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Abstract Battery production cost models are critical for evaluating the cost competitiveness of different cell geometries, chemistries, and production processes. To address this need, we present a detailed bottom-up approach for calculating the full cost, marginal cost, and levelized cost of various battery production methods. Our approach ensures comparability across research fields and industries, reflecting capital and imputed interest costs. We showcase the model with case studies of a prismatic PHEV2 hardcase cell and a cylindrical 4680 cell in four different chemistries. Our publicly available browser-based modular tool incorporates up-to-date parameters derived from literature and expert interviews. This work enables researchers to quickly assess the production cost implications of new battery production processes and technologies, ultimately advancing the goal of reducing the cost of electrified mobility.

Filamentous microorganisms exhibit a complex macro-morphology constituted of branched and cross-linked hyphae. Fully resolved mechanical models of such mycelial compounds rely heavily on accurate input data for mechanical properties of individual hyphae. Due to their irregular shape and high adaptability to environmental factors, the measurement of these intrinsic properties remains challenging. To overcome previous shortcomings of microfluidic bending tests, a novel system for the precise measurement of the individual bending stiffness of fungal hyphae is presented in this study. Utilizing two-photon polymerization, microfluidic molds were fabricated with a multi-material approach, enabling the creation of 3D cell traps for spore immobilization. Unlike previous works applying the methodology of microfluidic bending tests, the hyphae were deflected in the vertical center of the microfluidic channel, eliminating the adverse influence of nearby walls on measurements. This lead to a significant increase in measurement yield compared to the conventional design. The accuracy and reproducibility of bending tests was ensured through validation of the measurement flow using micro-particle image velocimetry. Our results revealed that the bending stiffness of hyphae of Aspergillus niger is approximately three to four times higher than that reported for Candida albicans hyphae. At the same time, the derived longitudinal Young’s Modulus of the hyphal cell wall yields a comparable value for both organisms. The methodology established in this study provides a powerful tool for studying the effects of cultivation conditions on the intrinsic mechanical properties of single hyphae. Applying the results to resolved numerical models of mycelial compounds promises to shed light on their response to hydrodynamic stresses in biotechnological cultivation, which influences their expressed macro-morphology and in turn, product yields.

Abstract Innovative soft robotic grippers, such as granular grippers, enable the automated handling of a wide spectrum of different geometries, increasing the flexibility and robustness of industrial production systems. Granular grippers vary in their design as well as in their configuration, which affects the specific characteristics and capabilities regarding grippable objects. Relevant aspects are the selection of granulates and membranes, as they affect the deformability. This influences the achievable gripping forces, which vary with the gripped objects geometry. On the basis of experimental studies, the modeling of interpolations as well as through experimental validations, the present research investigates the influences of different configurations on the achievable gripping forces for a specific concept of an innovative vacuum-based granular gripper. Specifically, the focus lies on design as well as configuration parameters, which could influence the achievable gripping force. Influencing parameters are determined based on a literature review of similar gripping concepts. Various adjustment possibilities are identified, such as materials of granulates or membranes. The possible configuration options are experimentally analyzed with a one-factor-at-a-time approach. The possibility of modelling the effects of their interrelations on the achievable gripping force is examined with approaches for linear models and compared to interpolations based on Machine Learning. Especially the granulate filling level and the membrane configuration exhibit the largest influences, which were best predicted with the approach based on artificial neural networks. A selection of an optimized gripper configuration for a specified object set as well as possible further developments such as a continuous expandability of the approaches and integrations with simulations are discussed. As a result of these analyses, this research provides methodologies for an optimized selection of a gripper configuration for an improved object-specific achievable gripping force and allows for more efficient handling processes with the examined type of vacuum-based granular gripper.

Future industrial applications of microparticle fractionation with deterministic lateral displacement (DLD) devices are hindered by exceedingly low throughput rates. To enable the necessary high-volume flows, high flow velocities as well as high aspect ratios in DLD devices have to be investigated. However, no experimental studies have yet been conducted on the fractionation of bi-disperse suspensions containing particles below 10 µm with DLD at a Reynolds number (Re) above 60. Furthermore, devices with an aspect ratio of more than 4:1, which require advanced microfabrication, are not known in the DLD literature. Therefore, we developed a suitable process with deep reactive ion etching of silicon and anodic bonding of a glass lid to create pressure-resistant arrays. With a depth of 120 µm and a gap of 23 µm between posts, a high aspect ratio of 6:1 was realized, and devices were investigated using simulations and fractionation experiments. With the two-segmented array of 3° and 7° row shifts, critical diameters of 8 µm and 12 µm were calculated for low Re conditions, but it was already known that vortices behind the posts can shift these values to lower critical diameters. Suspensions with polystyrene particles in different combinations were injected with an overall flow rate of up to 15 mL/min, corresponding to Re values of up to 90. Suspensions containing particle combinations of 2 µm with 10 µm as well as 5 µm with 10 µm were successfully fractionated, even at the highest flow rate. Under these conditions, a slight widening of the displacement position was observed, but there was no further reduction in the critical size as it was for Re = 60. With an unprecedented fractionation throughput of nearly 1 L per hour, entirely new applications are being developed for chemical, pharmaceutical, and recycling technologies.

Despite the variety of solid electrolytes available, no single solid electrolyte has been found that meets all the requirements of the successor technology of lithium-ion batteries in an optimum way. However, composite hybrid electrolytes that combine the desired properties such as high ionic conductivity or stability against lithium are promising. The addition of conductive oxide fillers to sulfide solid electrolytes has been reported to increase ionic conductivity and improve stability relative to the individual electrolytes, but the influence of the mixing process to create composite electrolytes has not been investigated. Here, we investigate Li3PS4 (LPS) and Li7La3Zr2O12 (LLZO) composite electrolytes using electrochemical impedance spectroscopy and distribution of relaxation times. The distinction between sulfide bulk and grain boundary polarization processes is possible with the methods used at temperatures below 10 °C. We propose lithium transport through the space-charge layer within the sulfide electrolyte, which increases the conductivity. With increasing mixing intensities in a high-energy ball mill, we show an overlay of the enhanced lithium-ion transport with the structural change of the sulfide matrix component, which increases the ionic conductivity of LPS from 4.1 × 10−5 S cm−1 to 1.7 × 10−4 S cm−1.

Current research focuses on lithium-ion battery cells with a high energy density and efficient fast-charging capabilities. However, transport limitations, and, therefore, the uniform diffusion of lithium-ions across the electrode layers, remain a challenge and could lead to reduced cell performance. One approach to overcome these transport challenges is the use of subsequently produced two-layer anodes with the particle size variation of spherical graphite (x50 = 18 µm; x50 = 11 µm). Thereby, a defined pore network is created, which reduces the ionic resistance and ensuring improved fast charging capabilities. The analysis focuses on the evaluation of electrode properties and the electrochemical performance. By examining the pore size distribution of the anodes, it has been found that during the manufacturing of the two-layer anodes, carbon black and binder particles are transported into the existing microstructure of the lower layer, resulting in localized densification between the anode layers. This could also be supported by color measurements. This effect also extends to electrochemical investigations, with electrochemical impedance spectroscopy showing significantly lower ionic resistances in all two-layer anodes. Reduced ionic resistance and tortuosity near the separator due to absorption effects enhance the ion diffusion and have a direct impact on anode performance. Cell ageing analysis showed a significant capacity decrease of almost 15 mAh g −1 in the single-layer references only, in contrast to the stability of the two-layer anodes. This could also be attributed to the reduced ionic resistance and active counteraction of binder migration. In conclusion, this study highlights how subsequently produced two-layer anodes significantly shape the electrode properties and cell performance of lithium-ion batteries.

As manufacturing and assembly processes continue to require more adaptable systems for automated handling, innovative solutions for universal gripping are emerging. These grasping systems can enable the handling of wide varieties of shapes, with gripping forces varying with grasped geometries. For the efficient usage of handling systems, precise offline and online prediction models for resulting grasping forces for different objects are necessary. In previous research, a flexible vacuum-based granular gripper was developed, for which no option for predicting gripping forces is currently available. Various gripping force prediction methodologies within the current state of the art are examined and evaluated. For an assessment of grasping forces of previously untested objects for the examined gripper with limited data and low computational effort, two methodologies are proposed. An analytical, 2D-geometry-derived gripper-specific metric for geometries is compared to a methodology based on similarities of objects to a small existing dataset. The applicability and prediction quality for different object types is analyzed through validation experiments. Gripping force estimations are possible with both methodologies, with individual weaknesses towards geometric features such as air permeabilities. With further development, robust predictions of gripping forces could be achieved for a wide range of unknown object geometries with limited experimental effort.

Sulfur‐polyacrylonitrile (SPAN) is a sulfur‐based active material for next‐generation lithium‐sulfur battery cathodes. Due to the covalent bonding between sulfur chains and the polymeric backbone, the shuttle effect degrading classical sulfur‐based cathodes can be suppressed while also achieving a high active material content in the cathode. In this paper, we investigate the processability of an industrially scalable SPAN active material with 38 wt.‐% of sulfur in a water‐based and scalable process route. The potential of the SPAN material for industrial adoption and the impact of the process route on the cell performance are discussed. We show that when processed correctly, the SPAN material delivers exceptional cycling stability and good C‐rate performance with ether‐based electrolytes. However, the performance of the SPAN cathode is influenced by the mixing characteristic. Using higher mixing intensities during the slurry preparation leads to deterioration of the electrochemical performance. This can be attributed to a decreasing carbon black percolation with increasing tip speed in combination with the kinetic limitation of sulfur cathodes during Li2S2 and Li2S oxidation. [ABSTRACT FROM AUTHOR]

One possible approach to improve the fast charging performance of lithium‐ion batteries (LIBs) is to create diffusion channels in the electrode coating. Laser ablation is an established method for creating such structures and improving the performance of conventional LIBs. However, this method has not yet been used in industrial battery production due to different reasons. The drawbacks of this method are thermal stress, loss of active material, and discontinuous process flow. Herein, a novel concept is presented that enables the structuring of electrodes by selectively introducing a secondary fluid into the wet coating of the electrode. This displaces the active material prior to drying, resulting in no loss of active material and maintaining mechanical integrity. This innovative process is being tested for graphite anodes on a lab scale. Initial results show that the process can create pores that are comparable to laser‐structured electrodes. There is no visible damage to the electrode and no decrease in mechanical strength due to the structuring is observed. By varying the process parameters, different pore geometries can be generated with continuous process control, which are visually measured in this work. There is also a noticeable increase in performance when fast‐charging these electrode anodes. [ABSTRACT FROM AUTHOR]

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Future industrial applications of microparticle fractionation with deterministic lateral displacement (DLD) devices are hindered by exceedingly low throughput rates. To enable the necessary high-volume flows, high flow velocities as well as high aspect ratios in DLD devices have to be investigated. However, no experimental studies have yet been conducted on the fractionation of bi-disperse suspensions containing particles below 10 µm with DLD at a Reynolds number (Re) above 60. Furthermore, devices with an aspect ratio of more than 4:1, which require advanced microfabrication, are not known in the DLD literature. Therefore, we developed a suitable process with deep reactive ion etching of silicon and anodic bonding of a glass lid to create pressure-resistant arrays. With a depth of 120 µm and a gap of 23 µm between posts, a high aspect ratio of 6:1 was realized, and devices were investigated using simulations and fractionation experiments. With the two-segmented array of 3° and 7° row shifts, critical diameters of 8 µm and 12 µm were calculated for low Re conditions, but it was already known that vortices behind the posts can shift these values to lower critical diameters. Suspensions with polystyrene particles in different combinations were injected with an overall flow rate of up to 15 mL/min, corresponding to Re values of up to 90. Suspensions containing particle combinations of 2 µm with 10 µm as well as 5 µm with 10 µm were successfully fractionated, even at the highest flow rate. Under these conditions, a slight widening of the displacement position was observed, but there was no further reduction in the critical size as it was for Re = 60. With an unprecedented fractionation throughput of nearly 1 L per hour, entirely new applications are being developed for chemical, pharmaceutical, and recycling technologies. [ABSTRACT FROM AUTHOR]

Within the realm of lithium‐ion batteries, there is a growing emphasis on achieving high energy density and environmentally friendly production at a low cost. To address these demands, the battery slurries in this study incorporate the high‐energy anode material silicon. They are systematically produced through continuous extrusion, aiming to realize cost reductions by significantly reducing the overall process time. In this study, it is demonstrated that the choice of screw configuration and solids content during kneading influences the specific energy input and the stress intensity during processing significantly. The stress intensity, represented here by the specific torque, has a great influence on the slurry properties as well as the electrochemical performance of the battery. An increased stress intensity leads to an increase in adhesive strength and ionic resistance. In the results, it is indicated that carbon black decomposition increases significantly, but when a critical specific stress intensity in form of the specific torque is reached, delamination and fracture of the graphite particles occur, leading to a loss of lithium‐ion storage capacity, favoring lithium plating and severely degrading both capacity by up to 40% at 1C and long‐term performance by up to 10% after 50 cycles. [ABSTRACT FROM AUTHOR]

Among the technologies used for spent lithium-ion battery recycling, the common approaches include mechanical treatment, pyrometallurgical processing and hydrometallurgical processing. These technologies do not stand alone in a complete recycling process but are combined. The constant changes in battery materials and battery design make it a challenge for the existing recycling processes, and the need to design efficient and robust recycling processes for current and future battery materials has become a critical issue today. Therefore, this paper simplifies the current treatment technologies into three recycling routes, namely, the hot pyrometallurgical route, warm mechanical route and cold mechanical route. By using the same feedstock, the three routes are compared based on the recovery rate of the six elements (Al, Cu, C, Li, Co and Ni). The three different recycling routes represent specific application scenarios, each with their own advantages and disadvantages. In the hot pyrometallurgical route, the recovery of Co is over 98%, and the recovery of Ni is over 99%. In the warm mechanical route, the recovery of Li can reach 63%, and the recovery of graphite is 75%. In the cold mechanical route, the recovery of Cu can reach 75%, and the recovery of Al is 87%. As the chemical compositions of battery materials and various doping elements continue to change today, these three recycling routes could be combined in some way to improve the overall recycling efficiency of batteries. [ABSTRACT FROM AUTHOR]

Drying is a critical process step during battery electrode production due to its microstructure defining nature. Distribution and interconnectivity of active material particles, pores, and the overall porosity significantly influence the later cell performance. Knowledge about structure formation as well as electrode property prediction are crucial for optimization and targeted electrode design. However, the exact microprocesses during electrode drying are not yet understood well and very difficult to access experimentally. Therefore, in this study, a combination of computational fluid dynamics (CFD) and discrete element method (DEM) simulation models for investigating structure formation considering particle–particle as well as fluid‐particle interactions and vice versa is presented. , The volume of fluid method is used for taking into account the fluid‐fluid interface, evaporation and capillary interactions. The simulations reveal the formation of a top–down consolidation front which interacts with the fluid leading to a backflow of liquid. The results show good agreement with experimental measurements for NMC622 cathodes. Furthermore, the influence of production parameters such as mass loading and solids content is examined. The findings demonstrate the modeling tool's suitability for process engineers to anticipate and enhance electrode characteristics and facilitate scientists to understand complex structure formation relationships. [ABSTRACT FROM AUTHOR]

Despite the variety of solid electrolytes available, no single solid electrolyte has been found that meets all the requirements of the successor technology of lithium-ion batteries in an optimum way. However, composite hybrid electrolytes that combine the desired properties such as high ionic conductivity or stability against lithium are promising. The addition of conductive oxide fillers to sulfide solid electrolytes has been reported to increase ionic conductivity and improve stability relative to the individual electrolytes, but the influence of the mixing process to create composite electrolytes has not been investigated. Here, we investigate Li3PS4 (LPS) and Li7La3Zr2O12 (LLZO) composite electrolytes using electrochemical impedance spectroscopy and distribution of relaxation times. The distinction between sulfide bulk and grain boundary polarization processes is possible with the methods used at temperatures below 10 °C. We propose lithium transport through the space-charge layer within the sulfide electrolyte, which increases the conductivity. With increasing mixing intensities in a high-energy ball mill, we show an overlay of the enhanced lithium-ion transport with the structural change of the sulfide matrix component, which increases the ionic conductivity of LPS from 4.1 × 10−5 S cm−1 to 1.7 × 10−4 S cm−1. [ABSTRACT FROM AUTHOR]

Current lithium (Li)‐metal anodes are not sustainable for the mass production of future energy storage devices because they are inherently unsafe, expensive, and environmentally unfriendly. The anode‐free concept, in which a current collector (CC) is directly used as the host to plate Li‐metal, by using only the Li content coming from the positive electrode, could unlock the development of highly energy‐dense and low‐cost rechargeable batteries. Unfortunately, dead Li‐metal forms during cycling, leading to a progressive and fast capacity loss. Therefore, the optimization of the CC/electrolyte interface and modifications of CC designs are key to producing highly efficient anode‐free batteries with liquid and solid‐state electrolytes. Lithiophilicity and electronic conductivity must be tuned to optimize the plating process of Li‐metal. This review summarizes the recent progress and key findings in the CC design (e.g. 3D structures) and its interaction with electrolytes. [ABSTRACT FROM AUTHOR]

Precise coating processes demand sensitive drying processes. The present work investigates the operation of hybrid convective drying nozzles for combining impingement nozzles with impingement-free nozzles. Impingement-free nozzles show good uniformity, whereas impingement nozzles are characterized by higher heat transfer but greater non-uniformity across the pitch. Volumetric flow ratio between the nozzle types, lateral distance, substrate distance and angle of impingement are the parameters of this study. Compared with purely impingement-free nozzles, the combination can achieve increased heat transfer with moderate losses in distribution uniformity. A divergent impingement jet with a small lateral distance and a small substrate distance proves to be advantageous. In addition, a consideration of energy requirements shows that impingement-free nozzles, due to their lower resistance, can deliver the same volume flow rates with lower blower power. As a result, the reduction of the impingement component in the hybrid nozzle is advantageous in terms of energy. [ABSTRACT FROM AUTHOR]