Coating electrodes with battery slurries requires tight control of slurry consistency. This is important in both the mixing and the coating processes, for both anode and cathode slurries. The highly non-newtonian rheology of these slurries makes inline measurement and control necessary for getting consistent and reliable coatings, since laboratory analysis of samples pulled from the coating line do not necessarily mirror the properties of the slurries during the coating process. The interval between sampling and laboratory report makes it difficult to correct process deviations without risking substantial waste of costly materials. Rheonics SRV and SRD viscosity and density sensors have proven reliable instruments for continuous inline monitoring of battery slurry consistency in both anode and cathode slurries. Field studies have explored laboratory and in-line measurements and determined that inline measurements can more quickly detect viscosity changes to the battery slurries. More importantly, the in-line measurements correlate well with the actual performance of the slurries during the coating process.

The sensors are compact and therefore substantially non-intrusive in the electrode coating lines, allowing easy installation in operators’ process lines with only minimal modifications. This opens a path toward full automation of the coating process. Realtime measurements from Rheonics SRV and SRD can be used in predictive controllers to stabilize slurry consistency during the coating process, helping battery manufacturers maintain control of slurry density and viscosity. This can ensure uniform electrode fabrication, reduce waste, and support scalable, high-performance battery production.

• Inline viscosity and density monitoring enables real-time control of battery slurry quality.
• Laboratory measurements often fail to capture true process behavior in coating lines.
• Rheonics SRV and SRD sensors provide fast, accurate, and reliable inline data.
• Compact, non-intrusive sensor design allows easy retrofit in coating systems.
• Real-time control supports automation, reduces waste, and improves electrode consistency.