Compounding technology for battery compounds

The development and implementation of high-density accumulator and battery systems are important contributions in responding to the global trend and UNO sustainability goals. The sustainable and decentralized generation, storage and use of energy play a key role thereby.

In researching suitable substance combinations and processes, the adequate handling of electrically conductive materials is of great importance. Typical requirements include intensive mixing in the solid as well as the viscous phase, without deteriorating the physical structure of the functional fillers and thus reducing the conductivity. In addition to this, adherence to narrow temperature limits is a possible requirement.

The knowledge acquired over decades of handling conductive materials, which may also be on a nano scale (such as graphene or different variants of carbon nanotubes (CNTs)), enables BUSS process developers to find, evaluate and successfully implement customized solutions. Thus, the full potential of continuous processing systems is utilized. Uniform process conditions, narrow residence time distribution, continuous process control and the integration of various process steps are among the typically beneficial features.

Processing requirements

This combination of process engineering expertise and the system-specific capabilities of the BUSS Kneader make it possible to implement sophisticated solutions: high fill levels of conductive additives can be distributed across multiple feeders. The immediate onset of mixing at moderate shear rates and intermediate relaxation phases result in excellent distributive mixing, without damaging the internal structure of the conductive materials and/or polymers. Often, with reduced levels of conductive components, the same electrical properties can be achieved. This results in a better processability due to the lower viscosities. The inherent design freedom of the BUSS Kneader also makes it possible to respond specifically to viscosity changes in the process zones with targeted configurations. This allows customized and fine-tuned control and regulation of the process conditions.

Thanks to our broad spectrum of process expertise and the unique BUSS Kneader compounding technology, BUSS as technology leader is the ideal partner in the development and commercialization of sustainable system solutions.

Typical plant layout for processing of battery compounds

Typical plant layout for processing of battery compounds

BUSS compounding systems offer the following specific benefits

  • Intensive mixing at low specific energy input
    BUSS multiple-flight Kneaders of the latest generation achieve better mixing at a lower overall specific energy input. This is because of an increased number of mixing cycles according to the needs of each individual process section. The energy is provided almost entirely mechanically and optimally dissipated according to the imparted shear rates.

  • Precise temperature control
    The BUSS compounding technology and the BUSS Kneader permits precise temperature control owing to controlled energy input and uniform, moderate shear rates, along with precise temperature monitoring by thermocouples mounted at relevant positions along the barrel in hollow-bored kneading pins surrounded by compound.

  • Intensive distributive mixing
    The BUSS Kneader achieves intensive distributive mixing because the combined rotation and axial motion of the Kneader screw generates extensional flow, a large number of shear interfaces, and cross channel mixing.

  • Flexible configuration of process section
    Screw elements, barrel liners and kneading pins are easily exchangeable components that are easily accessible by opening the BUSS Kneader’s split barrel. All these elements can be changed without removing the barrel or screw shaft.
  • Liquid injection at any position
    Injection pins that can be mounted at any pin position along the process section allow liquid additives injection directly into the already dispersed product at the optimal position for the process. Mixing in begins instantly, without smearing on the barrel wall, enabling mixing even on the shortest processing lengths.

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