Periodic Reporting for period 2 - Coldab (A unique multi-layer deposition process for optimised production of the next generation of Li-ion batteries.)
Reporting period: 2022-01-01 to 2023-12-31
Although Lithium Batteries (LiBs) are the gold standard in the industry, they suffer many issues that slow widespread adoption of EVs. The major limitation is found in the physical architecture of LiBs. The layers that comprise the anode and cathode are formed using thin film deposition and coating techniques, but state-of-the-art processes still have many deficiencies that prevent industrial production of next-gen LiBs. These include high production costs (~€171/kWh), unscalable processes, low performance (~200 km), dependence on limited and expensive materials and safety concerns (Li dendrites). Materials for next-gen batteries like thin metallic Li anodes and solid-state electrolytes are difficult to process in current film deposition techniques due to e.g. reactivity and sensitivity for air and moisture, further limiting innovation. Furthermore, existing processing technologies hinder the production of Li metal anode layers, solid state electrolyte-based separators and barriers with optimum thickness; reducing energy and power density and increasing costs. These technological limitations in LIB manufacturing though deposition systems, which create a substantial barrier to the wide spread adoption of EVs and represent one of the biggest challenges faced by this market. European EV manufacturers are struggling to create strong technological and cost competitive edge to gain market share. There are no means to access advanced batteries (Gen4 a-c) based on solid state electrolytes, Li metal anodes and/or high nickel cathode active materials to create permanent, strong position in the market and efficiently reduce cell and pack level battery costs by increasing energy density as well as dependence on scarce, expensive materials.
Pulsedeon is developing the Coldab technology; an innovative, cost effective dry thin film deposition process for direct deposition of anode, cathode, separator and SEI (Solid electrolyte interphase) layers of LiB components. Coldab is based in Ultra-Short Pulsed Laser Deposition (USPLD), where a laser beam is focused inside a vacuum chamber to strike a target material that is vaporized and deposited on a substrate in the form of a thin film functional layer. Coldab deposits a wide variety of coatings: ceramic separator coatings, Si and Si-C micro-composite anodes, Li-metal anodes, solid electrolyte depositions, barrier and lithiophilic layers.
Coldab allows multiple layers of different materials to be deposited with precise control of physical properties within a single machine and under an inert, protective atmosphere. The adhesion between functional material layers is excellent and layer thickness can be adjusted freely to reach optimum cell structure. The system has unique scalability of process arrangement to easily meet manufacturers’ quantitative and qualitative needs.
During the EIC Accelerator project (Grant n.: 959259), Pulsedeon will carry out the following objectives:
- Improved design, manufacturing and assembly of modular Coldab system.
- Development of USPLD process diagnostics and control system to enable automation.
- In-house testing and validation of the Coldab system.
- Set-up of Coldab system production supply chain.
- Pilot tests with first end-users.
- File additional IP.
- Data collection, analysis to attain regulatory compliance.
- Expand Commercial reach and actuate the business strategy.
Pulsedeon is developing the Coldab technology; an innovative, cost effective dry thin film deposition process for direct deposition of anode, cathode, separator and SEI (Solid electrolyte interphase) layers of LiB components. Coldab is based in Ultra-Short Pulsed Laser Deposition (USPLD), where a laser beam is focused inside a vacuum chamber to strike a target material that is vaporized and deposited on a substrate in the form of a thin film functional layer. Coldab deposits a wide variety of coatings: ceramic separator coatings, Si and Si-C micro-composite anodes, Li-metal anodes, solid electrolyte depositions, barrier and lithiophilic layers.
Coldab allows multiple layers of different materials to be deposited with precise control of physical properties within a single machine and under an inert, protective atmosphere. The adhesion between functional material layers is excellent and layer thickness can be adjusted freely to reach optimum cell structure. The system has unique scalability of process arrangement to easily meet manufacturers’ quantitative and qualitative needs.
During the EIC Accelerator project (Grant n.: 959259), Pulsedeon will carry out the following objectives:
- Improved design, manufacturing and assembly of modular Coldab system.
- Development of USPLD process diagnostics and control system to enable automation.
- In-house testing and validation of the Coldab system.
- Set-up of Coldab system production supply chain.
- Pilot tests with first end-users.
- File additional IP.
- Data collection, analysis to attain regulatory compliance.
- Expand Commercial reach and actuate the business strategy.
In the first 15 months of the project, Pulsedeon has achieve progress in the following tasks:
- Engineering of Coldab system for multilayered LIB components: The Proof of Concept Coldab equipment for single layer deposition was redesigned into a Pilot System for Multi-layer USPLD. Pretesting has been done to key equipment before defining final design and component selection and specification.
- Design of process diagnostics and control subcomponent for automation: An integrated measurement, control and automation systems was developed for in-situ precision control of all submodules and the deposition process.
- Developed supply chains for key components for Coldab equipment and manufacturing services to support target materials manufacturing system, deposition systems from 100 to 500 mm and post processing systems. This was taking into account technical capabilities, flexibility, cost reduction based on fit for purpose analysis and present “short term situation” with pandemic related challenges.
- Producing pretest samples using Coldab S50 equipment and tested inhouse and partially with partners and selected customers
- Manufacturing finished for part of the upgraded Coldab processing system (Target materials unit, Coldab S100 system modified for LIB system), and advanced Coldab S250 system and postprocessing stages, gradually upgraded the system from app. 100 mm processing widths to 250 300 mm.
- In Exploitation and communication activities:
a) As part of business plan creation and preparation for commercialization validation programs have been agreed with battery production companies and new SME battery producers in EU, USA and Asia.
b) Bilateral company and technology presentations for wide variety of industrial and R&D partners.
c) Public presentation: “Common Challenges in Li based batterie organized by LEITAT Spain”.
d) Our Top Entrepreneurs & Innovators 2020_Bottom up #EiA European innovation Area.
e) Finland EU Embassy website presentation for Pulsedeon technology and Coldab project.
f) Presentations at R&D partner’s websites (Aalto University, Tampere University, CIC…).
- IPR Management: Priority IP has been filed for Pulsedeon key applications. Preliminary additional IP has been outlined and patents are filed after key R&D results are available especially from Coldab S250 multilayer materials and post processed materials.
- Engineering of Coldab system for multilayered LIB components: The Proof of Concept Coldab equipment for single layer deposition was redesigned into a Pilot System for Multi-layer USPLD. Pretesting has been done to key equipment before defining final design and component selection and specification.
- Design of process diagnostics and control subcomponent for automation: An integrated measurement, control and automation systems was developed for in-situ precision control of all submodules and the deposition process.
- Developed supply chains for key components for Coldab equipment and manufacturing services to support target materials manufacturing system, deposition systems from 100 to 500 mm and post processing systems. This was taking into account technical capabilities, flexibility, cost reduction based on fit for purpose analysis and present “short term situation” with pandemic related challenges.
- Producing pretest samples using Coldab S50 equipment and tested inhouse and partially with partners and selected customers
- Manufacturing finished for part of the upgraded Coldab processing system (Target materials unit, Coldab S100 system modified for LIB system), and advanced Coldab S250 system and postprocessing stages, gradually upgraded the system from app. 100 mm processing widths to 250 300 mm.
- In Exploitation and communication activities:
a) As part of business plan creation and preparation for commercialization validation programs have been agreed with battery production companies and new SME battery producers in EU, USA and Asia.
b) Bilateral company and technology presentations for wide variety of industrial and R&D partners.
c) Public presentation: “Common Challenges in Li based batterie organized by LEITAT Spain”.
d) Our Top Entrepreneurs & Innovators 2020_Bottom up #EiA European innovation Area.
e) Finland EU Embassy website presentation for Pulsedeon technology and Coldab project.
f) Presentations at R&D partner’s websites (Aalto University, Tampere University, CIC…).
- IPR Management: Priority IP has been filed for Pulsedeon key applications. Preliminary additional IP has been outlined and patents are filed after key R&D results are available especially from Coldab S250 multilayer materials and post processed materials.
Pulsedeon has created first integrated processing system for multilayer Li metal anode – solid state electrolyte components suitable for (a) all-solid-state, (b) semi-solid state, (c) hybrid-solid state and (d) LiS batteries. Integrated system includes (i) PLD processing of 100 mm and 250-300 mm components in controlled and/or protective atmosphere, (ii) target materials manufacturing line for PLD suitable target materials and (iii) post-processing technology especially for sulfite solid state electrolyte postprocessing to finetune the microstructure and crystallinity. The developed technology allows energy densities up to 1100-1200 Wh/l with good safety and cyclability. The developed solutions is unique, patented both with previous patents and patents filed during this project (more to be filed) and has attracted a lot of interest by customer in EU, USA and Asia for collaboration and future business creation.
This technology allows wider acceptance of electric vehicles by consumers due to longer driving range, faster charging and lower costs. Furthermore, highly competitive EU battery processing technology allows differentiation with global competition which promotes job opportunities in EU both in battery production, equipment business and technology licensing. Pulsedeon has integrated several universities and research institutes in EU for R&D collaboration.
This technology allows wider acceptance of electric vehicles by consumers due to longer driving range, faster charging and lower costs. Furthermore, highly competitive EU battery processing technology allows differentiation with global competition which promotes job opportunities in EU both in battery production, equipment business and technology licensing. Pulsedeon has integrated several universities and research institutes in EU for R&D collaboration.