What the Coating Line Doesn’t Tell You. Read the article

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Industry

Batteries and Energy Storage

Batteries are essential to electrification, from vehicles to homes, businesses, grids and data centers. Across all of them, yield and consistency decide who competes.

Manufacturers are converting EV lines to storage cells and developing new chemistries and processes under intense price pressure, and each change sends a line back up its yield curve.

Many of the properties that decide cell performance and safety are set during coating and calendering, yet they are checked on sampled coupons days later, or stay hidden until formation and aging.

Batteries and Energy Storage industry

PlasmaSens is built to measure the electrodes in all kinds of cells, from established lithium-ion chemistries to solid-state, silicon anode, sodium-ion and dry electrode designs.

PlasmaSens™ gives electrode and separator manufacturing teams the information they need while there is still time to use it. One non-contact scan, with no sample preparation, reports multiple properties at the same locations, so engineers can read them together instead of waiting on separate lab results.

PlasmaSens can report many more properties based on what your process needs, using models calibrated on your reference materials.

The same platform also flags clusters of metallic contamination and identifies the metal, which points teams to its source on the line, and it reveals separator variation that batch averages hide.

This helps teams find a drifting step sooner, shorten yield ramp, narrow the margins built into their specs, and bring earlier evidence to qualification when a chemistry, supplier or line changes.

Where It Sits

Where PlasmaSens Sits on a Battery Cell Line

The same platform fits in at the steps where the properties that matter are locked in. Customers define what to measure at each step.

PlasmaSens measurement locationOff-line or carried forward
1

Slurry Mixing

Off-line, sample
  • Viscosity and rheology
  • Solids content
  • Agglomeration
2

Coating

  • Mass loading
  • Front and back
  • Edge alignment
  • Surface quality
3

Drying

  • Mass loading
  • Tensile strength
  • Density
  • Binder migration
  • Residual moisture
4

Calendering

  • Resistance
  • Density
  • Surface roughness
  • Porosity
  • Mechanical integrity
5

Slitting

  • Edge location and integrity
  • Metal contaminants
  • Edge cracks, burrs
6

Assembly and Finishing

  • Every upstream measurement carries forward, so end-of-line results are read against the material record.

Every Measurement Is Stored in PlasmaSmart™

Drift can be spotted while material is still on the line, not after offline lab results return.

What We Measure

Where PlasmaSens Fits

01
Properties we measure
Mass loadingPorosityTensile strengthSheet resistanceVolume resistivityMore properties, based on your needs
02
Anomalies we can capture
Copper, aluminum and iron clustersCracks and edge burrsVoidsDelaminationMore defect types, based on your needs
03
Materials we can measure
ElectrodesSeparatorsSlurries, on off-line samples

Where PlasmaSens Adds Value

Improve Cell Consistency

Tighter control of electrode properties lays the groundwork for consistent energy density, power and durability.

Increase Yield

Drift at coating and calendering can be caught before the electrode absorbs the cost of later steps.

Shorten Yield Ramp

Faster feedback helps new lines, chemistries and converted lines reach stable production sooner.

Reduce Safety and Recall Risk

Finding metal contamination and identifying its source gives teams a way to keep latent defects out of finished cells.

Manufacture Better Materials, Faster.

The fastest way to evaluate PlasmaSens™ is with your own material. Book a demo scan, or send us samples and we will return a report.

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