Novel Coatings Approach for Solid-State Thin-Film Batteries (NovelCABs)

Solid state thin film battery (SSTB) technology has garnered considerable attention among battery manufacturers due to utilization of inorganic solid electrolytes (SEs) that promise both a longer lifespan as well as greater safety than today’s state-of-the-art lithium-ion battery. To develop SSTB components like SE, anode and cathode, a wide spectrum of vacuum-based coating methods like magnetron sputtering and pulsed laser deposition have been investigated. However, they are inappropriate for large-scale deposition and characterized by slow deposition rate as well as high cost. These techniques also mostly yield amorphous coatings, which result in poor performance. Attempts at crystallization of deposited coatings through post-processing necessitates an additional processing step, leads to delamination of coatings due to formation of secondary phases and adds cost. Therefore, other innovative coating approaches that can overcome these shortcomings are desirable.

Liquid feedstock thermal spraying techniques, such as suspension plasma spraying (SPS) and solution precursor plasma spraying (SPPS) are the emergent new-generation liquid feedstock thermal spraying processes, which hold various technical as well as economic advantages over conventional vacuum-based techniques owing to their ability to provide dense coatings, refined microstructures, and superior performance.

NovelCABs aims to demonstrate the versatility of new-generation SPS and SPPS coating methodologies as a “proof of concept” to develop SE, anode and cathode components for SSTB applications. More specifically, the influence of spray variables on density, crystallinity, microstructure, and electrochemical performance will be assessed. The project presents a great opportunity for the Swedish battery manufacturers to embrace new robust coating platform and harness its unique benefits, not only for realizing current SSTB needs but also for their continued future development.

The project will combine the considerable complementary expertise of the Thermal Spray Group at Högskolan Väst (only academic R&D group on TS in Sweden) and the Angström Advanced Battery Centre (ÅABC) at Uppsala University.