Topic 12a. Scalable Manufacturing of Multilayer Electrodes with Integrated Ceramic Separators for Improved Safety, Increased Energy Density, and Reduced Cell Assembly Cost

Every lithium-ion battery in production for the world’s largest markets requires a polyolefin separator between anode and cathode. These separators, even at their most advanced, do not provide a preferable level of safety in the event of physical trauma to a cell or heat buildup within the cell. This problem will only become more acute as batteries move towards the higher energy densities and power densities that industry and Department of Energy are targeting. To solve this problem, Integrated Ceramic Separator technology is being developed, which incorporates a layer of ceramic particles directly into the surface of anode and cathode electrodes. The robustness of ceramic materials and their interfaces with electrodes will improve safety, enhance cell performance, reduce cell cost, and increase manufacturing throughput. Eventually, this will allow total elimination of polyolefin separator from current lithium-ion battery production. In Phase I, the work proposed in this program will focus on advancing the manufacturability and performance of integrated ceramic separator technology. Two tasks of the project will focus on anode and cathode, respectively. Iterative studies will be made of slurry formulation and mixing, coating, and calendering parameters. A statistically meaningful number of cells will be produced and tested to confirm targeted improvements in safety and performance with the new technology. Commercial applications include light automotive markets most prominently, as well as construction and off-highway vehicles, power tools, medium and heavy commercial vehicles, and Electric Vertical Takeoff and Landing. The technology will significantly improve battery safety, de-risk the higher energy densities and power densities that allow longer range and faster charging and reduce battery cost. The technology is drop-in compatible with the existing battery manufacturing base and so industry-wide adoption is feasible.