode Stacking/Winding
• Cell Assembly
Lithium ion battery production in research dry room
Electrode Coating Process
• Laser Welding
• Vacuum Drying
• Electrolyte Filling
• Battery Sealing
• Aging and Formation

Organic Solvent Abatement:

Although the main concern with lithium battery processing is ensuring ultra- dry, low dew
point atmospheres, a secondary concern is the treatment of organic solvent exhaust from
the coating and electrolyte filling processes.
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