Periodic Reporting for period 1 - PULSELiON (PUlsed Laser depoSition tEchnology for soLid State battery manufacturIng supported by digitalizatiON)
Periodo di rendicontazione: 2022-09-01 al 2024-02-29
There is a growing demand for batteries in Europe. The energy density of current liquid electrolyte cells is relatively low, and they are composed of flammable liquid electrolytes, which poses safety concerns. As a response to this need, PULSELiON aims to develop high-energy-density batteries with enhanced safety features. The PULSELION concept is based on a real industrial need with a high market demand and implemented through the utilization of appropriate cell components and processing technologies that allows us to develop novel solid-state battery with increased energy density and safety. The PULSELiON project aims to develop the manufacturing process for Gen 4b solid-state batteries (SSBs). These batteries will be based on a lithium-metal anodes, sulfide solid electrolyte, and Nickel-rich NMC cathodes. To achieve this, a novel pulsed laser deposition technique (PLD) will be adapted and modified into a single-step vacuum process. This process ensures the safe and efficient manufacturing of anodes, composed of lithium metal, protective layers, and a sulfide solid electrolyte. The NMC cathode will be fabricated using conventional wet processing techniques. The anode and cathode will be developed on a small scale for coin- and monolayer cells first and finally 10Ah pouch cell will be demonstrated (TRL6).
Project achievements:
Within the WP2:
- KPIs and testing protocols were defined according to the calculations and information supplied by the end-user. Energy density/power, cyclability, cost and design targets (technical and cost related) were taken from the cells for battery electric vehicles.
- Automotive specifications were provided to all partners involved in the work packages.
Within the WP3:
- Handling protocol for Li-metal/ and or sulfide-based materials was established (reported in the Deliverable D3.1 on M6.)
- The reference cell and standardized tests were established. A RRT (Round Robin Test) to verify the quality of the measurement methods, was carried out by partners involved in this task (reported in the Deliverable D3.1 on M6). T3.1.2 was concluded on M6.
- Li-on-Cu samples comprising of disks with ~5 µm (M7) and ~10 µm (M10) of Li on top of 25 µm thick Cu foil was made by S50 equipment. 20 µm Li was deposited on top of Cu foil by S100.
T3.2.1 has been concluded on M18 with achieving of MS3.
- Protection layers such as LiPON and LLZO were deposited on thin Li-metal anode as protective layers to enhance the stability of Li metal.
First versions of PLD targets were produced by Pulsedeon. An improved LLZO targets were produced (M18).
- The new approach, Li-Mg alloy, was studied depositing thin film of Mg by PLD (S100) on top of Li metal and LPSCl (S50) on the Li-Mg alloy.
- Li and Mg were deposited during the same process cycle, thus proving the capabilities for multilayer deposition in S100 equipment.
-LPSCl thin layers by PLD has been manufactured as well as bilayers consisting of PLD-Li metal and PLD-LPSCl layers on top of Cu foil prior to move to roll-to-roll scalable process.
Within WP5:
- “Safe handling & testing protocol” was established. It includes performance tests, safety tests and accelerated ageing, and detect defects in the cell and define at which point to perform cell post-mortem analysis. (see deliverables D5.1 for details).
Within WP6:
-Upgraded electrochemical model with new faster solver, sub-models for modelling solid-state half-cell configurations and EIS calculation capabilities.
-Coupling of the stress enhanced diffusion model on the homogeneous single electrode particle.
-Code restructuring of the electrochemical model to be suitable for running larger DoEs (design-of-experiment) on the HPC architecture.
-Performed several case studies by analysing impact of certain parameter variation on the calculated EIS curves.
-Discretised thin layer which represents porous SEI layer on the separator/Li-anode interface was implemented. Impact of this additional layer on the performance of the cell was investigated.
-Developed code to simulate the SED problem in homogenous materials.
-Developed a workflow to simulate heterogenous particles and numerical simulation of diffusion in them, also with tensorial diffusion coefficients.
-Implemented a more robust and advanced numerical solver suitable for DAE systems – the IDA solver from the Sundials solver suite.
-Established the manufacturing workflow for Solid State Battery cathodes with realistic particle geometries extracted from tomography images. Calibration of models based on experimental data.
Within WP7:
-Deployed the final version of the platform and the user manual to all partners (MS9 achieved) The platform SUNDIAL is now in use.
-A comprehensive analysis of the current literature on lithium-ion batteries was conducted regarding environmental studies to identify the components /materials/processes with the highest environmental burdens.
-The baseline was defined and assessed to identify the key challenges related to environmental performance.
-Data collection regarding the PULSELiON production processes to build the life cycle inventory (WP3), was initiated.
-Review on the existing literature on lithium-ion batteries regarding cost analysis was performed to understand the main cost drivers. Thus, the baseline for this analysis was the same as defined for environmental analysis. Initiating data collection on the inherent costs of the PULSELiON production processes to build the economic inventory (WP3).
-SSBs Recycling Process Flow Design was established(See the deliverable D7.2). This deliverable defines the conceptual recycling process flow for PULSELiON cells, which was designed based on the research performed in sub-task 7.4.1. (MS10 was achieved).
Within the WP2:
- KPIs and testing protocols were defined according to the calculations and information supplied by the end-user. Energy density/power, cyclability, cost and design targets (technical and cost related) were taken from the cells for battery electric vehicles.
- Automotive specifications were provided to all partners involved in the work packages.
Within the WP3:
- Handling protocol for Li-metal/ and or sulfide-based materials was established (reported in the Deliverable D3.1 on M6.)
- The reference cell and standardized tests were established. A RRT (Round Robin Test) to verify the quality of the measurement methods, was carried out by partners involved in this task (reported in the Deliverable D3.1 on M6). T3.1.2 was concluded on M6.
- Li-on-Cu samples comprising of disks with ~5 µm (M7) and ~10 µm (M10) of Li on top of 25 µm thick Cu foil was made by S50 equipment. 20 µm Li was deposited on top of Cu foil by S100.
T3.2.1 has been concluded on M18 with achieving of MS3.
- Protection layers such as LiPON and LLZO were deposited on thin Li-metal anode as protective layers to enhance the stability of Li metal.
First versions of PLD targets were produced by Pulsedeon. An improved LLZO targets were produced (M18).
- The new approach, Li-Mg alloy, was studied depositing thin film of Mg by PLD (S100) on top of Li metal and LPSCl (S50) on the Li-Mg alloy.
- Li and Mg were deposited during the same process cycle, thus proving the capabilities for multilayer deposition in S100 equipment.
-LPSCl thin layers by PLD has been manufactured as well as bilayers consisting of PLD-Li metal and PLD-LPSCl layers on top of Cu foil prior to move to roll-to-roll scalable process.
Within WP5:
- “Safe handling & testing protocol” was established. It includes performance tests, safety tests and accelerated ageing, and detect defects in the cell and define at which point to perform cell post-mortem analysis. (see deliverables D5.1 for details).
Within WP6:
-Upgraded electrochemical model with new faster solver, sub-models for modelling solid-state half-cell configurations and EIS calculation capabilities.
-Coupling of the stress enhanced diffusion model on the homogeneous single electrode particle.
-Code restructuring of the electrochemical model to be suitable for running larger DoEs (design-of-experiment) on the HPC architecture.
-Performed several case studies by analysing impact of certain parameter variation on the calculated EIS curves.
-Discretised thin layer which represents porous SEI layer on the separator/Li-anode interface was implemented. Impact of this additional layer on the performance of the cell was investigated.
-Developed code to simulate the SED problem in homogenous materials.
-Developed a workflow to simulate heterogenous particles and numerical simulation of diffusion in them, also with tensorial diffusion coefficients.
-Implemented a more robust and advanced numerical solver suitable for DAE systems – the IDA solver from the Sundials solver suite.
-Established the manufacturing workflow for Solid State Battery cathodes with realistic particle geometries extracted from tomography images. Calibration of models based on experimental data.
Within WP7:
-Deployed the final version of the platform and the user manual to all partners (MS9 achieved) The platform SUNDIAL is now in use.
-A comprehensive analysis of the current literature on lithium-ion batteries was conducted regarding environmental studies to identify the components /materials/processes with the highest environmental burdens.
-The baseline was defined and assessed to identify the key challenges related to environmental performance.
-Data collection regarding the PULSELiON production processes to build the life cycle inventory (WP3), was initiated.
-Review on the existing literature on lithium-ion batteries regarding cost analysis was performed to understand the main cost drivers. Thus, the baseline for this analysis was the same as defined for environmental analysis. Initiating data collection on the inherent costs of the PULSELiON production processes to build the economic inventory (WP3).
-SSBs Recycling Process Flow Design was established(See the deliverable D7.2). This deliverable defines the conceptual recycling process flow for PULSELiON cells, which was designed based on the research performed in sub-task 7.4.1. (MS10 was achieved).
PULSELiON has allowed Europe to position itself competitively with respect to Asia and the USA in the solid-state battery technology domain. This has induced innovation-based growth across the value chain. The PULSELiON partner, ABEE, has solidified its unique position as a European solid-state battery manufacturer. ABEE is building a 0.5GW cell manufacturing facility in Ninove, Belgium. This can potentially create new job in Europe when it becomes operational. Project partner, PULSEDEON, successfully developed and established pulse laser deposition equipment that allows roll-to-roll deposition of lithium metal anode, protection layers, as well as sulfide/oxide solid electrolytes. This technology is currently being optimized and evaluated. There is a potential for commercialization of this unique technology in Europe. The PULSEDEON has a patent on this technology. Finally, if successful, PULSELION solid-state batteries can offer inherently safer solid-state batteries and thus it contributes to the acceptance of EVs by general public.