Battery Electrode Optimization Services

Enhance your battery electrode processes with our elegant solutions, focusing on coating process optimization and tailored consulting services.

About Maki LLC Consulting

Two men in a factory discussing work near industrial machines.

Our Expertise

With 30 years of engineering experience, Maki LLC specializes in battery electrode processes, focusing on process development and optimization. Our consulting services emphasize coating process optimization, as well as mixing and drying processes to enhance efficiency and productivity.

Our Services

Core Services:

Mixing, Coating, and Drying Process Optimization: Enhance the efficiency and quality of your battery electrode processes with our expert analysis and recommendations focused on coating process optimization.

R&D Support: Leverage our extensive research and development experience to innovate and improve your products.

Capital Equipment Design: Benefit from our expertise in designing and optimizing capital equipment specifically for coating applications.

Problem-Solving Consulting: Address and resolve complex coating challenges with our tailored consulting services and expert guidance.

Training: Provide training on mixing, coating, and drying technologies.

IP Research and Review: Conduct thorough IP research and review.

IP Strategy and FTO Analysis: Develop effective IP strategies and perform freedom to operate analysis.

Brief list of key accompliSHMENTS

Equipment/Process Improvements

Novel mechanical and process improvements for mixing and coating operations.

a. Developed a low-cost flushed mechanical seal for a Henschel (Zeppelin) FM-10 mixer that utilized the mix process fluid as the flushing agent to eliminate cross-contamination. This innovative design, which integrates battery electrode processes, ensured that the seal leakage rate was engineered for consistent mix solids content. The incorporation of coating process optimization techniques led to a significant increase in mechanical seal life, extending it from just 1 month to over 1 year, showcasing the effectiveness of our consulting services in enhancing industrial applications.

b. Developed an optimized slot die lip geometry and vacuum box process for coating a highly filled static-dissipative adhesive on a tamper evident label stock for a large consumer mobile phone manufacturer. The improvement increased yields from 70% to over 90% by reducing the defect rate for the adhesive coating step.

Experimental Design and Analysis

Executed hundreds of designed experiments to solve process problems and optimize battery electrode processes, including mixing, coating process optimization, and drying processes. A couple of highlighted examples:

a. Response surface design revealed a saddle point in process conditions that enabled a coating speed from 180 fpm to 300 fpm.

b. A factorial experiment determined not only the root cause for drying process instability and failure points but also provided a working operational theory for the dryer function. This was a roll-supported dryer with air temperature controlled by dampers blending hot and cold air to achieve and maintain optimal drying. Airflow through the dryer was not controlled automatically, but was a side effect of reaching the desired temperature.

c. A series of factorial experiments enabled the development and process mapping of a novel intermittent coating process, showcasing our consulting services in advancing manufacturing techniques.

IP and IP Strategy

Developed novel intellectual property for coating, drying, and web stabilization, with a focus on battery electrode processes.

a. Conducted an intermittent coating IP review and analysis that led to innovative IP on a coating process optimization.

b. Carried out an IP review and analysis that resulted in patents for web stabilization improvements specifically for TWOSD (tensioned-web-over-slot-die) coating.

c. Performed IP review and mapping for strategy development and planning, enhancing our consulting services.

Battery Electrode Optimization Services