from chemistry to pack
Kerem Batuş
AION Engineering INC For years, battery engineers have relied on the Single-Particle Model with Electrolyte (SPME) as the industry standard for cell simulation. SPME operates on a convenient mathematical simplification: it collapses the entire complex, porous electrode into a single representative particle. At low C-rates, this volume-averaged macroscopic assumption holds. But when a cell is … Read more
AION Engineering INC In battery continuum modelling, few parameters are as universally accepted—and as fundamentally flawed for modern cells—as a Bruggeman exponent of 1.5. While it is widely understood that tortuosity and porosity are distinct structural metrics, the industry consistently defaults to this idealized constant to bridge the gap between them. To understand why modern … Read more
AION Engineering INC While silicon (SiOx/SiC/Si) based anodes skyrocket battery capacity, their swelling character reaching up to 300% volume expansion transforms cell design from a purely electrochemical challenge into a brutal mechanical packaging problem. It is not just about how much lithium the active material can store; how the casing structurally resists (its rigidity) when … Read more
AION Engineering INC When engineering a Battery Thermal Management System (BTMS) for electric vehicles or energy storage, one of the most critical factors is hidden within the microscopic architecture of the cell itself. Whether a cell utilizes a wound (jelly roll) or stacked electrode assembly, its physical construction fundamentally dictates its thermal behavior. Heat does … Read more
AION Engineering INC When you open the datasheet of a lithium-ion cell, one of the first values to catch your eye is the internal resistance. Typically, it sits there as a single, proud number: ACIR: 15 mOhm. Many engineers look at this number, validate the “quality” of the cell, and integrate it into their vehicle … Read more
AION Engineering INC No matter how optimized your internal cell structure, electrode design, or N/P ratio might be, the ultimate bottleneck in freezing temperatures is the electrolyte. Just as a flawless, 1,000-horsepower engine is utterly useless if the diesel in its fuel tank has frozen, a lithium-ion battery faces the exact same fate. The electrolyte … Read more
AION Engineering INC In lithium-ion batteries, electrode performance is governed not only by material chemistry but by the three-dimensional microstructure formed by particles, pores, binder, and conductive additives. Before production begins, this microstructure already defines how ions and electrons will move through the electrode. Once manufacturing starts, many of these structural characteristics can no longer … Read more
The Hidden Hero of Electrode Manufacturing AION Engineering INC In Lithium-ion battery production, the electrode coating process is a defining step for the cell’s final performance. However, achieving a pristine coating isn’t just about machine settings; it begins with the correct formulation of the slurry structure. In this article, we examine slurry viscosity not merely … Read more
AION Engineering INC In lithium‑ion battery design, internal resistance is one of the most critical parameters governing power capability, heat generation, fast‑charge performance, and overall efficiency. The difference in internal resistance between wound (spiral/jelly‑roll) cells and Z‑stack (stacked) cells is often misunderstood as a chemistry issue, while in reality it is largely a current‑path and … Read more
AION Engineering INC 1. Doctor Blade Coating Classification: Self-Metered Process Best For: Material screening, coin cells, basic R&D. Doctor blade coating is the foundational technique for battery research. It relies on a “self-metered” mechanism, meaning the final wet film thickness is determined by the geometric gap between the blade and the substrate, combined with the … Read more