Solid state batteries (SSB) are considered a promising future technology in the field of energy storage. In contrast to conventional lithium-ion batteries, they use solid materials instead of liquid electrolytes, which can lead to a higher energy density, improved safety and a longer lifetime. To this end, a jet-based direct mixing process in the gas phase for mixing, coating and agglomeration of cathode materials for SSB was proposed and realised to improve the homogeneity and electrochemical properties of the battery materials. In the method used, the various particle systems lithium iron phosphate (LFP), carbon black (CB) and lithium halide (LIC) are dispersed in the gas phase. The materials are then brought together as particle-laden aerosol jets in a turbulent mixing zone in which the different primary particles can interact with each other and form hetero-agglomerates. The microstructures produced in the process are analysed using scanning electron microscopy in combination with focused ion beam (SEM-FIB) and the resulting material functions are characterised by measuring the electrochemical properties (e.g. electronic/ionic conductivity, specific capacity). Furthermore, a laser light diffractor and a cascade impactor are used to determine the particle size distribution (PSD) of the materials. In addition, the gas phase process is analysed using a CFD/DEM approach in order to investigate process details that are not accessible experimentally using numerical simulations.

In experimental work, the influence of various process parameters on the mixing and structuring of the cathode material is investigated to optimise the existing process and finally to link ...