This presentation will cover Umicore Solid State Battery (SSB) from both technology and business viewpoints. Topics covered include the SSB market and value proposition, SSB products portfolio, as well as research and development achievements and challenges. Also, we will discuss the upscaling focus in 2024-2026 and the challenges of going to mass production.

I discuss our novel dynamic 3D-resolved numerical models able to predict how manufacturing parameters impact the microstructure of lithium-ion and solid-state battery electrodes, produced via solvent-based and dry methods. These models, confronted to experimental data, demonstrate the chemistry-agnostic character of our ARTISTIC battery manufacturing simulation platform. The coupling of these models with deep learning techniques, and our Virtual Reality battery manufacturing metaverse, are also discussed.

Outlook on achieving manufacturing targets with on-demand supply balance for Li, Ni, Co, Mn, and graphite; alternative feedstock and processing routes; comparing costs and CO2 emission; strategies to secure critical raw materials adopted by major players; framework for holistic evaluation of manufacturing strategies.

Laser processing has been successfully developed for structuring thick-film composite electrodes. Compared to cells with conventional electrodes, lithium-ion batteries with 3D electrodes show excellent capacity retention for high-power operation, lithium plating is significantly suppressed, fast charging is drastically improved, and cycle life is at least doubled. Roll-to-roll machine concepts for process upscaling have been implemented using high-power ultrafast lasers to enable damage-free structuring of thick-film electrodes with a large footprint. Topics will include fast charging enabled for high mass loaded electrodes, increased battery cycle lifetime, high intrinsic operating safety, homogeneous electrode wetting and re-wetting and advanced cylindrical battery designs.

The tab welds are the most important on Li-ion cells. Poor welds deteriorate over time due to mechanical vibrations, reducing battery longevity. Rapid, automated feedback on weld quality is essential for maintaining optimal weld process. Eddy Current is shown to be a feasible NDT Technique for automated quality control of cell foil tabs that have been ultrasonically welded. The technique identifies over-welding, under-welding, tears, missing foils, and lack of fusion.

DSC and ARC were common methods to study Li-ion thermal runaway caused by Internal Shorts, which serious mismatch the time scale (<25mS) and heating area (Spot, 2 mm2) of battery internal shorts. The DSC (1998) and ARC (2003) created many theories on battery thermal runaway. Here, we are going to analyze various internal shorts supported by various giant battery producers (DATA) and analyze these shorts (via IEEE) and use laser (ms and 2mm2, SAFT) to mimic the internal short of the batteries to understand the thermal runaway caused by internal shorts. Through short Resistance study, Thermal propagation observation, Explosive GAS analysis, the Li-ion fire and explosion Mechanism will be presented, and the real solutions will be provided to reduce or eliminate Li-ion battery thermal runaway. The conclusions of this study, such as using ceramic coated separator (active approach), direct Cu/Al shorting (passive approach), etc. have been (extremely) broadly used in Li-ion industry today. The fire and explosion rate has been improved by 5 orders of magnitude. Now, all 3C and all NMC EDV and 70% LFP EDV are using the methods result from these improving methods.

The transition from research to full-scale manufacturing in the automotive battery industry is fraught with challenges. Explore how Siemens' most comprehensive suite of digital tools accelerates R&D cycles and optimizes manufacturing in the automotive battery industry. By enabling virtual prototyping and commissioning, Siemens helps avoid costly and time-consuming re-designs and re-engineering. Siemens' solutions for seamless OT/IT integration support real-time data analytics and production optimization, driving high yields and reducing delays.

Since our company's inception, we have collaborated with cell manufacturers and automotive OEMs to address numerous development and production challenges related to cells. Leveraging the expertise of our engineers who have extensive experience in the lithium-ion battery field, we offer comprehensive solutions from cell design to mass production. In this presentation, we will showcase the development methodologies using the Beff Platform, complemented by real-world examples.

As part of the U.S. government’s focus on developing a robust domestic supply chain for Li-ion batteries, ENTEK is constructing a new separator plant in Terre Haute, Indiana. ENTEK has partnered with Bruckner and Bonfanti, world leaders in biaxial stretching equipment and automated roll handling to ensure state-of-the-art “wet process” polyethylene separator lines in combination with coating technology to produce = 1.4 billion m² of coated separator in 2030.

As the battery industry continues to expand, who you hire into your organization is a critical component of your success. In what seems like an increasingly competitive industry and talent still in short supply, how can you stand out? We will provide insight to help promote a positive company reputation, efficient talent acquisition practices, and other solutions to help secure the talent you are looking for without the need to just "pay more."

In order to securely “twin” a real battery with its cloud-based virtual twin, one needs to use tags or unique markings in transporting goods and parts for batteries, implement unique IDs in cells and modules, secure storage on a battery level, and communication methods that respect CRA and GDPR together with the DPP and EU battery regulation.