Dense 3D Nanoscale Electrode Batteries with a Conformal Solid Electrolyte

Using dense, 3-dimensional (3D) arrays of nanoscale cathodes and anodes offers the potential to increase the energy density of rechargeable batteries for electric vehicles by at least an order of magnitude. However, developing batteries with such fine-scale patterns requires the development of a conformal solid electrolyte material that serves as a very thin, but durable separator between the 3D cathode and anode. Suitable conformal electrolytes are not yet available and need to be developed. To solve this limitation, TDA Research will develop a new, durable nano-porous polymer material as a conformal solid separator/electrolyte for 3D batteries. The material is based on an ionically conductive, nonporous polymer that can be coated or inserted as a liquid into the small gaps between electrode features prior to in situ self-assembly and solidification. The new material will bond both electrodes together and keep them physically separated by a thin, highly conductive conformal material. TDA will prepare cathodes, anodes, and precursors for the in situ solidifying conformal electrolyte materials and use them to prepare battery cells. TDA will prepare half cells and full cells with a 3D nano-structured LiFePO4 cathode, combined with the new conformal solid electrolyte. Half cells will be made with a lithium metal anode and the full cells will have a Si/C anode. Cells will be evaluated by EIS and then cycled to demonstrate the performance of the new conformal solid electrolyte. Commercial applications include hybrid electric vehicles (HEV), electric vehicles (EV) and other products using rechargeable lithium batteries such as portable electronics and electrical appliances that are currently powered by lithium-ion batteries.