Why Is The Granulation Of Active Powders Necessary Before Pressing Battery Green Bodies? Ensure Structural Integrity

Granulation is a critical preprocessing step that transforms loose active powders into a cohesive state by introducing organic binders, such as polyvinyl alcohol (PVA). This process is strictly necessary to optimize the powder's flowability for even mold filling and to significantly strengthen the inter-particle bonding force. Without granulation, the pressed "green body" remains fragile and prone to cracking during demolding, handling, or subsequent sintering.

While laboratory presses apply high pressure to reduce voids, they cannot correct inherent powder flow issues; granulation ensures the structural integrity and uniform density required to prevent catastrophic defects like warping and cracking.

The Mechanics of Powder Stabilization

Improving Flowability and Mold Filling

Raw active powders often possess poor flow characteristics, making it difficult to fill a pressing die evenly. Granulation adds specific proportions of binders to modify the surface properties of the powder.

This modification improves flowability, ensuring the powder distributes itself widely and evenly within the mold. Uniform filling is the foundational step for achieving a consistent battery cell structure.

Strengthening Particle Bonding

When creating a green body, the particles must adhere to one another to form a solid shape before the final sintering phase.

Granulation increases the bonding force between these particles. This internal adhesion is essential to withstand the mechanical stresses applied during the compaction process.

Preventing Structural Defects

Eliminating Demolding Cracks

The process of ejecting a compacted green body from a die subjects the material to significant physical stress.

Because granulation strengthens the internal bonding of the compact, it significantly reduces the risk of cracking during this demolding stage. It creates a robust structure that can be handled and transferred without falling apart.

Ensuring Uniform Density

Inconsistent density within a pressed pellet leads to unpredictable behavior during thermal processing.

Granulated powders compress more evenly, resulting in a uniform density distribution throughout the green body. This uniformity is crucial for preventing warping or deformation when the material is eventually sintered.

Understanding the Trade-offs

The Necessity of Binder Removal

While organic binders like PVA are essential for structural integrity during pressing, they are not active battery components.

These binders must be fully burned off during the sintering process. Incomplete removal can leave residues that hinder the electrochemical performance of the solid-state battery.

Increased Process Complexity

Granulation adds a distinct variable to the manufacturing workflow.

You must precisely calculate the proportion of binder; too little results in cracks, while too much can reduce the overall density of active material or complicate the debinding process.

Making the Right Choice for Your Goal

To optimize your solid-state battery assembly, assess your specific manufacturing priorities:

If your primary focus is Structural Yield: Prioritize optimizing the binder ratio to maximize bonding force, ensuring green bodies survive demolding without cracks.
If your primary focus is Dimensional Accuracy: Focus on the granulation process to improve flowability, which ensures uniform density and prevents warping after sintering.

Mastering granulation ensures your high-pressure pressing results in a viable, defect-free battery cell.

Summary Table:

Feature	Impact of Granulation	Benefit for Battery Green Bodies
Powder Flow	High (using binders like PVA)	Ensures even mold filling and consistent density
Inter-particle Bonding	Increased bonding force	Prevents cracking and breakage during demolding
Structural Stability	Enhanced structural integrity	Prevents warping and deformation during sintering
Handling Durability	Robust green body state	Facilitates safe transfer and processing

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References

Derrick Shieh, Maw‐Kuen Wu. Preparation of all solid-state electrolyte lithium ion batteries by multi-layer co-fired process. DOI: 10.2298/pac2501094s

This article is also based on technical information from Kintek Press Knowledge Base .