Jonathan Bernecker, M.Sc.

  • 76131 Karlsruhe
    Kaiserstraße 12

Jonathan Bernecker, M. Sc.

Area of Research:

  • Battery Produktion: Calendering of electrodes

General Tasks:


  • Sustainable production of electrodes for lithium-ion battery cells for the future mobility

Test benches:

  • Calendar (

Curriculum Vitae:

since 06/2021

Research Associate at the Institute of Production Science (wbk) at Karlsruhe Institute of Technology (KIT)

10/2018 - 06/2021

Study of Mechanical Engineering (M.Sc.) at Karlsruhe Institute of Technology (KIT)

10/2014 - 09/2018 

Study of Mechanical Engineering (B.Sc.) at Karlsruhe Institute of Technology (KIT)


[ 1 ] Bold, B.; Weinmann, H.; Bernecker, J. & Fleischer, J. (2019), "Identifying the Impact of Calendering on Subsequent Processes Using a New Approach to Quality Assurance". Advanced Battery Power 2019, eds. Haus der Technik e.v., pp. 1.
Electric mobility is of core importance for the German automotive industry. The development of the German economy strongly depends on activities in battery production and on their integration into the process chain - from material to final battery system. On the one hand, further development of the material systems is necessary and on the other hand, progress is needed in production. Both aspects influence the energy density of the battery cell and thus determine the range of electrically driven vehicles or the available capacity for stationary applications. The aim of a high energy density can be achieved by finding the ideal material composition or by using the right manufacturing process. The decisive process step is calendering, in which the volumetric energy density is increased by compressing the active material. Residual stresses are induced into the material, which become visible at high densities through wrinkling at the boundary between the coated and uncoated areas. The characteristics of the wrinkles allow a conclusion to be drawn about the strength of the residual stresses. These effects in the electrode constitute a hindrance for further process steps and thus prevents the maximum possible density. In the single sheet stacking process, this is expressed through the tolerance of dimensional accuracy. Due to excessive residual stresses, the shape can no longer be guaranteed after cutting. First, the poster presents results that show which deviation is to be expected at what calendering degrees. Investigations into the cause of wrinkle formation are to be carried out by detecting the residual stresses induced. The residual stresses are determined by recording the distortions of the material. For this purpose, a pattern is printed on the electrode before calendering. A picture is taken before and after calendering, allowing the strain of the electrode to be known through the displacement of the color points. Therefore, results are presented which show the material behavior for different parameter settings at the calender for high volumetric densities. The described undertaking reveals which calender parameter is responsible for the wrinkle development. This in-line quality assurance forms the basis for modelling the relationships between the calender parameters and the properties of the material in particular residual stresses. In addition, it is the starting point for an additional module on the calender, which enables wrinkle-minimized processing of current and future material systems allowing for better qualities also in further process steps, as exemplified by the stacking process.