Further Cost Reduction of Battery Manufacturing

Abstract

Abstract:The demand for batteries for energy storage is growing with the rapid increase in photovoltaics (PV) and wind energy installation as well as electric vehicle (EV), hybrid electric vehicle (HEV) and plug-in hybrid electric vehicle (PHEV). Electrochemical batteries have emerged as the preferred choice for most of the consumer product applications. Cost reduction of batteries will accelerate the growth in all of these sectors. Lithium-ion (Li-ion) and solid-state batteries are showing promise through their downward price and upward performance trends. We may achieve further performance improvement and cost reduction for Li-ion and solid-state batteries through reduction of the variation in physical and electrical properties. These properties can be improved and made uniform by considering the electrical model of batteries and adopting novel manufacturing approaches. Using quantum-photo effect, the incorporation of ultra-violet (UV) assisted photo-thermal processing can reduce metal surface roughness. Using in-situ measurements, advanced process control (APC) can help ensure uniformity among the constituent electrochemical cells. Industrial internet of things (IIoT) can streamline the production flow. In this article, we have examined the issue of electrochemical battery manufacturing of Li-ion and solid-state type from cell-level to battery-level process variability, and proposed potential areas where improvements in the manufacturing process can be made. By incorporating these practices in the manufacturing process we expect reduced cost of energy management system, improved reliability and yield gain with the net saving of manufacturing cost being at least 20%.

Survey of Smart Grid Concepts and Technological Demonstrations Worldwide Emphasizing on the Oman Perspective

“…Some of the available energy storage means are electrochemical (batteries and fuel cells), electromechanical (flywheels, pump hydro, and compressed air), electrostatic (ultra-capacitors) and electromagnetic type (superconducting magnetic storage) [51,52]. Electrochemical batteries, however, has a growing demand in the market for their downward price and upward performance [53]. Their use in advanced automotive technology, such as plug-in EVs [54] are garnering interest, as the retired EV batteries can be replenished for further use as second life batteries in energy storage Bi-directional communication system may increase the operational performance of the SG by providing more controllability, whereas AHC increases the efficiency and power quality (PQ) of the SG.…”

Improvement in Energy Efficiency by Implementing Direct Current Based Nano-grid and Its Impact on Manufacturing Industry

“…Moreover, the local generation was not very convenient at that time. The key changes in this modern age are: (a) reduced price of solar panels and cheaper generation [10] [11], (b) lower cost of storage battery, [12]- [14] (c) improvement in power electronics [15] [16] to fabricate high power devices, (d) improvement in communication networks and processing powers of devices, etc. If for a standalone household, the model in Fig.1 is deployed, the removal of inverter (the conversion from DC to AC) will be eliminated and a significant amount of energy can be saved.…”

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“…Lithium ion cells are no exception to this and thus, manufacturing variation must be considered during cell performance evaluations [6]. Whether it be the formed aluminum laminate package dimensions for prismatic cells, electrode dimensions, electrode coating mass loading, or electrode calender thickness, as well as other production steps, these variations inevitably affect the final product [7]. Numerous authors have indirectly investigated the impact of these manufacturing tolerances on cell performance.…”