Scale-up of Low-Cost Encapsulation Technologies for High Capacity and High Voltage Electrode Powders

Incremental improvements and cost reduction efforts are perpetually underway to allow the vehicular battery industry to meet and exceed the energy, power and lifecycle targets set forth by the USABC. Higher capacity layered-type electrode powders are being produced to reduce the $/kWh metric, though cycle lifetimes of these materials is still not sufficient. Higher voltage (5V) spinel powders can achieve very high rate capabilities, though high temperature stability of conventional electrolytes in the presence of these materials is similarly insufficient. Surface coatings on primary electrode powders can prevent core material dissolution, allow for higher voltage operation, increase safety by preventing thermal runaway caused by high temperature electrolyte interactions, and all without increasing he surface resistivity of the materials. This SBIR Phase I project will focus on applying stabilizing coatings to two high-impact cathode materials of interest, namely high capacity layered NMC (target: 260 Ah/kg @ 0.1C rate) and high voltage LiNi0.5Mn1.5O4 spinel (target: 140 Ah/kg @ 1C rate). Surface coatings of Al2O3, TiO2 and AlF3 inorganic material compositions will be applied using the Atomic Layer Deposition (ALD) and Co-Precipitation (CP) techniques, in order to quantify the value proposition offered by each. A scalable roadmap to surface-protected battery materials will be realized for vehicular, military/aerospace, high-drain portable electronics and many other products increasingly using Li-ion battery systems. These materials will be tested with both conventional and novel anodes and electrolytes for a holistic approach to achieving the cost and performance targets of the USABC today. This nanotechnology-driven solution will be manufactured domestically and can be exported globally to achieve U.S. nanomanufacturing initiative goals. Honing the production of pilot-scale batches of Li-ion battery powders during Phase I will allow for full-scale battery packs to be designed and produced during the Phase II work plan for performance-intensive vehicular applications.