from chemistry to pack
What “Generation” Actually Means in Lithium Iron Phosphate Lithium iron phosphate (LFP) has spent the last five years closing the energy density gap with nickel-based chemistries, and almost none of that progress has come from changing the underlying LiFePO₄ crystal. Instead, the industry has been fighting a materials-processing battle centred on one metric: compaction density. … 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
AION Engineering INC Anode Electrode Porosity vs. Energy Density: The Turning Point in High-Energy Lithium-Ion Cells In lithium-ion cell design, one of the most critical relationships shaping performance is the link between anode porosity and energy density. As energy density increases, conventional design logic suggests reducing anode porosity to pack more active material into the … Read more
AION Engineering INC Why High Porosity Can Lower Resistance in Power Cells Introduction Area Specific Resistance (ASR) is one of the most important performance indicators in lithium ion cathodes. Engineers often assume that reducing porosity improves conductivity and therefore lowers ASR. This idea comes from the expectation that a denser structure provides better particle contact … Read more
AION Engineering INC Calendaring is a crucial step in lithium-ion battery manufacturing, where electrodes are compressed to reduce porosity and increase density. Optimizing this process directly impacts the performance, longevity, and efficiency of the final cell. Why Calendaring Matters The primary goals of calendaring are: Effectively, proper calendaring ensures a balance between mechanical stability, electrochemical … Read more
AION Engineering INC In previous discussions, we explored the relationship between cell capacity, C-rate, and electrode density. A key parameter influencing electrode density—and thus overall cell performance—is the particle size distribution (PSD) of the active material. Why PSD Matters The PSD of active materials directly impacts their tap density and compactibility—two critical factors that determine … Read more
In school, we learn that the voltage across circuit components in parallel is the same, and the current is split between them according to their resistances. For components in series, the current through each is equal and the voltage drops off. In a simple model, the total capacity of a battery pack with cells in … Read more