Enhancing Lithium Ion Battery Materials Research through Advanced Mixing Technology

Introduction

In this case study, we explore the challenges faced by a university laboratory in achieving optimal results during the mixing process of lithium-ion battery slurries. The traditional mixing methods they employed, such as stir bars, mortar and pestle, and ball milling, proved to be inefficient, ineffective, or resulted in defects during the coating process due to entrapped air.  Roll milling was considered but presented significant hazards to the students.  However, their research took a significant leap forward when they discovered the Hauschild SpeedMixer® DAC 150.3 SP, a cutting-edge mixing technology that revolutionized their experimentation process.

Problem Statement

This laboratory faced the same challenges as many others in the industry due to the conventional mixing they had been using:

a. Inadequate Dispersion and Deagglomeration: Lower energy methods like stir bars were unable to effectively disperse and deagglomerate the material, hampering the achievement of optimal material properties. The mortar and pestle sometimes worked well but was very inconsistent from operator to operator.

b. Material Consumption: Ball milling worked well but required larger quantities of expensive materials, which limited the laboratory’s ability to conduct experiments on a smaller scale.

c. Entrapped Air Bubbles: Most of the processes they had tried inherently entrained air which resulted in the presence of bubbles, leading to defects during the subsequent coating process.

d. Unsafe operating conditions: Roll mills had been considered but were ultimately deemed too unsafe for use in their lab.

The Hauschild SpeedMixer® Solution

The laboratory’s breakthrough came when they adopted the Hauschild SpeedMixer® DAC 150.3 SP, a state-of-the-art mixing device. This advanced technology provided a range of benefits that addressed the laboratory’s specific challenges:

a. Efficient Dispersion and Deagglomeration: The Hauschild SpeedMixer® DAC 150.3 SP proved highly effective in breaking down agglomerates, resulting in a superior dispersion. This improved dispersion contributed to achieving the desired material properties consistently.

b. Reduced Material Consumption: The ability to mix in small sample containers allowed the laboratory to work with smaller quantities of expensive materials, offering significant cost savings and the ability to conduct more experiments on a more manageable scale.

c. Bubble Elimination: Unlike conventional methods, the Hauschild SpeedMixer® facilitated a bubble-free mixing process. This feature proved crucial in eliminating defects during the subsequent coating process, ensuring higher-quality battery materials.

d. Safety: Mixing in a closed cup with no cleaning required helped protect students from potentially hazardous materials. It had the added benefit of protecting the materials from ambient air. Because the Hauschild SpeedMixer® is a closed system that will only run when the enclosure is locked, it also eliminated all mechanical hazards. 

Results and Benefits

By incorporating the Hauschild SpeedMixer® DAC 150.3 SP into their research workflow, the university laboratory experienced remarkable outcomes:

a. Improved Data Generation: The accelerated the mixing process, enabling the students to generate meaningful data more quickly. The enhanced dispersion and deagglomeration facilitated a better understanding of the material properties, leading to more accurate, precise, and repeatable results.

b. Successful Demonstration of Novel Materials: The faculty members were delighted with the outcomes as the laboratory was able to successfully demonstrate the utility of their new and novel materials. The improved mixing process contributed to showcasing the potential of these materials, boosting their academic and commercial prospects.

c. Time and Cost Efficiency: The SpeedMixer® not only saved time by significantly reducing the mixing duration but also helped conserve expensive materials due to its ability to work with smaller quantities. This led to increased efficiency and cost-effectiveness in the laboratory’s research endeavors.

Conclusion

The adoption of the Hauschild SpeedMixer® DAC 150.3 SP by the university laboratory proved instrumental in overcoming the challenges faced during the mixing process of lithium-ion battery slurries. The advanced mixing technology provided efficient dispersion, deagglomeration, and bubble elimination, resulting in improved material properties and defect-free coatings. This breakthrough enhanced the laboratory’s research capabilities, allowing for faster data generation, successful material demonstrations, and improved overall efficiency. The Hauschild SpeedMixer®’s contribution to the advancement of lithium-ion battery research highlights its potential to revolutionize mixing processes in various fields of study and industry applications.