High-Throughput Manufacturing of Lithium Dendrite Suppression Membranes for High-Energy Density Anodeless Lithium Metal Batteries

Lithium-ion batteries are the core technology in electric vehicles (EV). But safety concerns and limited driving ranges (i.e. low energy densities of <300 Wh/L) have hindered widespread EV implementation. Anodeless solid-state lithium metal batteries are a safe, high energy (≥1000 Wh/L) alternative. However, lithium dendrite penetration through the solid-state electrolyte membrane continues to hamper their development. Moreover, the lack of scalable membrane processing methods continue to make anodeless battery commercialization impractical. To address these challenges, Ampcera is developing a dendrite suppressing solid-state electrolyte membrane using a high-throughput processing technology. The processing method enables a unique grain boundary structure that is advantageous for suppressing dendrite growth. The grain boundary engineered membranes can be fabricated directly onto current collectors and incorporated into anodeless batteries. Moreover, as-processed membranes can be directly integrated into battery production, eliminating the need for handling and any thermal treatment. In Phase I, grain boundary engineered membranes (≤50 µm in thickness) will be processed onto current collectors. As-processed membranes will be integrated into pouch cells for electrochemical evaluation. A systematic materials evaluation will demonstrate the lithium suppression capabilities of the membrane. Results from material and electrochemical evaluations will be used to optimize processing parameters to further improve membrane performance. Approach and concept feasibility will be demonstrated in pouch cells of ≥200 mAh in size. Ampcera’s anodeless lithium metal battery technology will double the current EV driving range. The low-cost manufacturing method will enable a battery cost of ≤$80/kWh, which is one of the main goals of the U.S. Department of Energy’s “Energy Storage Grand Challenge”. Moreover, the high-throughput nature of the method will lower the risk of a death valley situation by offering higher yield rates, and lower equipment and operating cost compared to conventional membrane casting and high temperature treatment methods. The anodeless battery technology developed in Phase I will help to overcome the consumer adoption barriers inhibiting widespread EV implementation in the ongoing effort to reach net zero carbon emissions by 2050.