Modelling of dry manufacturing of LFP cathode filaments with twin-screw extruder using the Discrete Element Method

IF 4.7 2区材料科学 Q2 ENGINEERING, CHEMICAL

Particuology Pub Date : 2026-02-01 Epub Date: 2025-12-11 DOI:10.1016/j.partic.2025.11.020

Kaize Shi , Ali Hassanpour , Meisam Babaie , Masoud Jabbari

{"title":"Modelling of dry manufacturing of LFP cathode filaments with twin-screw extruder using the Discrete Element Method","authors":"Kaize Shi , Ali Hassanpour , Meisam Babaie , Masoud Jabbari","doi":"10.1016/j.partic.2025.11.020","DOIUrl":null,"url":null,"abstract":"<div><div>Material extrusion is a key step in the solvent-free fabrication of lithium-ion battery (LIB) electrodes, offering reduced costs and environmental impact compared to slurry-based methods. While discrete element method (DEM) based mesoscopic models have been used to study twin-screw extrusion, the microstructural characterisation of extrudates immediately after nozzle exit remains unexplored. In this study, a series of DEM simulations were conducted to perform a sensitivity analysis of the microstructure and electrochemical performance-related parameters of extruded electrode filaments by varying the feeding rate and feeding mode, screw rotational speed, and particle cohesion. Furthermore, this work addresses the previously unexamined phenomenon of filament expansion during extrusion. By introducing the Augmented Dickey-Fuller (ADF) method, the study also provides the first analysis of the temporal dynamic stability of filament quality during the dry electrode manufacturing extrusion process. The results show that increasing the screw speed from 100 to 500 RPM reduces porosity by 10 % and limits expansion, while lower speeds improve consistency in electrode quality. A novel approach to quantifying dynamic behaviour is proposed, offering insights for optimising solvent-free electrode manufacturing.</div></div>","PeriodicalId":401,"journal":{"name":"Particuology","volume":"109 ","pages":"Pages 1-11"},"PeriodicalIF":4.7000,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Particuology","FirstCategoryId":"88","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S1674200125003244","RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"2025/12/11 0:00:00","PubModel":"Epub","JCR":"Q2","JCRName":"ENGINEERING, CHEMICAL","Score":null,"Total":0}

引用次数: 0

Abstract

Material extrusion is a key step in the solvent-free fabrication of lithium-ion battery (LIB) electrodes, offering reduced costs and environmental impact compared to slurry-based methods. While discrete element method (DEM) based mesoscopic models have been used to study twin-screw extrusion, the microstructural characterisation of extrudates immediately after nozzle exit remains unexplored. In this study, a series of DEM simulations were conducted to perform a sensitivity analysis of the microstructure and electrochemical performance-related parameters of extruded electrode filaments by varying the feeding rate and feeding mode, screw rotational speed, and particle cohesion. Furthermore, this work addresses the previously unexamined phenomenon of filament expansion during extrusion. By introducing the Augmented Dickey-Fuller (ADF) method, the study also provides the first analysis of the temporal dynamic stability of filament quality during the dry electrode manufacturing extrusion process. The results show that increasing the screw speed from 100 to 500 RPM reduces porosity by 10 % and limits expansion, while lower speeds improve consistency in electrode quality. A novel approach to quantifying dynamic behaviour is proposed, offering insights for optimising solvent-free electrode manufacturing.

Abstract Image

查看原文本刊更多论文

用离散元法对双螺杆挤出LFP阴极灯丝干式加工进行建模

材料挤压是无溶剂制造锂离子电池（LIB）电极的关键步骤，与基于浆料的方法相比，可以降低成本和对环境的影响。虽然基于离散元方法（DEM）的细观模型已被用于研究双螺杆挤压，但挤出物在喷嘴出口后的微观结构特征仍未被探索。在本研究中，通过一系列DEM模拟，通过改变进料速率和进料方式、螺杆转速和颗粒内聚力，对挤压电极细丝的微观结构和电化学性能相关参数进行敏感性分析。此外，这项工作解决了以前未检查的现象，长丝膨胀期间挤压。通过引入ADF （Augmented Dickey-Fuller）方法，首次分析了干电极制造挤压过程中长丝质量的时间动态稳定性。结果表明，将螺杆转速从100转/分提高到500转/分，气孔率降低了10%，并限制了膨胀，而较低的转速提高了电极质量的一致性。提出了一种量化动态行为的新方法，为优化无溶剂电极制造提供了见解。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

求助全文

约1分钟内获得全文求助全文

来源期刊

Particuology 工程技术-材料科学：综合

CiteScore

6.70

自引率

2.90%

发文量

1730

审稿时长

32 days

期刊介绍： The word ‘particuology’ was coined to parallel the discipline for the science and technology of particles. Particuology is an interdisciplinary journal that publishes frontier research articles and critical reviews on the discovery, formulation and engineering of particulate materials, processes and systems. It especially welcomes contributions utilising advanced theoretical, modelling and measurement methods to enable the discovery and creation of new particulate materials, and the manufacturing of functional particulate-based products, such as sensors. Papers are handled by Thematic Editors who oversee contributions from specific subject fields. These fields are classified into: Particle Synthesis and Modification; Particle Characterization and Measurement; Granular Systems and Bulk Solids Technology; Fluidization and Particle-Fluid Systems; Aerosols; and Applications of Particle Technology. Key topics concerning the creation and processing of particulates include: -Modelling and simulation of particle formation, collective behaviour of particles and systems for particle production over a broad spectrum of length scales -Mining of experimental data for particle synthesis and surface properties to facilitate the creation of new materials and processes -Particle design and preparation including controlled response and sensing functionalities in formation, delivery systems and biological systems, etc. -Experimental and computational methods for visualization and analysis of particulate system. These topics are broadly relevant to the production of materials, pharmaceuticals and food, and to the conversion of energy resources to fuels and protection of the environment.