from chemistry to pack
Lamination bonds the separator directly to both electrode faces using heat and pressure to soften a thin adhesive coating already on the separator before the electrode stack is built. Rather than leaving the separator as a free-floating layer held in place only by winding tension or external pack clamping. Why Bond the Separator to the … Read more
What is electrode overlap and why does it matter? In lithium-ion cell manufacturing, electrode overlap refers to the region where the active areas of the anode and cathode are aligned across the separator as shown in Figure 1. Maintaining adequate overlap, whereby the anode active area overlaps the cathode, is critical to achieving uniform current … Read more
The conventional framing of carbon black in lithium-ion battery electrodes is electrochemical – it is an electronic conducting agent that enables the formation of the electrical wiring within an electrode. It has typically been specified by loading, surface area and subsequent powder or electrode resistivity. For wet slurry coating, this framing is broadly adequate. The … 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 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
Burrs and wavy edges on cell electrodes can have serious consequences up to and including an internal short-circuit and thermal runaway. Hence it is important to understand the slitting process and under what conditions burrs and waviness occurs. Slitter Cutting Control Parameters There are basically three slitter cutting control parameters for the shear cut method, … Read more
AION Engineering INC What is the N/P Ratio? The N/P ratio refers to the ratio between the effective capacity of the anode (negative electrode, N) and the cathode (positive electrode, P). In simple terms, it compares how much lithium the anode can store versus how much the cathode can provide. For a safe and reliable … 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
During the charge / discharge the cathode and anode undergo an expansion and contraction. As you charge a cell it expands, when you discharge a cell it contracts and as the cell ages over its lifetime we see a continuing cell expansion. Thus the cell expansion can be divided into: This expansion and contraction puts … Read more