Analytical and Mechanical Solutions for Lithium-Ion Batteries

Lithium-Ion Batteries: Key Components for Energy Innovation

Lithium-Ion batteries (LiBs) have become indispensable in achieving a carbon-free society. They are critical for applications in mobility and energy sectors, particularly in electric vehicles.

These batteries are composed of the following key components:

• Anode (Negative Electrode): Typically created using graphite or advanced carbon materials such as carbon nanotubes (CNT) or silicon-based compounds.
• Cathode (Positive Electrode): Made from materials like Nickel-Manganese-Cobalt (NMC) or Lithium Iron Phosphate (LFP), combined with binders and conductive additives.
• Electrolyte: The medium for ionic transfer between the electrodes, available as liquid, gel, or solid-state.
• Separator: A porous membrane that prevents short-circuiting while allowing lithium-ion movement.

Challenges in Lithium-Ion Battery Production and Sustainability

We Support the Entire Lifecycle of Lithium-Ion Batteries

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Anode Active Materials (AAM) and Negative Electrode 

Anode Active Materials (AAM) are predominantly composed of carbon-based materials, with graphite being the most commonly used. The structure and composition of these materials are critical for ensuring the efficient storage (intercalation) of lithium ions during charging. These factors directly influence the key characteristics of the battery cell, including energy density, power density, safety, and service life. To optimize performance and prevent risks, thorough analysis of metallic impurities is essential. Impurities can trigger parasitic reactions that degrade battery performance and, in extreme cases, lead to serious issues such as cell autoignition. Moreover, compliance with European Regulation 2023/1542, which prohibits the use and presence of mercury, lead, and cadmium in batteries, requires careful verification to ensure the complete absence of these substances. For precise detection and quantification of trace metals, the ICPMS-2040/2050 Series offers advanced elemental analysis capabilities, supporting both performance optimization and regulatory compliance. Additionally, particle size distribution and shape significantly impact ionic and electronic conductivity, which are vital for battery efficiency. As a result, detailed studies of these properties are necessary to achieve optimal performance and reliability. The SALD-2300 Particle Size Analyzer enables accurate measurement and analysis of particle size and morphology, and the MCT Series : SHIMADZU (Shimadzu Corporation) allows to directly measure the strength of these single particles. For broader material characterization, the AGX-V2 Series Universal Tester provides comprehensive material testing solutions, while the AXIS Supra+ X-ray Photoelectron Spectrometer delivers high-resolution surface analysis for in-depth understanding of surface properties.

Anode Active Materials (AAM) and Negative Electrode 

 

Anode Active Materials (AAM) are predominantly composed of carbon-based materials, with graphite being the most commonly used. The structure and composition of these materials are critical for ensuring the efficient storage (intercalation) of lithium ions during charging. These factors directly influence the key characteristics of the battery cell, including energy density, power density, safety, and service life.

To optimize performance and prevent risks, thorough analysis of metallic impurities is essential. Impurities can trigger parasitic reactions that degrade battery performance and, in extreme cases, lead to serious issues such as cell autoignition. Moreover, compliance with European Regulation 2023/1542, which prohibits the use and presence of mercury, lead, and cadmium in batteries, requires careful verification to ensure the complete absence of these substances

Additionally, particle size distribution and shape significantly impact ionic and electronic conductivity, which are vital for battery efficiency. As a result, detailed studies of these properties are necessary to achieve optimal performance and reliability.

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Anode / Negative Electrode Manufacturing

 

Anodes, or negative electrodes, are produced by coating a current collector—typically made of copper—with electrode material, followed by a drying process. Once dried, the coated material is cut into strips using a slitting process. Evaluating composite electrode materials created through multiple manufacturing steps requires distinct evaluation criteria compared to assessing individual raw materials. This is essential for optimizing the manufacturing process and ensuring consistent quality.
One of the most critical steps in battery production is the formation process, which occurs after assembly. During this phase, the Solid-Electrolyte Interface (SEI) forms at the boundary between the anode and the electrolyte. This thin layer is vital for the proper functioning of the battery, as it significantly influences its lifetime and overall performance. Accurate characterization of the SEI is crucial to understanding and optimizing battery properties and durability.

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Cathode Active Materials ((p)CAM) and Positive Electrode

Cathode Active Materials ((p)CAM) and Positive Electrode Cathodes are produced by coating aluminum foil with a slurry of Cathode Active Materials (CAM), a binder (e.g., PVDF), conductive carbon, and a solvent (e.g., NMP), then drying and calendering. Common CAMs include NMC and LFP. Because purity, composition, and structure directly determine energy density, power density, and reliability, manufacturers typically verify elemental stoichiometry and trace-metal impurities in CAM powders and aluminum foils with the ICPE-9800 series, monitor residual NMP and other volatiles in slurries and coated electrodes using the Brevis GC-2050, identify unknown organics and degradation products with the GCMS-QP2050, and track organic load in process and cleaning waters via the TOC-L series. Mechanical robustness of the coated foils, tabs, and composite electrodes can then be quantified with the Autograph Precision Universal Tester (AGX-V2 Series), while routine peel, puncture, and compression checks are streamlined by the versatile Autograph AGS-V Series. Integrating these measurements into incoming-material QC and in-process control helps ensure consistent cathode performance, higher yield, and safer operation.

Cathode Active Materials and precursors analysis (CAM & pCAM)

 

Constructing an efficient cathode is a complex process that involves the careful selection and combination of various materials. A wide range of Cathode Active Materials (CAM) and their precursors, typically based on lithium metal oxides, are available. These include  nickel-cobalt-based lithium oxides (NMC) and Lithium Iron Phosphate (LFP), each offering distinct properties and contributing to different performance characteristics in the final battery cell.
To ensure optimal performance and safety, a thorough analysis of metallic impurities is essential. Impurities can trigger parasitic reactions that degrade battery performance and, in severe cases, lead to critical issues such as cell autoignition. Additionally, compliance with European Regulation 2023/1542, which prohibits the use and presence of mercury, lead, and cadmium in batteries, requires rigorous testing to verify the absence of these restricted substances.
The inclusion of conductive agents, such as carbon, is also vital for efficient electronic conduction within the cathode. As such, these materials must also be carefully analyzed to ensure they meet the required standards for performance and reliability.

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Cathode/Positive Electrode Manufacturing

 

Cathodes, or positive electrodes, are produced by coating a current collector -typically aluminum - with electrode material, followed by a drying process. Once dried, the coated material is cut into strips using a slitting process. Evaluating composite electrode materials created through multiple manufacturing steps requires distinct evaluation criteria compared to assessing individual raw materials. This approach is essential for optimizing the manufacturing process and ensuring consistent quality and performance

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Liquid Electrolytes and All Solid State Batteries (ASSB)

Electrolytes enable ionic transfer between electrodes during charge and discharge, and in conventional lithium‑ion systems this is typically achieved with complex liquid electrolytes that can suffer from temperature-related performance loss, capacity limits, safety concerns, and aging. To overcome these issues, semi‑solid (gel) and ion‑conducting solid materials are being adopted in next‑generation all‑solid‑state batteries (ASSB), targeting improved performance, enhanced safety, and longer lifespans. Robust characterization accelerates this transition: routine QC of solvent blends and impurities in liquid and gel electrolytes is handled by the compact Brevis GC-2050, while trace and unknown volatile degradation products are identified with the GCMS-QP2020 NX. For solid and gel electrolytes, separators, and composite layers, mechanical integrity—tensile/compressive strength, puncture resistance, and adhesion—is quantified using the Autograph AGS-V Series, supporting safer processing and durable performance.

Electrolytes Characteristics (Liquid and Solid Electrolytes)

 

The electrolyte is the medium situated between the cathode and anode, containing ions that act as carriers to facilitate ionic transfer. In liquid lithium-Ion batteries, the electrolyte is typically a solution composed of a mixture of ethylene carbonate (EC) or other organic solvents, lithium hexafluorophosphate (LiPF6) or other lithium salts, and vinylene carbonate (VC) or similar additives. Since the condition and composition of the electrolyte solution directly impact battery performance, thorough evaluation of its chemical makeup is essential.

In all-solid-state batteries, three types of solid electrolytes are commonly used: oxide-based, sulfide-based, and polymer-based electrolytes. The properties of these solid electrolytes, including particle size, surface characteristics, thermal behavior, and chemical composition, significantly influence battery performance. Therefore, detailed analysis of these attributes is crucial to ensure optimal functionality and reliability in advanced battery technologies.

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Separator

 

Separators consist of a porous membrane used to separate cathode anode when liquid electrolytes are  used. Separators are mainly made of polyethylene or other polyolefin polymer.

 It is important to evaluate the physical and thermal properties of separators and their composition, because separators must not obstruct lithium ion movement during charging-discharging and must be electrically insulative and mechanically strong in order to prevent short-circuiting between positive and negative electrodes. Moreover,  the pores close up if the battery becomes hot. Thus, the separators serve to prevent uncontrolled heating. 
 

Solution Highlights

Evaluation of Batteries Manufacturing

Lithium-Ion batteries are produced through electrode fabrication and cell assembly, where materials experience mechanical, thermal, and chemical stresses that influence final quality and performance. To evaluate batteries in their composite state—assembled from multiple raw materials—and to track changes during formation and cycling, manufacturers assess mechanical robustness (tensile, peel/adhesion, puncture, and stack compression) with the Autograph AGS-V Series. Chemical cleanliness is controlled by monitoring residual solvents and process volatiles using routine GC on the compact Brevis GC-2050, while high‑throughput QC workflows are standardized on the Nexis GC-2030. Emerging or unknown decomposition products from electrolytes and binders are identified and quantified via single‑quadrupole GC–MS using either the GCMS-QP2050 or the GCMS-QP2020 NX. To understand interfaces that govern impedance growth and capacity fade, nm‑scale surface chemistry—including SEI and cathode surface states—is mapped by XPS with the AXIS Supra. Together, these measurements ensure consistent product quality and reliability from incoming materials through finished cells and packs.

Electrode Manufacturing

 

Battery materials are typically produced in sheet form using roll-to-roll processing methods. Cathodes and anodes are most commonly manufactured by coating a current collector with electrode material, followed by a drying process. Once dried, the coated material is cut into strips through a slitting process. Separators, on the other hand, are produced as thin polymer films.
Evaluating composite electrode materials created through these multi-step manufacturing processes requires distinct criteria compared to assessing individual raw materials. This tailored approach is essential for optimizing production methods and ensuring the quality and performance of the final battery components.

Solution Highlights

Cell Assembly

 

Electrode materials produced through various manufacturing steps are laminated and rolled together before being assembled into a battery cell. Once the rolled materials are inserted into the cell, the cell is sealed through welding and injected with an electrolyte solution.
After assembly, the newly formed cell undergoes an initial charge/discharge cycle using a battery cycler. This process, known as the forming step, activates internal electrochemical processes essential for proper battery operation. Non-destructive analysis of the assembled cell, along with the evaluation of gases generated during the forming and aging processes, plays a critical role in enhancing product reliability and ensuring battery safety.

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Understand and Study Ageing and Battery lifetime

Batteries do not maintain their initial performance levels throughout their entire lifespan. Over time, various chemical and physical phenomena occur internally during repeated charge and discharge cycles, such as electrolyte degradation and separator clogging. These processes, collectively referred to as battery ageing, require thorough study and understanding to effectively manage battery lifespan and ensure consistent performance throughout usage. To reveal the mechanisms behind ageing, nm‑scale surface chemistry at the SEI and cathode interfaces is mapped by XPS using the AXIS Supra, volatile degradation products and off‑gases are identified by GC–MS with the GCMS-QP2020 NX, routine monitoring of solvents and degradants is streamlined on the Nexis GC-2030, and ionic species from salt hydrolysis and electrolyte breakdown (e.g., fluoride and phosphate) are quantified by ion chromatography with the HIC-ESP. By addressing these challenges with targeted analyses, manufacturers can optimise battery reliability and durability for long‑term applications.

Liquid Electrolyte Ageing

 

As a complex mixture in charge of the fundamental ionic transfer, liquid electrolyte ageing is one of the bigger contributor in the lose of performances of the battery cells, cycle after cycle. 

Degradation of the additive or the solvent can produce various species with a negative effect on the ionic conductivity or on the other cell parts like separator or electrodes. Moreover, electrolyte degradation can also produce gases which can cause major safety  issues for the cell. It is thus fundamental to monitor and identify degradation products and process inside the electrolyte.  

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Solution Highlights

Black Mass and Recycling

Shimadzu provides a wide range of analytical and measuring instruments tailored to lithium-Ion battery applications. These solutions support every stage of the battery lifecycle—from R&D and material characterization to quality control, degradation analysis, and the evaluation of recycled materials such as black mass. For electrolyte and salt studies, ion chromatography with the HIC-ESP quantifies anions, cations, and hydrolysis products, while non-destructive elemental profiling of powders, electrodes, and black mass is performed by the EDX-7200. Volatile solvents, off-gases, and degradation products are identified and quantified by single‑quadrupole GC–MS using the GCMS-QP2020 NX, with automated headspace sampling provided by the HS-20 NX series for robust, repeatable VOC analysis.

Driven by a commitment to sustainability, Shimadzu delivers integrated workflows that help customers optimise materials, improve product quality, and accelerate safe, efficient recycling—contributing to a more sustainable society in all aspects of lithium-Ion battery production and innovation.

Recycling of Lithium-Ion Battery

 

From a product life cycle perspective, lithium-Ion batteries are ideally reused or recycled to maximize their value and minimize environmental impact. Determining whether a battery is suitable for reuse requires a non-destructive inspection to assess its State of Health (SOH). This ensures that degraded batteries can operate safely if reused.

If a battery is too degraded for reuse, recycling becomes the optimal solution to recover high-value materials such as lithium (Li), cobalt (Co), and nickel (Ni). Required under European Regulation 2023/1542, lithium-Ion battery recycling is a complex process that involves treating the crushed remains of batteries, commonly referred to as "black mass."

Analyzing the composition of black mass is essential for assessing the quality of valuable metal powders extracted from used batteries and identifying any contaminants that could interfere with refining processes. This step is crucial for ensuring efficient material recovery and supporting sustainable battery production.

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Comprehensive Data and Tools for Lithium‑Ion Battery Lifecycle Management

The market for lithium-ion and all-solid-state batteries is poised for further expansion; however, achieving the required performance, safety enhancements, and stable mass production continues to pose significant challenges. This solutions guide offers analytical instruments and applications specifically designed for materials and manufacturing processes, assisting developers and manufacturers in addressing critical challenges in the development and production of lithium-ion batteries.

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