Vacuum technology is relevant to the quality and safety of various stages in the production of lithium-ion batteries. The vacuum specialists at Leybold have been supporting manufacturers of lithium-ion batteries in their processes and technological challenges and, as such, heavily involved in the development of electric mobility.

Electric mobility is the latest trend in a very dynamic market environment. “From the perspective of vacuum technology, we have been closely monitoring this evolution for many years,” said Dr. Sina Forster, Business Development Manager at Leybold GmbH.

Vacuum technology is relevant to the quality and safety of various stages in the

production of lithium-ion batteries.

In her opinion, one of the main tasks is to determine new vacuum applications and markets from new technologies and developments as early as possible. The strategic role of vacuum technology is therefore to enable and advance these developments.

For example, the design of the vacuum environment is a factor that can have a positive influence on processes. Vacuum is often used during the electrolyte filling stage to ensure that the cell is evenly saturated with the electrolyte and to lend purity to the filling process.

Lithium-ion batteries as a vacuum application

Leybold studied developments in this area and identified opportunities for vacuum application in the manufacturing process of lithium-ion batteries. Because there was initially little information available regarding the manufacturing process of lithium-ion components, the company joined forces with Verband Deutscher Maschinen und Anlagenbau (VDMA) and the Chair of Production Engineering of E-Mobility Components at RWTH Aachen University in order to establish a manufacturing process.

In addition to lithium-ion batteries, Leybold has also been working on developments in fuel cells. Applicable vacuum processes are already emerging, including the coating of the bipolar plates under vacuum. Here, it’s important to observe the technological developments over the next few years and, if necessary, to provide support through cooperation.

Vacuum technology is used in various process steps in electrode manufacture as well as in research and development. As such, Leybold works closely with machine and plant manufacturers who supply battery manufacturers with production plants.

Vacuum improves processes

Vacuum is also essential during the drying stage to remove even the smallest remaining amounts of solvents and moisture. Without vacuum, the drying process would need to be carried out at much higher temperatures and would last much longer. This would have a negative effect on the electrode quality.

Using dry-compressing pumps like Varodry, battery manufacturers save time and

money since they would otherwise need to change the pump oil frequently.

As soon as electrolytes are incorporated into subsequent process steps, vacuum takes on a safety aspect, since many of the electrolytes used are highly reactive and inflammable. High-quality vacuum is essential here.

High-quality drying results under vacuum

Opportunities for improvement exist in many areas, as there are still no established processes that have proven to be efficient. Vacuum drying, for example, is a customer-specific process of pressure, temperature and process gases (such as nitrogen).

In order to achieve high-quality drying results through the aid of vacuum drying, industry-related research projects are already being conducted under the direction of the VDMA.

Leak detection also plays a central role in production from a safety perspective. The cell must be 100% leak-proof in order to ensure a long battery life. A valid leak test can only be performed via a vacuum leak detection system. Even the smallest leaks can be detected with the aid of a helium leak detector or mass spectrometer.

Some components of lithium-ion batteries that are treated in a vacuum are toxic. In order to protect the environment and the vacuum technology from pollutants, the vacuum pump must have the ability to withstand these gases. Additionally, the toxic materials must be confined within the process and discharged in a correspondingly safe manner.

Dry pumps save time and money

For these toxic gases, dry-running vacuum pumps are used. Oil-sealed vacuum pumps tend to be unsuitable for these applications, as the pump oil could be damaged or contaminated by the gases. Using dry-compressing pumps, battery manufacturers save time and money since they would otherwise need to change the pump oil frequently.

In order to ensure sufficient process reliability when handling toxic gases, hermetically-sealed pumps are used, which prevent even the smallest quantities of gas from escaping. This is an important factor, especially in the case of toxic electrolytes, where occupational safety is also important.

Vacuum technology is relevant to the quality and safety of various stages in the production of lithium-ion batteries. The vacuum specialists at Leybold have been supporting manufacturers of lithium-ion batteries in their processes and technological challenges and, as such, heavily involved in the development of electric mobility.

Electric mobility is the latest trend in a very dynamic market environment. “From the perspective of vacuum technology, we have been closely monitoring this evolution for many years,” said Dr. Sina Forster, Business Development Manager at Leybold GmbH.

Vacuum technology is relevant to the quality and safety of various stages in the

production of lithium-ion batteries.

In her opinion, one of the main tasks is to determine new vacuum applications and markets from new technologies and developments as early as possible. The strategic role of vacuum technology is therefore to enable and advance these developments.

For example, the design of the vacuum environment is a factor that can have a positive influence on processes. Vacuum is often used during the electrolyte filling stage to ensure that the cell is evenly saturated with the electrolyte and to lend purity to the filling process.

Lithium-ion batteries as a vacuum application

Leybold studied developments in this area and identified opportunities for vacuum application in the manufacturing process of lithium-ion batteries. Because there was initially little information available regarding the manufacturing process of lithium-ion components, the company joined forces with Verband Deutscher Maschinen und Anlagenbau (VDMA) and the Chair of Production Engineering of E-Mobility Components at RWTH Aachen University in order to establish a manufacturing process.

In addition to lithium-ion batteries, Leybold has also been working on developments in fuel cells. Applicable vacuum processes are already emerging, including the coating of the bipolar plates under vacuum. Here, it’s important to observe the technological developments over the next few years and, if necessary, to provide support through cooperation.

Vacuum technology is used in various process steps in electrode manufacture as well as in research and development. As such, Leybold works closely with machine and plant manufacturers who supply battery manufacturers with production plants.

Vacuum improves processes

Vacuum is also essential during the drying stage to remove even the smallest remaining amounts of solvents and moisture. Without vacuum, the drying process would need to be carried out at much higher temperatures and would last much longer. This would have a negative effect on the electrode quality.

Using dry-compressing pumps like Varodry, battery manufacturers save time and

money since they would otherwise need to change the pump oil frequently.

As soon as electrolytes are incorporated into subsequent process steps, vacuum takes on a safety aspect, since many of the electrolytes used are highly reactive and inflammable. High-quality vacuum is essential here.

High-quality drying results under vacuum

Opportunities for improvement exist in many areas, as there are still no established processes that have proven to be efficient. Vacuum drying, for example, is a customer-specific process of pressure, temperature and process gases (such as nitrogen).

In order to achieve high-quality drying results through the aid of vacuum drying, industry-related research projects are already being conducted under the direction of the VDMA.

Leak detection also plays a central role in production from a safety perspective. The cell must be 100% leak-proof in order to ensure a long battery life. A valid leak test can only be performed via a vacuum leak detection system. Even the smallest leaks can be detected with the aid of a helium leak detector or mass spectrometer.

Some components of lithium-ion batteries that are treated in a vacuum are toxic. In order to protect the environment and the vacuum technology from pollutants, the vacuum pump must have the ability to withstand these gases. Additionally, the toxic materials must be confined within the process and discharged in a correspondingly safe manner.

Dry pumps save time and money

For these toxic gases, dry-running vacuum pumps are used. Oil-sealed vacuum pumps tend to be unsuitable for these applications, as the pump oil could be damaged or contaminated by the gases. Using dry-compressing pumps, battery manufacturers save time and money since they would otherwise need to change the pump oil frequently.

In order to ensure sufficient process reliability when handling toxic gases, hermetically-sealed pumps are used, which prevent even the smallest quantities of gas from escaping. This is an important factor, especially in the case of toxic electrolytes, where occupational safety is also important.