Understanding the effect of coating-drying operating variables on electrode physical and electrochemical properties of lithium-ion batteries

The effect of coating and drying process variables (comma bar gap, web speed, coating ratio, drying temperature and drying air speed) on NMC622 cathode physical properties (thickness, mass loading and porosity) and electrochemical properties (gravimetric capacity, volumetric capacity and rate performance) is studied by a design of experiments approach. Electrochemical performance is assessed on half coin cells at C-rates from C/20 up to 10C. The statistical analysis of the data reveals that the cathode physical properties are mainly affected by comma bar gap and coating ratio. The electrochemical properties also show high correlations between comma bar gap and coating ratio for some C-rates. As a second evaluation, the relationship between the cathode half-cell physical characteristics with the electrochemical performance is studied through multiple linear regression analysis. A correlation mainly between coating weight and the electrochemical properties is found. Empirical linear models representing the relationship between the output and input variables are provided, showing correlation coefficients (R2) as high as 0.99. •Pilot-plant scale studies of the coating-drying process of NMC622 cathodes.•Comma bar gap and coating ratio are the key parameters influencing performance.•Cathode coating weight is the main physical property influencing performance.•Empirical models represent the performance as a function of the main variables.