Production of high-capacity, structured electrodes (HighEnergy)

Project duration:
01.08.2016 – 31.07.2019


  • Institute for Particle Technology (iPAT)
  • Institute of Energy and Systems Process Engineering (InEs)
  • Institute of Thermal Process Engineering / Thin Film Technology (TVT-TFT)
  • Institute for Production Engineering (wbk)
  • Institute of Stochastics
  • ZSW – Accumulators Materials Research (ECM)
  • DLR – Institute of Engineering Thermodynamics – Computational Electrochemistry
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Technische Universität BraunschweigDeutsches Zentrum für Luft- Und Raumfahrt
Karlsruher Institut für TechnologieZentrum für Sonnenenergie- und Wasserstoff-Forschung Baden-Württemberg
Universität Ulm

For economical battery cell production, the produced lithium-ion cells have to demonstrate high quality and performance. Furthermore, the material and production costs may only be so high that the process as a whole remains profitable and economical.
This is where the HighEnergy project comes in. The project will investigate the production of very thick electrode structures with a high energy content. The high energy content should significantly increase the range of electric vehicles.

The consortium plans to investigate the entire electrode manufacturing process chain. The aim is not only to gain basic knowledge about the materials required, such as binders, additives and active materials, but also about the individual processing steps for electrodes. The entire process is to be developed in such a way that it can be easily transferred to new battery cell generations such as lithium-ion solid batteries or lithium-sulfur batteries. This should enable a faster entry into new cell technologies. The challenge in the production of very thick high-energy electrodes is to achieve high homogeneity, mechanical stability, good adhesive properties and high elasticity as well as a correspondingly long cycle life.

The so-called roll-to-roll process is to be used in production. Another goal is the development and qualification of a significantly shortened process for stack formation with thick electrodes. In addition to practical work, the focus is on the simulation of the electrochemical performance of high-capacity lithium-ion cells. The simulations help to to determine the optimal structure of the electrodes and, moreover, allow to identify and minimize loss mechanisms during battery operation.
If successful, it would be possible to produce improved electrodes with a higher production throughput and thus lower costs.