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  4. Powder Rheological Characterization of Battery Powders

Powder Rheological Characterization of Battery Powders

Dry battery electrode (DBE) processing offers energy, environmental, cost, and performance advantages over solvent-based coating. This study applied powder rheology to characterize graphite–carbon black–PTFE anode mixtures and developed a method to monitor PTFE fibrillation. Rheological measurements successfully predicted powder behaviour throughout DBE processing, with higher PTFE contents reducing segregation and improving flowability. Temperature-controlled wall friction measurements showed a sharp increase in shear stress above PTFE’s crystalline transition temperature, correlating with fibrillation observed by scanning electron microscopy. The approach supports process optimization and fibrillation characterization.

Key learnings:

  • Powder rheology predicts DBE processability: Established rheological methods effectively characterized powder behaviour across different DBE process stages
  • PTFE content influences powder behaviour: Increasing PTFE content reduced segregation and improved flowability, supporting higher binder contents for process stability
  • Fibrillation can be quantified rheologically: Temperature-controlled wall friction measurements identified a clear shear-stress increase associated with PTFE fibrillation, validated by SEM observations
     

Dr Kartik Pondicherry (Dil: English)
Kartik Pondicherry

Dr. Pondicherry is a business and technology professional associated with Anton Paar for over 13 years. With a background in engineering and a PhD in Materials Science (Tribology), he is involved in bridging technical innovation with strategic business development in the field of Rheology and Tribology. Over the course of his career, he has supported initiatives that strengthen Anton Paar’s position in industries such as pharmaceuticals, chemicals, and food science. He is active in the scientific communities and has authored several white papers on innovative test methodologies and has also presented several invited and keynote lectures at international conferences.

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