Future Battery Forum 2025

Monitoring parameters inside the cells

Monitoring parameters inside battery cells offers considerable potential, as critical values can be detected earlier than on the outer wall of the battery. However, a number of key points must be taken into account for the successful integration of sensors inside the cell:

• Inertness of the sensor technology: the sensors used must be inert to the conditions inside the cell, particularly with regard to the electrolyte, and must not exert any mechanical or electrical influences on the cell.
• Signal transmission: It must be possible to lead the measurement signal out of the cell.
• Unimpaired cell processes: The sensor technology must not interfere with the processes in the cell in order to avoid additional cell ageing.
• Compact design: The sensors should be as small and light as possible.
• Cost-effectiveness: Price and market availability must be in line with potential applicability.

Despite these challenges, Fraunhofer ISIT has managed to successfully integrate various sensor technologies into lithium-ion cells. These technologies can be used effectively to characterize the cells and monitor cell operation.

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Dry coating process for battery electrodes:

Environmentally friendly, cost-efficient, space- and energy-saving

The production of high-strength electrodes is a promising approach to increasing the energy density of Li-ion batteries, as they have a favorable ratio of active to inactive materials. However, modern tape casting processes with relatively high solvent content are limited in terms of layer thickness and drying process, which is associated with undesirable effects such as binder migration. Therefore, advanced processes for electrode production are urgently needed.

Fraunhofer ISIT has developed a dry coating process that works completely without solvents. Drying the coated electrode sludge is an energy-intensive process. It also requires a large amount of space, as long drying distances are necessary for optimum process results. The dry coating process developed by Fraunhofer ISIT makes the use of solvents superfluous. In addition, higher loads are possible that exceed the range of conventional electrodes. This leads to considerable cost savings and is more environmentally friendly.

Innovation for the battery technology of tomorrow

The “Integrated Energy Systems” (IES) department at ISIT is involved in the further development of existing cell systems and the research and adaptation of new approaches for rechargeable batteries. The focus is on new electrode materials and formulations, electrolyte systems and separators - always with the aim of improving cell performance, reducing costs and protecting the environment.

Our flexible cell architecture (pouch cells) allows customized adaptation to individual requirements and installation space specifications. Our patented separator concept and the precise coordination of all materials result in a modular electrochemical system with a wide range of applications.

From electrode and separator production to cell assembly - in our technical center in Itzehoe we transfer laboratory developments to small series production. State-of-the-art test benches enable comprehensive electrochemical analyses and ageing tests over a wide temperature range.

In this way, we combine research, development and industrial implementation under one roof - for the battery solutions of the future.

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