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Logo Battery LabFactory Braunschweig der TU Baunschweig
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Infrastructure

On this page we present an overview of the different Labs, the process chain and highlights of the equipment employed for each process step.

The BLB holds the technical equipment to analyze large-size traction batteries as well as battery modules and packs. Our infrastructure allows us to answer fundamental and application-oriented research questions.
A focus is put on flexible production strategies and process technologies to increase energy density, quality and safety of traction batteries considering electrical, electrochemical, constructive, environmental, and economic aspects.

Battery LabFactory I Pilot and lab facilities

Raumplan

ProductionLab

1500 m² cell production pilot line

100 m² mixing lab

  • Broad variety of equipment for dry and wet treatment of powders and slurries

180 m² coating and calendering line

  • Novel drying techniques
  • Mini-environment for continuous coater

200 m² dry room

  • Large dry room with -45°C dew point for cell assembly and ASSB production
  • Separate dry room for laser processes

> 500 formation and cycling channels

  • With state-of-the-art security system

  • Currents up to 100A

Versuchshalle

CircularLab

  • 1300 m² circular production
  • 400 m² for recycling in laboratory and pilot scale

  • Continuous coating equipment for two-sided coating
  • Mechanical recycling line
Diagnosestraße

DiagnosisLab

  • Post-mortem investigations of aged battery cells and components in an inert atmosphere
  • Reassembly of aged and fresh materials to gain insights into degradation processes

The BLB operates a wide range of specialized equipment for all of the steps involved in research on circular battery production. This covers electrode production, cell assembly, cell finishing and battery recycling. This is supported by a large variety of equipment for quality control and diagnostics.

Pretreatment and Mixing
Pretreatment and Mixing

Equipment (selection):

  • Turbula dry mixer for powder homogenization
  • Dissolver for discontinuous suspension mixing (0,15 ml – 1,6 l)
  • Eirich EL1 and EL5 dry and wet mixer
  • Planetary Mixer >5-6 l batches
  • Double screw extruders 1-6 L/h

Analysis equipment (selection):

  • Rotational rheometer
  • Dry and wet particle size analysis by laser diffraction (0.1 – 5000µm)
  • Inline sensors for pressure, electrical conductivity, particle size, color in the extruder
Coating and Drying
Beschichten_Trocknen

Equipment (selection):

  • Continuous coating line (6m dryer length) with web speeds of up to 10m/min
  • Second line for simultaneous two-sided coating (tandem-coating) in construction
  • Novel drying technologies (IR, VCSE-Laser, Induction)
  • Several tabletop coating devices
  • In-line measurement equipment (mass loading, defect detection, color detection)

Innovative coating equipment:

  • 4-roll calander for semi-dry and dry coating (0.1-15 m/min)
Calendering
Calendering

Pilot scale calander (Saueressig):

  • Heated rolls (1-15 m/min)

  • Roller gap controlled

  • Line load and gap detection

Analysis equipment:

  • Inline analysis (electrode thickness, color, gloss, defects)
  • Adhesion strength
  • Electric conductivity
  • Mercury intrusion (Pore radii distribution)
  • Gas adsorption analysis (BET)
Cutting
Cutting

Laser cutting:

  • Different laser sources for individual material combinations
  • Freedom of design with scanner controlled laser cutting
  • Cutting of Li-foils for all-solid-state manufacturing

Laser based electrode structuring:

  • Increasing electrode capacity
  • Flexible geometry variations
Packaging
Packaging

Single sheet stacker (Jonas & Redmann)

  • Pouch cells with industrially relevant size
  • Stacking of conventional cells, mono-cells an bi-cells
  • Anode size of 250x90 mm
  • Up 50+ compartments possible

Z-folder (Sovema)

  • Lab scale multilayer pouch cells
  • Z-folding of ESCs
  • Anode size of 70x50 mm
  • Typically 10-20 compartments
Contacting
Contacting
  • Ultra sonic welding
  • Laser welding
  • Resistance welding
  • Different electrode materials possible (thickness, polymer-metal-composites)
Enclosure and Welding
Enclosure and Welding
  • Deep drawing to form pouch cases
  • Impulse sealing for cell closure
  • High flexibility allows for various formats and capacities
Electrolyte Filling
Electrolyte

Filling and degassing system (Sovema)

  • Filling and sealing of pouch cells
  • Automatic filling (electrolyte pump); only integer electrolyte; useful for large-format cells (30 - 40 ml)
  • Degassing and sealing of (partially) formed pouch cells
  • Residual gas is dry room

Filling glovebox (mbraun)

  • Filling and sealing of pouch cells
  • Manual filling (pipettes); also for small BLB1 cells
  • residual gas is argon with O2 and H2O < 0.1 ppm
Formation and Quality Control
Formation

Cell test equipment:

  • 15 climate chambers (20 °C – 60°C)
  • over 500 test channels (0 – 100A)
  • over 50 channels with EIS
  • 40 channels for 3-electrode setups

Safety equipment:

  • smoke sensors
  • overpressure protection
  • automatic nitrogen flood and gas filtering
Diagnostics
Diagnostics

Post-mortem glovebox line with 4 connected boxes:

1:   Disassembly of aged cells
2 + 3:   Post-mortem analytics in inert atmosphere and/or sample preparation for Raman spectroscopy, scanning electron microscopy, …
4:  (Re)assembly of fresh or aged components

Applied techniques:

  • Electrochemical impedance spectroscopy
  • Ultrasonic scanning of pouch cells
  • Differential electrochemical mass spectrometry
Recycling and Resynthesis
Industriefotografie - Industrial - Corporate

Equipment (selection):

  • Laboratory and pilot line for mechanical LIB recycling
  • Various crushers and classifiers
  • Pyrolysis furnaces
  • Synthesis equipment (solid state and solvent-based)

Analysis equipment:

  • Elemental analysis (ICP-OES)
  • Structural analysis (XRD, TGA, etc.)
  • (Exhaust) gas analysis (FTIR)
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Technische Universität Braunschweig
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P. O. Box: 38092 Braunschweig
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Phone: +49 (0) 531 391-0

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