In order to produce lithium-ion batteries efficiently and to meet the growing demands on the production process, a reduction of the corresponding processing costs, process time, material and energy consumption are of central importance. In this context, the mixing process is particularly relevant, as its quality significantly determines the properties of the generated electrode paste and thus the quality of the subsequent process steps of coating, drying, and finally the electrochemical performance, including the longevity and fast-charging capability of the generated electrodes and batteries [1,2]. During the mixing process, active material(s), binder(s) and conductive additive(s) are supposed to be efficiently deagglomerated, homogenized and dispersed. Therein, both particle agglomerates due to insufficient deagglomeration and particle fractures due to excessive energy input must be prevented by tailoring the process parameters and equipment setup.
The state of the art process for electrode paste production is a batch-based process, which offers the necessary flexibility especially required in the field of academic research and development where novel materials and components are commonly only available in limited scales and various formulations are investigated. In contrast, innovative continuous mixing processes represent a promising alternative when it comes to upscaling and production on industrial scale with established materials since it allows the continuous production of electrode pastes with consistently high quality .
Therefore, in this study a conventional batch-based mixing process is compared to an innovative continuous process using a twin-screw extruder. Different aqueous anode formulations relevant for high-energy and high-power battery applications, particularly graphite and graphite/SiOx composites are considered. For both formulations process parameter variations are carried out in the continuous and discontinuous process to compare relevant processes and processing steps, respectively, as well as material and electrode characteristics such as: process time, energy input, properties of the produced pastes (rheology, particle size distribution, etc.) and electrodes with regard to morphological, mechanical, electronic and electrochemical properties.
Based on the comprehensive characterization, relevant correlations between the quality of the electrode pastes, electrodes, and LIB cells and the respective production process and specific process parameters can be established and differences related to either the process or the material composition can be revealed.
 Haarmann, Matthias, Wolfgang Haselrieder, and Arno Kwade. “Extrusion‐Based Processing of Cath-odes: Influence of Solid Content on Suspension and Electrode Properties.” Energy Technology 8.2 (2020): 1801169.
 Bockholt, Henrike, et al. “The interaction of consecutive process steps in the manufacturing of lithium-ion battery electrodes with regard to structural and electrochemical properties.” Journal of Power Sources 325 (2016): 140-151.
 Haarmann, Matthias, Desiree Grießl, and Arno Kwade. “Continuous Processing of Cathode Slurry by Extrusion for Lithium‐Ion Batteries.” Energy Technology (2021): 2100250.