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MATERIALS USED IN BATTERIES
MOL-52226 Functional materials
GROUP 5
HAMZA
MADAN
SANTHOSH KUMAR
YASHWANTH
CONTENT
Introduction
Primary batteries and applications
Secondary batteries and applications
Case study on processing of Li ion battery
Conclusion
INTRODUCTION
Alessandro volt invented the first battery in 1745
In 1898 the first commercial available are sold in united stated by
the Colombia Dry cell
Through ‘Wilhelm konig’, while doing his archeological studies in
1938 he found some clay pots with iron rods encased with copper
built in 200 BC itself
DEFINITION
“Battery consist of electrochemical
cells which convert chemical energy in
to electrical energy”
Primary Batteries
Non-Rechargeable
Power source for electronic devices
and so on.
Convenient and simple to use
Good shelf life
Reasonable energy
Power density
Reliability, when stored in moderate
temperature improves shelf life
Primary Batteries
System Characteristics Applications
Zinc-carbon
(Leclanché), Zinc/MnO2
Common, low-cost primary battery; available in a
variety of sizes
Flashlight, portable radios, toys, novelties, instruments
Magnesium (Mg/MnO2) High-capacity primary battery; long shelf life Formerly used for military receiver-transmitters, and aircraft
emergency transmitters (EPIRBs)
Mercury (Zn/HgO) Highest capacity (by volume) of conventional types;
flat discharge; good shelf life
Hearing aids, medical devices (pacemakers), photography,
detectors, military equipment, but in limited use at present
due to environmental hazard of mercury
Mer-cad (Cd/HgO) Long shelf life; good low- and high-temperature
performance; low energy density
Special applications requiring operation under extreme
temperature conditions and long life; in limited use
Alkaline
(Zn/alkaline/MnO2)
Most popular general-purpose battery; good low-
temperature and high-rate performance; low cost
Most popular primary battery; used in a variety of
portable battery operated equipment
Lithium/ soluble
cathode
High energy density; long shelf life; good
performance over wide temperature range
Wide range of applications requiring high energy density,
long shelf life, e.g., from utility meters to military electronics
applications
Lithium/ solid cathode High energy density; good rate capability and low-
temperature performance; long shelf life;
competitive cost
Replacement for conventional button and cylindrical cell
applications, such as digital cameras
Lithium/ solid
electrolyte
Extremely long shelf life; low-power battery Medical electronics
Table 1: Characteristics and applications [1]
Magnesium Batteries
Twice the service life or capacity of zinc battery
Disadvantages – voltage delay and parasitic corrosion
Potential > 2.8V, but 1.1V is achieved
Battery chemistry, Mg + 2 MnO2 + H2O Mn2O3 + Mg (OH) 2
Figure represents
Magnesium batteries
[2]
Zinc Carbon batteries
Leclanché and zinc chloride systems
low cost, ready availability, and acceptable performance
Electrolyte – Ammonium chloride and zinc chloride
Carbions with Mg2O- Conductivity
Specific capacity- 75-35 A h/kg
Basic chemistry Zn + 2MnO2 ZnO.Mn2O3
Figure represents Zinc-Carbon
batteries
[3]
Secondary Batteries
Rechargeable batteries
Many applications such as ignition automotive and portable
devices
Two categories of applications
1)Energy storage device
2)Discharged and recharged after use
Secondary Batteries [4]System Characteristics Applications
LEAD-ACID:
Automotive Popular, low-cost secondary battery, low
specific-energy, high-rate, and low-
temperature performance; maintenance-
free designs
Automotive SLI, golf carts, lawn mowers, tractors, aircraft,
marine, micro-hybrid vehicles
Traction (motive power) Designed for deep 6-9 h discharge,
cycling service
Industrial trucks, materials handling, electric and hybrid
electric vehicles, special types for submarine power
Stationary Designed for standby float service, long
life, VRLA designs
Emergency power, utilities, telephone, UPS, load levelling,
energy storage, emergency lighting
Portable Sealed, maintenance-free, low cost, good
float capability, moderate cycle life
Portable tools, small appliances and devices, portable
electronic equipment
NICKEL-CADMIUM:
Industrial and FNC Good high-rate, low-temperature
capability, flat voltage, excellent cycle life
Aircraft batteries, industrial and emergency power
applications, communication equipment
Portable Sealed, maintenance-free, good high-rate
low-temperature performance, good
cycle life
Consumer electronics, portable tools, pagers, appliances,
photographic equipment, standby power, memory
backup
NICKEL-METAL
HYDRIDE
Sealed, maintenance-free, higher
capacity than nickel-cadmium batteries;
high energy density and power
Consumer electronics and other portable applications;
hybrid electric vehicles
LITHIUM-ION High specific energy and energy density,
long cycle life; high-power capability
Portable and consumer electronic equipment, electric
vehicles (EVs, HEVs, PHEVs), space applications, electrical
energy storage
Nickel Cadmium batteries
Nickel oxy hydroxide as positive electrode and Cadmium plate is negative
electrode
Circuit voltage difference is nearly 1.29 V
Electrolyte used is KOH (31% by weight) or NaOH, LiOH is added to improve
life cycle and high temperature operations.
The major advantages are they have a long life line, excellent long - term
storage, and flat discharge profile.
Disadvantages are the energy density is low and they are expensive than
lead-acid batteries and also contains cadmium which is hazardous
There are two types of cells Vented and Recombinant
Chemistry involved
Positive electrode:
2NiOOH + 2H2O + 2e- ⇋ 2Ni(OH)2 + 2(OH)-
Negative electrode:
Cd + 2(OH)- ⇋ Cd(OH)2 + 2e-
Overall reaction:
2NiOOH + 2H2O + Cd ⇋ 2Ni(OH)2 + Cd(OH)2
Due to faster discharge rate or over charging the O2 is generated from which the
following reaction undergoes in Recombinant cells
Cd + H2O + ½ O2 Cd(OH)2
Construction of battery
Considering Aircraft battery design consists of steel case containing
identical, individual cells connected in series
And the end of the cells of the series are connected to receptacle located on the outside of the case
[5] [6]
Lithium Ion Batteries
Li ions exchange between the positive and negative electrodes
The major advantages are they are sealed and no maintenance is required, they have long life cycle, they have long shelf life, and low self-discharge rate. High power discharge rate capability
The major disadvantages are that, they degrade at high temperatures, capacity loss and potential for thermal runway when charged, possible venting and possible thermal runway when crushed, and may become unsafe when rapid charge at low temperature (< 0 0C).
higher specific energy (up to 240 Wh/kg)
energy density (up to 640 Wh/L)
self-discharge rate is around 2-8% per month
The working temperature range is at 0 to 45 0C
Single cell Operating Voltage between 2.5 and 4.3 V
[7]
Chemistry involved
Positive Electrode:
LiMO2 ⇋ Li1-x MO2 + x Li+ + x e-
Negative Electrode:
C + y Li+ + ye- ⇋ LiyC
Over all reaction:
LiMO2 + x/y C ⇋ x/y LiyC + Li1-xMO2
Battery materials
There are wide range of cathodic, anodic and electrolyte materials
Anodic materials are lithium, graphite, lithium-alloying materials (Lithium
titanate, Li4/3Ti5/3O4), intermetallic, Tin or silicon
Electrolytes include salts (aqueous) and organic solvents(non - aqueous) (They should be conductive)
Salt electrolytes are LiAsF6, LiPF6, LiSO3CF3, and LiN(SO2CF3)2
Organic solvents are EC = ethylene carbonate, PC = propylene carbonate, DMC = dimethyl carbonate, DEC = diethyl carbonate, DME = dimethylether, AN =
acetonitrile, THF = tetrahydrofuran, γ-BL = γ-butyrolactoneEC, ethyldiglyme, triglyme, tetraglyme, sulfolane,and Freon
Battery materials [7]
Material
Specific
capacity
mAh/g
Comments
LiCoO2 155 Still the most common. Co is expensive.
LiNi1-x-yMnxCoyO2 (NMC) 140-180Safer and less expensive than LiCoO2. Capacity depends on
upper voltage cut-off.
LiNi0.8Co0.15Al0.05O2 200 About as safe as LiCoO2, high capacity.
LiMn2O4 100-120Inexpensive, safer than LiCoO2, poor high temperature stability
(but improving with R&D).
LiFePO4 160Synthesis in inert gas leads to process cost. Very safe. Low
volumetric energy.
Li[Li1/9Ni1/3Mn5/9]O2 275 High specific capacity, R&D scale, low rate capability.
LiNi0.5Mn1.5O4 130 Requires an electrolyte that is stable at a high voltage.
IMPORTANCE OF BATTERIES
Battery Manufacturing Process[11]
Mixer
Mixing of Electrode Materials
Anode: Carbon/Graphite
Cathode: Lithium Metal Oxide (with conductive binding agent)
No Dissolution and breakup of
Particles
homogeneous distribution of components
Coating
Copper Coating on Anode
Aluminum Coating on Cathode
Coting thickness variance should be in tolerance of 1 to 2 µm
Coating thickness must be
homogeneous
Compressing
Drying of Solvent at 150 C in
drying tunnel
Reducing porosity by compression
No cracking should take place in material surface
Homogeneous material
properties should be maintained
Drying
After compression to pass
electrode through drying process is optional.
Purpose is to reduce
residual humidity in drying chamber with air humidity
of ~ 0.5%
Slitter /Cutter/ Puncher
Highly precise cutting by means
of laser cutting tolls
No burr formation on edges
Fraying of edges and material
particles on surface
Assembling
Stacking of cells in housing
Contacting of electrodes
Housing is sealed partially later on for filling of electrolyte
Positioning of cells should be
very much accurate ~0.1mm
Stacking speed shouldn’t be maintained regarding
production targets
Filling
Electrolyte Filling
Complete sealing of
housing
Cleaning cell in dry room
Filling should be
homogeneous and rapid
Toxic reaction may take place with air humidity
Formation / Ageing
Activation by means of
charging discharging routines
Gradually increasing voltage
Storage for 2 to 4 weeks
leading towards high cost and time expenditures
Increased risk of fire
After formation battery’s
operability should be confirmed
Grading
Grading is done on the basis of discharge,
resistance and capacitance measuring
Cells in batteries should have identical characteristics
Packaging
Sorting cells by grades
Packaging materials specifications
Special requirements
Measures to be taken for transportation
Conclusion
Primary and secondary batteries.
Lead Acid batteries, Nickel batteries, Silver Batteries, Alkaline
Manganese batteries, Carbon-zinc and so on.
Different battery mechanism is studied
Materials used for the production of cathode and anode is studied.
Electrode material preparation is explained in the manufacturing
process.
REFERENCES
[1] Thomas Reddy. "Chapter 8 - An Introduction to Primary Batteries". Linden's Handbook of Batteries, FourthEdition.McGraw-Hill, © 2011. Books24x7. Web. Apr. 7, 2015. http://common.books24x7.com/toc.aspx?bookid=35916
[2] Thomas Reddy. "Chapter 10 - Magnesium and Aluminium Batteries". Linden's Handbook of Batteries, Fourth Edition.McGraw-Hill. © 2011. Books24x7. http://common.books24x7.com/toc.aspx?bookid=35916 (accessed April 8, 2015)
[3] Thomas Reddy. "Chapter 9 - Zinc-Carbon Batteries—Leclanché and Zinc Chloride Cell Systems". Linden's Handbook ofBatteries, Fourth Edition. McGraw-Hill, © 2011.Books24x7.Web. Apr.7, 2015.http://common.books24x7.com/toc.aspx?bookid=35916
[4] Thomas Reddy. "Chapter 15 - An Introduction to Secondary Batteries". Linden's Handbook of Batteries, FourthEdition. McGraw-Hill, © 2011. Books24x7. Web. Apr. 9, 2015.http://common.books24x7.com/toc.aspx?bookid=35916
[5] D. Vutetakis, “Batteries,” in Digital Avionics Handbook, Third Edition, CRC Press, 2014, pp. 419–442.
[6] Thomas Reddy. "Chapter 19 - Industrial and Aerospace Nickel-Cadmium Batteries". Linden's Handbook of Batteries, Fourth Edition. McGraw-Hill, © 2011. Books24x7. Web. Apr. 9, 2015. http://common.books24x7.com/toc.aspx?bookid=35916
[7] Thomas Reddy. "Chapter 26 - Lithium-Ion Batteries”. Linden’s Handbook of Batteries, Fourth Edition. McGraw-Hill, © 2011. Books24x7. Web. Apr. 9, 2015 http://common.books24x7.com/toc.aspx?bookid=35916
[8] A. Manthiram, “Smart Battery Materials,” in Smart Materials, CRC Press, 2008.
[9] D. Vutetakis, “Batteries,” in Digital Avionics Handbook, Third Edition, CRC Press, 2014, pp. 419–442.
[10] Z. Bakenov and I. Taniguchi, “Cathode Materials for Lithium-Ion Batteries,” in Lithium-Ion Batteries, CRC Press, 2011, pp. 51–96.
[11] http://www.industry.siemens.com/topics/global/en/battery-manufacturing/process/pages/default.aspx
THANK YOU