Hybrid Lithium Metal-based Scalable Solid State Battery Manufacturing

The HyLiST project aims at developing Generation 4b all-solid-state lithium-ion batteries (SSBs) for road and aeronautic applications. These will be based on a high voltage (HV) spinel structured LNMO cathode, and hybrid single-ion polymer electrolyte (HSICP) and laser pulse deposited lithium foil on current collector as anode. Overall, processing is aimed at being scalable and easy to transfer to currently available manufacturing infrastructure in Europe. Wet coating for composite cathode preparation and dry processing for the hybrid solid electrolyte increase production efficiency and shorten developing periods. Solvents’ environmental impact is minimized, e.g. by elimination of fluorinated binders. A cobalt-free, high voltage (ca. 4.7V) LNMO cathode de-risks on the dependence of cobalt, and a single-ion polymer electrolyte helps to develop high Li ionic conductivity (≥0.5 mS/cm at room temperature) with a high transfer number (~1.0). Roll-to-roll PLD manufacture of thin and ultra-thin Li anodes will strengthen the European supply chain for semi-finished anode components. A granulation process prepares uniform hybrid solid electrolyte feedstocks to guarantee microscopic uniformity and thereby the resulting electrochemical performance. Environmental impact will be monitored and materials and processes multicriteria optimization performed. Digital twinning is built simultaneously for the simulation of cell production, with further iteration aiming at improved energy density and reduced cost. HyList identifies the essential steps for making all-solid-state batteries at a large scale. It provides valuable insights into efficient manufacturing methods and helps various industry players, like machine engineers, cell producers, and equipment manufacturers, to move toward safer batteries with enhanced storage capacities and high energy densities of 450 Wh/kg, suitable for both electric vehicles and aviation applications.