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.
