Coin Cell Batteries Factory

Project mission:
▪ Community service by creating job opportunities and providing a work environment for the
community, especially the unemployment category.
▪ Reducing imports, starting the manufacturing stage, and supporting the local market with the
product.
▪ Obtaining a high level of quality and distinction.
▪ Raising the level of the local economy from its lowest level until progress.
▪ Making deals with interested companies and entrepreneurs and specialists in this field.

Vision:
▪ Manufacturing such products is a unique investment and is not available locally
▪ Innovation, development and quality in manufacturing.
▪ Support ideas and actions that fall into our field.
▪ Distinguishing as the first local factory that produces all kinds of (button cell batteries) lithium
batteries.
▪ Continuous development of the manufactured product.

Objectives:
▪ creating job opportunities.
▪ Reaching a high level of quality and excellence in the field.

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 Location:
▪ Name of Factory: M&A for Coin Cell Batteries.Ltd
▪ Location: Yemen, Sana’a City -Hizaz. (78C2+V96 ‫ اليَ َمن‬،‫)بيت الحضرمي‬
▪ Latitude & Longitude lines: 15°16'19.8"N 44°18'03.2"E
▪ Distance: 202.14 m
▪ Google map link: https://goo.gl/maps/9YQc2rsnQv7M2Rij9
▪ Location photo by google:

Demonstration Overview:

The following demonstration involves the assembly, charging, and testing of five identical
rechargeable lithium-ion coin cells. Pictures of a coin cell battery constructed in this demonstration are
shown in Fig. S1 along with pictures of a commercially-available CR2032 coin cell battery.
Note: The traditional definition of anode and cathode change depending whether the battery is
being charged or discharged. The convention among battery chemists is to refer to the anode as the
electrode that is oxidized (loses electrons) upon discharge, which in this case is the graphite. The
cathode is the electrode that is reduced (gains electrons) upon discharge, which in this case is the
manganese oxide).

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 Figure 1: Coin Cells Battery Sides

The battery contains seven components including the cathode and anode caps of the cell case,
a stainless-steel spring, stainless steel spacer, lithium manganese oxide cathode with steel mesh current
collector, glass fiber separator, and a graphite anode with steel mesh current collector (Fig S2). The
electrolyte (not shown) comprises 0.1 M {lithium tri-fluoro-methane-sulfonate} (LiO3SCF3, lithium
triflate) in propylene carbonate solvent. Each of the components and electrolyte can be prepared prior
to the demonstration. For the demonstration, the components are assembled in the correct order and
the cell case is sealed in a coin cell hydraulic crimper. The battery is then placed in a USB-powered
coin cell charger. The battery takes approximately 20 seconds to charge, which is indicated by the light
of the charger turning from red to green. The coin cell is then placed into a LED tea candle, which
operates for approximately 90 seconds. The charging procedure can be repeated several times.

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 Figure 2: Coin cell battery parts (from top to bottom)

Figure 2: a. Picture of battery components before assembly (top to bottom: cathode cap,
spring, spacer, cathode, separator, anode, anode cap with gasket). b. Diagram showing the
order of assembly, starting with the bottom.

Pre-Demonstration Preparation:
The battery components require approximately one hour of preparation time and
should be completed the day prior to the demonstration in order to adequately heat and dry the
electrodes. Table 1 lists the required materials, equipment and chemicals for the demonstration.
The most expensive component is the hydraulic crimping press by a significant margin, but
may be available to loan from a local university research lab. The other materials and chemicals
are relatively inexpensive and result in a marginal cost of approximately $5 per battery.

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Table 1: Office Requirements & Utilities, Required Materials, Equipment, and Chemicals

Office Requirements & Numbers & Other Details Cost (Approx.)

Utilities
• Desktops. $300
• Tables and Chairs. $200
• Furniture (doors, sofa, box, $4200
windows and etc.)
• Internet (wi-fi – Ethernet). • Router , modems , cables and $600
etc…
• Cars and Vans for products • 2 by 2 $7500
transporting.
• Laptops. $1700
• Cameras.
• Other utilities (T-shirt, $100
medical mask & gloves and
etc.)
•

Equipment Part Number Cost (Approx.)

• Hydraulic Crimper • MSK-110 $3,398

• Multimeter • AstroAI Digital $10.99
• Rechargeable USB charger • Zackees Coin Cell $19.95
Charger
• Balance
• Glass vials for mixing
• Metal spatula
• Tweezers
• Pipettes
• Scissors
• Hotplate or oven
• Stopwatch
Materials Part Number Cost (Approx.)
• CR2032 Coin Cell Cases EQ-CR2032-CASE-304-LD $195 per 100
• Steel Spring EQ-CR20Be-Spring $40 per 100
• Steel Spacer EQ-CR20-Spacer-05 $59 per 100
• Wire Cloth 200 Mesh 3GNX5 $66 per 16 sq. ft.
• Glass Fiber Filters 28297-978 $36.88 per 100
• Flameless LED Tea Lights Vivii Battery-powered LED $12.99 per 36

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 Chemicals Part Number Cost (Approx.)
• Conductive Graphite Powder EQ-Lib-CGP $60 per 80 g
• LiMn O cathode powder EQ-Lib-LMO $119 PER 200 g
2 4
• PTFE Liquid binder EQ-Lib-PTFE $190 per 360 g
• CF3SO3Li Electrolyte 481548-5G $43 per 5 g
• Propylene carbonate, 310328-100ML $56 per 100 mL
anhydr.

• Details of Table.1 & Vendor data sources:

1. MTI: MTI Corporation, www.mtixtl.com
2. Amazon: Amazon.com, Inc., www.amazon.com
3. Grainger: W.W. Grainger, Inc., www.grainger.com
4. VWR: VWR International, LLC. www.vwr.com
5. Aldrich: Millipore Sigma, www.sigmaaldrich.com

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 Product

Start-up of Coin cell batteries production:

▪ After purchasing tools, machines, equipment, chemicals, office supplies, electrical works, etc.,
which shown in (Table.1 above). The primary stage for manufacturing and producing batteries
begins, learning how to produce them, and knowledge of machines and their uses through the
stage of starting the manufacture of batteries until the stage of providing them in the local
market and starting the process of selling them, all of which will also be explained in detail
here.

▪ We will explain and explain how batteries are made in two ways:

I. The first is the traditional method in a simplified way, but there will be a slowdown in the production
process of the final product and also in the number of the final product.

II. The second is the modern method in a simplified, modern, efficient and high-quality manner that appears
in the final product and also in large quantities, unlike the traditional method. ( The main method of research
and we will go into it in detail and accurately).

First: The Traditional method

▪ First Stage:
I. Preparation of Current Collectors

• Stainless steel mesh current collectors are prepared by cutting stainless steel mesh (#200 threads per
inch) into ten squares (two per battery), each square 10 mm by 10 mm, with a pair of scissors.

• Preparation of Anode

▪ The anode is composed of an aqueous slurry of graphite and PTFE (i.e., Teflon) that is spread onto a
piece of stainless-steel mesh and dried overnight. The anode material was made by combining 0.9 g of
graphite powder with 0.1 g of PTFE binder in a glass vial. 1–3 mL of water is added in small increments
to the anode powder and mixed with a spatula to form a uniform paste with a consistency of toothpaste.

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 ▪ A pea-sized amount of the anode paste is spread on one-piece stainless-steel mesh current collector
(Figure 3) with a spatula. The anode is labeled and dried overnight at 150 °C, either in an oven or by
placement on a hot plate (Figure 4).

Figure 3: Spreading the anode slurry onto the stainless-steel mesh current collector.

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 Figure 4:The electrodes can be dried overnight by Hotplate device.

▪ Second Stage:
• Preparation of Cathode
▪ The cathode is composed of an aqueous slurry of lithium manganese oxide, graphite powder, and PTFE
binder that is spread onto a piece of stainless-steel mesh and dried overnight. The cathode material is made
by combining 0.6 g of lithium manganese oxide (LiMn2O4) with 0.3 g of graphite powder and 0.1 g of PTFE
binder. 1–3 mL of water is added in small increments to the cathode powder and mixed with a spatula to
form a uniform paste with a consistency of toothpaste.
▪ A pea-sized amount of the cathode paste is spread on one-piece stainless-steel mesh current collector with a
spatula. The cathode is labeled and dried overnight at 150 °C, either in an oven or by placing them on a hot
plate. Make sure to allow the electrodes to completely cool before beginning the demonstration.

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 • Electrolyte & Separator Preparation
▪ To create the 0.1 M lithium triflate electrolyte solution, 234 mg of lithium tri-fluor-methane-sulfonate
(LiO SCF ) is dissolved in 15 mL of propylene carbonate. The separator is made by cutting glass microfiber
3 3

filter paper in circles of 19 mm diameter. 5 mL of electrolyte should be added to the separators and left to
soak for at least an hour.

• Demonstration
▪ The demonstration consists of the assembly of the battery components according to Figure 2, sealing the
battery in a hydraulic crimper, charging the battery in a USB charger, and testing the battery in an LED tea
light.

• Battery Assembly and Crimping

▪ The anode cap with attached gasket is placed on the benchtop and the anode is placed inside of the anode cap
with active material facing up (steel mesh facing down). A few drops of electrolyte should be added into the
anode cap. The separator, now soaked with electrolyte, should be carefully removed from the electrolyte and
placed on top of the anode with tweezers. Next, the cathode is placed such that the active material faces the
separator and the stainless-steel current collector faces up. Next, the spacer is placed on top, taking care to
make sure that the separator is visible completely around the spacer. A small amount of pressure can be
applied to the spacer to compress the above components into the anode cap. The conical spring is the placed
on the spacer (wider side down) and a few more drops of electrolyte added over the spring to completely
saturate the cell. Finally, the larger cathode cap is placed on top, covering the battery, and all of the
components are gently pressed together.
▪ The battery is carefully removed from the benchtop and placed into the crimping die of the hydraulic press,
with the anode cap face up. The hydraulic valve is rotated to the lock position and the handle is pumped to
raise the coin cell into the die. The handle is manually pumped until a pressure of 500–700 psi is achieved.
The hydraulic valve is then rotated to the unlocked position and the battery is removed from the crimping
die. The battery is now sealed should be blotted with a towel and rinsed with water to remove any electrolyte
that may have leaked.

• Charging and Testing the Battery

▪ The battery is then placed into the USB-powered coin cell charger and the charging time recorded with a
stopwatch. Charging is complete when the LED light on the charger changes from red to green (Supporting
Information video of coin cell assembly). This process should take approximately 15–20 seconds. If the
battery does not charge properly, the battery can be put aside to rest for a few minutes; it is possible that

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 additional time is required for the electrolyte to wet the electrodes. Once charged, the battery voltage can be
tested with a multimeter. It should read about 3 Volts.
▪ The charged battery is then placed into the battery compartment of the LED tea light. The light is
switched on and the total illumination time is recorded with a stopwatch. We have found it is better
to use a flickering, dimmable tea candle, as it does not have a sharp cut-off, but fades somewhat
over time before the battery is fully discharged. The final battery voltage can be read after the tea
light shuts off. It is typically around 1.8 Volts. The process is repeated for several cycles, recording
the charge/discharge time and voltages for each cycle.

• Alternative Materials and Equipment

▪ Other cathode materials might be tested including lithium cobalt oxide (LiCoO2) or NMC
(LiNixMnyCozO2), which could give different voltages and different capacities. The electrolyte
was chosen because lithium triflate does not release hydrofluoric acid upon contact with water or
moist air. Propylene carbonate was chosen for its low toxicity, low flammability, and low volatility
(boiling point = 242 °C). Stainless steel mesh (SAE 304 steel, 200 wires per inch) is used as the
current collector. This mesh size is convenient as it can be cut with ordinary scissors. Thicker or
thinner mesh can be used, but wire cutters may be necessary to shape the electrodes. Circles can be
cut out instead of squares, as shown above. While this is slightly more difficult, the increased
surface area of the circle should increase the capacity by allowing more electrode material to be
added. The USB-powered battery charger used was a Zackees LIR2032, which retails for around
$20. Any similar such device designed to recharge 2032 batteries should suffice. The batteries
should be capable of powering a range of devices, if only for a short time. We chose to use an
inexpensive LED tea candle. The candles mimicked a traditional wax candle by flickering. The
most expensive component of the demonstration is the hydraulic battery crimper. We are currently
investigating cheaper methods to seal the battery.

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 ▪ Quantitative Analysis
Electrochemistry
Note: The traditional definition of anode and cathode change depending whether the battery is
being charged or discharged. The convention among battery chemists is to refer to the anode as the
electrode that is oxidized (loses electrons) upon discharge, which in this case is the graphite. The
cathode is the electrode that is reduced (gains electrons) upon discharge, which in this case is the
manganese oxide).
The battery is charged by removing electrons from the LiMn2O4 cathode (oxidation) and adding
them to the graphite anode (reduction). These processes are described by the following redox half
reactions:

▪ As the battery charges, lithium ions leave the LiMn2O4 and move into the electrolyte, travel
through the separator, and become intercalated in the graphite. Upon discharge, the reaction
flips. Lithium ions leave the graphite, pass through the separator once again, and intercalate
back into the manganese oxide to produce LiMn2O4. A detailed explanation of lithium-ion
battery electrochemistry can be found in an article by Richard S. Treptow1.

▪ Capacity
▪ After measuring the charging and discharging times with a stopwatch and voltages with
the multimeter for several cycles, the data can be used to quantitatively, albeit roughly,
estimate the capacity and efficiency of the battery. The battery typically behaves very
differently during first charge cycle due to side reactions within the cell. For the following
analysis, it is better to use data from the second cycle onward.
▪ The 2032 battery charger should indicate the charging current. If not, the multimeter can
be used to measure the current by connecting it in series between the battery and the leads
of the LED. This approach can also be used to approximate current draw of the LED tea
light. The charge and discharge stopwatch times can be converted to hours and then
multiplied by their respective currents to give a capacity in milliamp hours (mAh). An
example of this calculation follows. For our unit, the USB-powered 2032 charger is rated
to supply 40 mA to the battery. For one of the batteries we tested, it charged for 14 seconds,
giving a charging capacity of 560 milliamp-seconds, or 0.156 mAh. The battery was then
discharged for 80 seconds at a rate of 6.2 mA, giving a discharge capacity of 0.138 mAh.
The ratio of these numbers (0.138/0.156) gives 88.5% coulombic efficiency.

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 Next, a simple charge-discharge plot can be constructed using the voltages measured for the
battery before and after charging and discharging. The charging curve is made by plotting the voltage
before charging and the voltage at the fully charged capacity. The discharge curve is similarly made by
plotting the voltage before and after discharge.
If one would like to determine the specific capacity of the batteries, the finished battery should be
weighed. The capacity found with the stopwatch can be divided by the battery’s mass to determine the
specific capacity, in mAh/g.
Before charging, this battery was measured with the multimeter to have a potential of 1.15 V,
which rose to 2.87 V after charging. Using the multimeter, the tea-candle was measured to draw an
average of 6.2 mA from the 2032 battery. The tea candle remained visibly lit for about 80 seconds,
indicating a discharge capacity of about 0.138 mAh. After this discharge, the voltage was measured to be
1.85 V. This data is plotted on the chart below.
One can also determine the total energy capacity, in mWh, of the battery. First, charge and
discharge the battery three times to calculate an average discharge time. Discharge again for half of the
average discharge time, and measure the voltage. This will be the voltage of the battery at approximately
50% state of charge. Multiply this voltage by the mAh capacity found earlier to obtain the energy of the
battery. For example, our battery discharged for 80 seconds and maintained a voltage of 2.4 Volts after 40
seconds our energy. Thus, we calculate the energy capacity is 0.138 mAh × 2.4 V = 0.331 mWh.

▪ 0.138 𝑚𝑚𝑚𝑚ℎ ×2.4 𝑉𝑉=0.331 𝑚𝑚𝑚𝑚ℎ

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 Figure 5: Battery voltage before and after charging

▪ In Figure 5 explain the charging line (blue) shows an upward slope as the voltage increases as the
state of charge of the battery increases. The discharge line has a downward slope indicating that
the voltage decreases as the battery is discharged. The difference in capacity between the charge
and discharge curve indicates the loss of charge upon cycling.

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 Second: The Modern method

▪ Block Diagram of the method: It shows the stages of the production and manufacturing process of
batteries using modern machines, starting from the formation and mixing of chemicals until the
stage of testing the final product to obtain high quality and efficiency, then the stage of packaging
and providing them in the local market

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 ▪ Basic Equipment for Coin cell Battery

▪ Showing the Technical Tools & Equipments in Coin Cell Battery Production

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 ▪ Our main Method of Production Process is “Modern Method “ .We well explain in details the
whole process from A-Z in Theoretical, practical, technical, technical, financial and marketing. It
will all be explained step by step.

Production Processes of the product:

1. Battery Powder Processing: kick off preparing Li-ion battery cathode materials with
conductive coatings, such as LiFePO3, LiMnNiO3, and rotating CVD for Si/C anode
materials by using a two zones rotary tube furnace machine which designed for calcining
inorganic compound with better uniformity.

Figure 6:Two Zone Rotary CVD Tube Furnace 1200℃ Max.

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 2. Ball Milling: is a compact high-speed ball mill with 3D movement for making the small
quantity of samples at easy and fast. It has higher impact energy created by rotation,
vibration, and oscillation with frequency up to 1200RPM with a two-year warranty. They
can be used in either dry or wet methods to mill materials and mix all kinds of solids,
suspended liquids, and pastes with different sizes and materials. Two milling jars (SS and
Nylon) are included for the use of most of the materials. It is an ideal choice to make small
quantity samples in material and chemical research laboratories.

3. Slurry Vacuum Mixing: To provides more uniform slurry mixing. the dual shaft mixer
comes with three segments programmable mixing speed from 0 - 600 rpm, it has a built-in
pump for removing the gas bubble, which can vacuum the mixing container to -0.08 MPa.
is a high-quality mixer tool for preparing battery electrode paste and various ceramic
materials in a research lab. (Heating container is optional up to 200 Co).

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 4. Coating and Drying: Compact Tape Casting Film Coater with Dryer, Vacuum Chuck &
Adjustable Film Applicator110 V, by using a unique driving system to produce a smooth
coating on all types of materials. The flat vacuum chuck is built in to hold the substrate
sheet in place. One 100 mm width adjustable micrometer applicator (doctor-blade). The
heating plate with the digital controller either on top or bottom is optional for drying up to
100 °C with +/-1°C temperature accuracy. This equipment can be used by researchers on
ceramic tape castings and Li-Ion battery electrode coating.

5. Calendaring and Pressing: to achieve better heating uniformity and control accuracy by
using a hot rolling press with maximum working temp. up to 120C. The temperature of
two rollers is individually controlled by two PID temp. controllers. This tool is ideal for
calendaring battery electrodes, plastics media, and soft metal foils... Typical usage is to
increase material density and achieve better surface quality.

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 6. Drying: provides optimal uniformity and conserves chamber space for drying, curing,
vacuum embedding, and plating applications. 3" (7.6 cm) glass wool insulation prevents
heat loss from working chamber. Silicone door gasket and positive latch door maintain seal
at all vacuum levels. Exclusive polycarbonate safety shield protects door glass.

7. Disc Cutting: for cutting round discs of battery electrodes and separator film (<30um) by
using a compact disc cutter with quality sliding rail with ball bearing for precision cutting.
It can be easily placed into a glove box with a transition chamber diameter larger than
230mm. The resulting discs can be used as electrode/separator discs of the split test cell
and coin cell for battery researchers as well as TEM sample preparation.

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 8. Glove Box: is a stainless-steel glove box with the hinged type of front door designed for
much easy loading and unloading device into the glove-box. The purification cylinder is
made of BASF R3-11 Copper Catalyst and Lindy Molecular Sieve in order to achieve a
low water and oxygen concentration of lower than 1 ppm, such that experiments can be
conducted in an ultra-clean and highly purified gas environment. It is integrated with a
vapor pressure control system, purity control system, automatic gas purity regeneration
control system, and system data log recording. EQ-VGB-6 is widely used in preparing
nanomaterials, Li-ion battery materials, catalysts, and metalorganics.

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 9. Electrolyte Injection: is the new generation bottle top burette & dispenser from BRAND-
Tech. It has a number of innovative features and upgrades for performing more accurate
and convenient titrations. It is an excellent tool as an electrolyte dispenser; dispensing up
to 50mL per batch for Lithium-Ion Battery manufacturing.

10. Coin Cell Sealing: is a compact crimper driven by compressed inert gas or air for various types
of coin cells such as CR2016, CR2025, and CR2032. It provides more accurate pressure control to
achieve high-quality crimping with better consistency, repeatability, and faster speed. Such a device
is 1000 grade cleanroom compatible and it will satisfy the most demanding battery assembling
environment. In contrast to the hydraulic crimper, a gas-driven crimper is not going to contaminate
the glove box or cleanroom.

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 11. Cell Testing: is an eight-channel battery analyzer to analyze small coin cells and
cylindrical batteries from 0.005 mA to 1 mA, up to 5V, with gold-plated pins for the best
connection. Each channel of the analyzer has independent constant-current and constant-
voltage source, which can be programmed and controlled by computer software. This
system provides most applications in battery testing fields such as electrode materials
research, battery performance test, small-scale battery formation, capability grading,
battery pack testing.

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 Marketing & Pricing:

Marketing & Pricing Strategies:

▪ Summary: Targeting the local market and trading companies through wholesale and retail sales.
By making commercial partnership contracts with franchises so that any country can enter the
market and acquire local partners and customers through this, the factory will have a strong
commercial reputation and reputation. Actually, at the beginning of any commercial project, there
must be financial spending that is subject to loss without compensation, but this improves with a
period of time, such as a year or more, in order to obtain a financial return equivalent to even in a
simple way the spending. After that, the financial situation of the factory is improved through the
efficiency of the product, the quality and the plan of the monetary value of the product by making
a good financial and pricing plan suitable for the local market prices and creating commercial and
marketing competition with competitors.
▪ Our goal in marketing plan is to using the role of “be the low-cost producer in the industry or market
segment”, using it have a good benefit such as (reaching buyers who buy on basis of price) and price
floor.
▪ Accomplish seller’s note such as (get the highest price for the factory, avoid unreasonable contract
terms that limit future opportunities).
▪ Maximize of cash from the deal.
▪ Confirmation that the customer will be our preferred customer through the continuity of the
commercial relationship and financial transactions with us in the future.
▪ Building a competitive edge by:
o Branding.
o Embrace social marketing (start a blog, online video, Ads, host a special event).
▪ Important Key words:
o Respond quickly & publicly.
o Avoid defensive tone when faced.
o Create a database of complaints and suggestions
o Responsibility.
▪ Emphasis on speed by:
o Speed products to local market.
o reduce customer response time in delivery.

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 ▪ Using internet by creating website with online services, intelligent user interface and mobile apps.
▪ Communication with partner and customers with emails.
▪ Improve staff experiences by trainings, establishments of an accounting system.
▪ Provide financial permits for staff through rating of their performance.
▪ Provide promotions and job grades for staff by experience and job performance and
accomplishment of required tasks.
▪ Advertising campaigns in social networking platforms, Media & television platforms, via websites
and also carrying offshore market offers for our customers unevenly.

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 Pricing

Total operating and financial expenses:

Items Unit Quantity Size Price in $

Coin cell batteries 1 1 large 1.3$
(ready to export to local 1 1 Medium 0.9$
market)
1 1 Small 0.65 $
1 Case (contain 6 2 per size (L, M, S) L, M, S 17.1$
batteries)

1 packet (contain 60 360 per packet All sizes 1026$

cases)

10 packets (600 Produce 10 Packets All sizes 10260$ per day

cases) per day
Office’s utilities 17600$
Lunch website, 17900$
mobile apps and
accounting system
Equipment, tools, 46300$
chemical materials
Location, 57600$
construction m etc
Salary of staffs Every month 17 employees 6850$
Tax Per year 6700$
operating expenses Per month 1200$
Start-up fund 30000$
Partner 1 12000$
Partner 2 11000$
Partner 3 9500$
Partner 4 18000$
End fund 80500$
Total = $325,410$

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Pivot Chart:

1%
Estimated Cost
coin cell batteries ( 10 packets
3% per daily )
3%
7% Office's utilities

9% Lunch website, mobile apps and

accounting system
Equipment, tools, chemical
materials
Location, construction m etc

1% Salary of staffs

5% Start-up fund

50% Partner 1,2,3,4

8% End fund

Total
13%

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