Long-lifetime multilayer XNO® | | NMC532 pouch cells: Scale up and characterization

While new battery chemistries are being developed at a rapid pace, scaling them up to commercial production remains a considerable challenge. Since reconfiguring a commercial-scale production line to make use of a new material is a significant undertaking, any new chemistry must be substantially proven, at a smaller scale, to deliver significant benefits compared to the previous standard. Our work demonstrates a scale-up process for a proprietary niobium-containing anode material, highlighting the challenges that needed to be met and overcome. Following initial small-scale (tens of g) electrode coatings and testing in coin cells, we optimised the formulation of the electrodes. The electrode mixing and coating process was then scaled up to a 10 L volume of electrode slurry, with the resulting electrode properties being carefully monitored. We subsequently designed and built over 200 pouch cells containing the niobium-based anode against the well-studied cathode material, NMC532. Subsequent testing, under 45 °C accelerated aging conditions and at a rate of 2 C, has shown that these pouch cells retain over 90 % of their initial discharge capacity over > 2500 charge/discharge cycles. • A scale-up process for the manufacture of pouch cells is described, incorporating a proprietary niobium-containing anode material. • Challenges that were overcome during the scale-up process are highlighted, including the need for preliminary testing at coin cell scale.