Here, we report on innovative materials and architectural approaches that have the potential to disrupt current Li-ion battery technology, especially by combining high-capacity with high charging/discharging rates. We aimed at improving 3D battery performance by using large area atmospheric pressure spatial atomic layer deposition (sALD) for further tuning the electrode and electrolyte layers at the nanometer-scale. Apart from enabling high charge/discharge rates, 3D electrode architectures pave the way for the use of high-capacity materials without long-term cycling challenges. We will show the potential of the intrinsically safe 3D all-solid-state batteries that can be extended to energy densities required for automotive (850 Wh/l and 375 Wh/kg at cell level).
However, novel architectures demand newer processing techniques, especially for conformal layer stacks over 3D structures. In this regard, we will present the results on high-rate 3D Li-ion battery electrodes coated using our patented sALD technology, which enables charging times below 10 minutes. Next, we will discuss the first-ever sALD-based LiPON electrolyte material, deposited at least 10x faster than the current technologies using conventional ALD systems, and exhibiting high Li-ion conductivity > 10-7 S/cm and very low electronic conductivity (< 10-12 S/cm). The LiPON layers are pinhole-free and demonstrated to be cycled without shorts. Such electrolytes are also relevant for the development of protection layers in wet electrolyte-based lithium ion batteries, as well as for enabling thin-film planar and 3D solid-state batteries with ultrathin electrolyte layers (few 10’s of nanometers). Highlighted during the presentation will also be the attribute of the sALD technique to produce conformal and upscalable coatings that can be applied in roll-to-roll processing using metal foils to further enable the innovative and cost-effective 3D battery layers.