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Manufacturing Process

Jonathan Huang, Scott Lee, Ankit Sharma, and David Sung

Silicon Graphite Anodes for Lithium-Ion Batteries

  • In order for the automotive industry to transition from diesel fuel to electric for a more sustainable future, we must develop a rechargeable lithium ion battery with a high enough capacity for long-range travel
  • Our company FARADAY uses patented silicon-graphite technology to produce state-of-the-art EV batteries with longer mileage and lower cost
  • Production Target: 250,000 battery packs per year

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Battery Storage (kWh)

76

75

Vehicle Range (mi)

355

350

Battery Pack Weight (kg)

364

480

Battery Pack Cost ($)

$9,476

$12,000

Energy Cost ($/kWh)

$125

$160

Energy Capacity (Wh/kg)

209

156

Targeted price per battery pack: $9,476.60

Yearly profitability: $52,750,000

  1. Mixing: Active material, binders, additives, and solvent are mixed to make an anode and cathode slurry
  2. Coating: Slurries are coated onto copper and aluminum foil, respectively
  3. Drying: Coated foils are dried to remove remaining solvent
  4. Calendering: Dry foils are compressed, cleaned, and statically discharged
  5. Slitting: Anode and cathode foils are cut into smaller rolls for individual cells
  6. Vacuum Drying: Rolls are dried one final time to remove liquid impurities

**The negative and positive electrodes are then assembled into cell batteries

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F A R A D A Y

Future Works

F A R A D A Y

  • With our patented silicon-based battery, we developed a lighter and cheaper EV battery that directly competes with Tesla

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Mixing

Coating

Drying

Calendering

Slitting

Vacuum Drying

Cell Assembly (stacking, packaging...)

Cell Finishing (roll pressing, degassing...)

Electrode

Manufacturing

  • Although silicon is known to have a high energy density, it is very susceptible to degradation. Silicon expands up to 4x its original size when fully charged, causing stress and degradation of the anode material
  • Our R&D team has created a Silicon-Graphite composite with a high energy density that maintains integrity over multiple charging cycles.

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Objective and Production Target

Competitor Analysis

Our Technology

Cost Analysis

  • In order for EV to compete with and overtake diesel in the automotive industry, battery technology must push through the $100/kWh barrier
  • We are looking into redesigning our battery to pack more fuel cells and increase silicon concentration in order to achieve the $100/kWh benchmark