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Directly Applied Separator in Lithium Ion Battery Manufacturing

Award Information
Agency: Department of Defense
Branch: Defense Logistics Agency
Contract: SP4701-21-P-0055
Agency Tracking Number: L203-003-0049
Amount: $149,994.00
Phase: Phase I
Program: SBIR
Solicitation Topic Code: DLA203-003
Solicitation Number: 20.3
Solicitation Year: 2020
Award Year: 2021
Award Start Date (Proposal Award Date): 2021-03-25
Award End Date (Contract End Date): 2022-03-27
Small Business Information
20 New England Business Center
Andover, MA 01810-1111
United States
DUNS: 073800062
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
Principal Investigator
 Ankita Faulkner
 (978) 835-4078
Business Contact
 B. David Green
Phone: (978) 689-0003
Research Institution

Physical Sciences, Inc. (PSI) proposes a new process to apply the separator layer as a coating directly to the surface of battery electrodes. The directly applied (DA) separator method will simplify the traditional process of “stacking,” in which separator films are woven through stacks of battery electrodes.  The DA method will improve manufacturing speeds and reduce the cost of lithium ion batteries in the DLA supply chain. The DA separator will also mitigate safety risks associated with traditional stacking and improve cell performance. The separator layer is deposited on the surface of the electrode via electrophoretic assembly (EPA); a rapid, low-cost manufacturing process in which charged particles suspended in a solution assemble onto a substrate under an electric field.  EPA can readily be inserted into the back end of the electrode coating/calendaring line. In Phase I of the program, feasibility of the DA method will be demonstrated in multi-Ah cells, designed to meet the requirements of batteries currently purchased by DLA. The results of the Phase I studies will guide scale up efforts and the transition to roll-to-roll production in Phase II. PSI will demonstrate roll-to-roll production of the DA separator-electrode supporting production of cells for multiple DLA applications.

* Information listed above is at the time of submission. *

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