Numerical Modelling of Slot-Die Coating for Manufacturing of Lithium-Ion Batteries

Abstract

The primary aim of this project is to investigate the slot-die coating process for the application of advanced ceramic coatings on lithium-ion battery (LIB) electrodes, thereby achieving substantial improvements in battery performance and manufacturing efficiency. The growing demand for electric vehicles (EVs) and renewable energy solutions underscores the importance of enhancing LIB technology. This project focuses on simulating different parameters in slot-die coating, such as inlet velocity, gap coating, and coating velocity, to understand their impact on coating quality and production efficiency. The research begins with a comprehensive literature review, highlighting advancements in slot-die coating technology, innovations in anode coating techniques, and the challenges posed by edge effects. The literature review also examines the role of ceramic coatings in improving battery performance and the impact of process parameters on coating quality. The methodology involves developing and validating a Computational Fluid Dynamics (CFD) model to simulate the slot-die coating process. Key findings from the CFD simulations indicate that precise control of process parameters can significantly enhance coating uniformity and reduce defects, thereby increasing production speed. The primary challenge addressed is achieving a uniform and stable layer without air bubbles or non-uniformities, and maintaining an appropriate coating thickness 'h wet,' the height of the wet coating layer, which is critical for the performance of LIBs. The validated CFD model provides valuable insights into the slot-die coating process, demonstrating the potential for improved battery performance and manufacturing efficiency. In conclusion, this project contributes to the advancement of LIB technology by offering a detailed analysis of the slot-die coating process and presenting an understanding of how the investigated parameters affect the process. The findings support the broader adoption of electric vehicles and renewable energy solutions, promoting sustainability and reducing carbon emissions. Future work will focus on the viscosity of the slurry and its impact on results, the angle of the slot-die coating, and further changes in inlet velocity to continue enhancing LIB manufacturing.