Scaling Activated Dry Electrode« Process for Li-Ion Battery Cathode and Anode Manufacturing

Over the past years, the demand for high performance batteries for electric vehicles(EVs) has surged drastically and many Gigafactories are being built to satisfy the demand. Almost all the Gigafactories are foreign cell manufacturers and employ the traditional wet slurry method to manufacture electrodes which is energy-intensive and requires toxic solvents. Therefore, there is a need for sustainable and cost-effective domestic electrode manufacturing technology to support US efforts in vehicles electrification. LiCAP has patented a revolutionary Activated Dry Electrode® (ADE®) process for lithium-ion and solid-state battery electrode manufacturing. The ADE®process requires no toxic solvents, hence no energy-intensive drying ovens and solvent recovery systems are required. The goal of this project is to scale up ADE® for manufacturing of lithium-ion cathode and anode electrode for electric vehicles application. In Phase I, LiCAP will develop ADE® formulations for common EVs cathode/anode chemistries such as NMC, LFP and graphite/silicon. LiCAP will identify key process parameters to produce homogenous powder mixtures and free-standing film with good mechanical and electrochemical properties at lab and pilot scale. The target of Phase I is to produce 250mm wide, 1m long electrodes with roll-to-roll capability and electrochemical performance that meets EVs application targets. The initial formulation development will focus on identifying optimal powder characteristics and ratio of additives for manufacturing of high-quality electrodes with high tensile strength, flexibility, and electrical conductivity at lab scale. The process optimization stage will focus on scaling up the process to pilot scale, where process parameters will need to be refined to produce powder mixtures and films with identical properties to small scale samples. LiCAPĺs ADE® will be a key technology for manufacturing low cost EVs, as battery related cost can account for >35% of the vehicleĺs cost. Lowering the cost of EVs can incentivize the public to adopt EVs, and accelerate the vehicles electrification in the US. Further development of the ADE® in Phase II and III will not only benefit the transportation sector, but also other sectors which require low cost energy storage devices such as consumer electronics and grid energy storage. The technological advancements in ADE® will be vital to support the domestic battery manufacturing and increase the competitiveness of US battery manufacturer. The development of ADE® process would drastically decrease US demand for foreign-made batteries and reduce US reliance on the whims of international affairs.