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Battery, Battery Materials

<2023> The Present and Future of All Solid-State Battery Manufacturing Technology

(Subtitle: In-depth Analysis on Manufacturing Technology and R&D Trend of Major Companies)

 

 

 

The performance of lithium-ion battery (LIB), most widely used today, has been improved through continuous technology development propped up with an explosive demand in new electronic devices and electric vehicles. Particularly, the energy density has been dramatically increased from 80Wh/kg in the nascent stage to 300Wh/kg of these days. However, a high energy density implies a possible risk of fire or explosion. Lithium-ion battery may have an explosion triggered bWy internal overheating, secondary heat release from outside, and electrical defect caused by mechanical damage, excessive discharging, and overcharging.

 

 

 

To prevent such risk, all solid-state battery to which solid electrolyte is applied has become regarded as a next-generation battery technology. Megatrends in all solid-state battery can be summarized as follows: excellent safety; high energy density; high power output; wide range of workable temperature; and simple battery structure. Thanks to these properties, all solid-state battery can be free from explosion risks. In addition, solid electrolyte has a better ionic conductivity than liquid electrolyte when the temperature is below 0 or between 60~100.

 

 

 

According to market forecast by SNE Research, the global all solid-state battery market posted a high growth of 180%, reaching approx. 27.5 million dollar in 2022 and is expected to form a huge market worth of approx. 40 billion dollars in 2030. The Korean government also sees the next decade to be a turning point for countries to determine their positions in the global LIB market. Along with the announcement of <2030 K-Battery Development Strategy>, the government has been providing support for technology development with an aim to achieve the commercialization of all solid-state battery in 2027.

 

 

 

To brace for a rapid paradigm shift from lithium-ion battery to all solid-state battery, it is necessary to take an preemptive measure to carry out deep-dive research on key ASB materials and development of mass production technology. Meanwhile, the expected time frame for ASB commercialization has been postponed to 2030 because companies have not exerted sufficient effort to develop related materials and the production technology has not been fully established yet. Given all these circumstances, this report aims to present the cell configuration of all solid-state battery of which possibility in commercialization is highest. We identify the issues related to materials and manufacturing technology and then propose feasible solutions to those issues.

 

 

 

In addition, we analyze announcements and patent applications by major companies regarding the development of all solid-state battery to learn more about their manufacturing technology. Based on a deep-dive analysis on the manufacturing technology and processes, we identify their advantages/disadvantages and try to find suitable manufacturing processes for all solid-state battery.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 Strong Points:

 

    All solid-state battery technology trend and market outlook

 

    Solid electrolyte-related issues and solutions  

 

    Cell configuration and issues to consider in case of apply solid electrolyte to battery

 

    Comparison of all-solid-state battery cell manufacturing technology and process

 

    Trend of manufacturing technology by major companies such as Toyota, SES, Solid Power

 



 

 

 


 

 

- Contents -

 

 

 

  1. All-Solid-State Battery Overview

 

 

 

     1.1 All-Solid-State Battery (ASB)

 

        1.1.1 Limitations in LIB  12

 

        1.1.2 Necessity for All-solid-state Battery Development  13

 

        1.1.3 Application of All-solid-state Battery 14

 

        1.1.4 All-solid-state Battery Market Outlook 15

 

        1.1.5 All-solid-state Battery Patent Application Status by Country 16

 

        1.1.6 All-solid-state Battery Paper Publication Status by Country 18

 

 

     1.2 All-Solid-State Battery Solid Electrolyte

 

        1.2.1 Solid Electrolyte Type and Composition 19

 

        1.2.2 Solid Electrolyte Major Players by Type 20

 

        1.2.3 Solid Electrolyte Major Players’ Trend  21

 

        1.2.4 Solid Electrolyte Patent Application Status by Type 22

 

        1.2.5 Inorganic Solid Electrolyte Patent Application Status by Type 23

 

 

     1.3 All-Solid-State Technology Trend

 

        1.3.1 OEMs’ R&D and Response Status  24

 

        1.3.2 Material Parts Developers’ R&D and Response Status 25

 

        1.3.3 Battery Makers’ R&D and Response Status 26

 

1.3.4 Battery Makers (OEMs) Response Status by Solid Electrolyte 28

 

        1.3.5 Expected ASB Production Timeline and Energy Density by Battery Makers  30

 

 

    1.4 All-Solid-State Battery Market Outlook

 

        1.4.1 Market Outlook by Research Firm 31

 

        1.4.2 Market Outlook by Electrolyte Type 32

 

        1.4.3 Market Expansion Stage 33

 

        1.4.4 Solid Electrolyte Market by Type 34

 

        1.4.5 Solid Electrolyte Market Share Outlook by Type 35

 

 

 

  1. Solid Electrolyte

 

 

 

   2.1 Oxide-based Solid Electrolyte

 

      2.1.1 Properties of Oxide-based Electrolyte 37

 

      2.1.2 Related Properties of Oxide-based Electrolyte 38

 

      2.1.3 Ionic Conductivity and Applications of Oxide Solid Electrolyte by Type 39

 

2.1.4 NASICON-based 40

 

2.1.5 Garnet-based 41

 

      2.1.6 Perovskite-based 42

 

      2.1.7 Major Issues of Oxide Electrolyte 43

 

      2.1.8 Specific Issues and Solutions of Oxide Electrolyte 44

 

 

      2.2 Sulfide-based Solid Electrolyte

 

      2.2.1 Features of Sulfide-based Electrolyte: Advantages 45

 

      2.2.2 Features of Sulfide-based Electrolyte: Disadvantages 47

 

2.2.3 Features of Sulfide-based Electrolyte  47

 

      2.2.4 Ionic Conductivity and Application of Sulfide-based Solid Electrolyte by Type 48

 

      2.2.5 LPS-based 49

 

      2.2.6 LPS-based: crystal structure 50

 

      2.2.7 Thio-LISICON based 51

 

      2.2.8 LGPS-based  52

 

      2.2.9 LGPS-based : Structure and ionic conductivity  53

 

      2.2.10 Agyrodites 54

 

      2.2.11 Specific Issues and Solutions for Sulfide-base Electrolyte 55

 

   

      2.3 Polymer Solid Electrolyte

 

      2.3.1 Types and Properties of Polymer Matrix 56

 

      2.3.2 Types and Benefit/Shortcomings of Polymer Electrolyte 57

 

      2.3.3 Features of Polymer Electrolyte 58

 

      2.3.4 Issues and Solutions of Polymer Electrolyte 59

 

  

      2.4 Compatibility of Solid Electrolyte

 

      2.4.1 Issues with ASB Cell to Consider 60

 

      2.4.2 Cathode-Electrolyte Compatibility Issue  62

 

      2.4.3 Anode-Electrolyte Compatibility Issue  63

 

 

 

3.     All-Solid-State Battery Electrodes

 

 

 

     3.1 Cathode

 

     3.1.1 Cathode Active Material Applied to All-Solid-State Battery 65

 

     3.1.2 Trend in Cathode Active Material 66

 

     3.1.3 Cathode and Compound Cathode processing  67

 

 

     3.2 Anode

 

     3.2.1 Silicon Anode 70

 

     3.2.2 Si/Graphite Anode 71

 

     3.2.3 Lithium Anode -72

     3.2.4 Lithium Metal Anode processing -73

 

     3.2.5 Anodeless-75

 

     3.2.6 Thin film or anode-less application -76

 

     3.2.7 Lithium Metal and Silicon Anode processing 77

 

     3.2.8 Comparison of Anode-less and Other Anodes -78

 

     3.2.9 Comparison of production method for lithium metal anode and silicon anode -79

 

 

 

4.     All Solid State Battery Cell

 

 

 

   4.1 Manufacturing of solid state batteries

 

      4.1.1 Solid Electrolyte processing-81

 

      4.1.2 Cell Assembly-82

 

      4.1.3 Cell Finishing-83

 

      4.1.4 Comparison of manufacturing process of Solid state batteries and LIBs (1)-84

 

      4.1.5 Comparison of manufacturing process of Solid state batteries and LIBs (2) -86

 

      4.1.6 Material cost of solid state batteries-87

      4.1.7 Manufacturing cost of solid state battery cells-87

 

      4.1.8 Cost Comparison of Solid Electrolytes for Solid State Batteries -88

 

      4.1.9 Promising Concept of Solid State Battery Cell-89

 

      4.1.10 Manufacturing of solid state battery cells-90

 

4.2 Oxide-based Solid State Batteries

 

      4.2.1 Most promising cell configuration-91

 

      4.2.2 Considerations in terms of cell structure -92

 

      4.2.3 Considerations for Battery Production-93

 

      4.2.4 Key Performance Indicators-94

 

      4.2.5 Changes in Cell Concept-95

 

4.3 Sulfide-based Solid State Batteries

 

      4.3.1 Cell Configuration-96

 

      4.3.2 Considerations in terms of cell structure-97

 

      4.3.3 Considerations for Battery Production-98

 

      4.3.4 Key Performance Indicators -99

 

      4.3.5 Structure (Silicon anode applied)-100

 

      4.3.6 Considerations in terms of cell structure when applying Si/C composite anode -101

 

      4.3.7 Considerations for cell production when applying Si/C composite anode -102

 

      4.3.8 Key performance indicators when applying Si/C composite anode 103

 

4.4 Polymer-based Solid State Batteries

 

      4.4.1 Configuration of polymer solid state batteries -104

 

      4.4.2 Considerations in terms of cell structure -105

 

      4.4.3 Considerations for cell production -106

 

      4.4.4 Key performance indicators -107

 

      

      4.5 Cell Energy Density  

 

      4.5.1 Assumptions for Base and Advanced Version of Cell Materials -108

 

      4.5.2 Weight and volume energy density -109

 

      4.5.3 Expected scenario and Roadmap -110

 

 

 

5.     Manufacturing Technology of All Solid State Batteries

 

 

 

      5.1 Laboratory Cell Production

 

      5.1.1 Laboratory Level Cell Production -113

 

      5.1.2 Powder pressing Cell Production -114

 

      5.1.3 Three-electrode cell production process by using powder pressing -116

 

      5.1.4 Coin Cell Production Process -117

 

      5.1.5 All solid state battery roadmap of Japan NEDO -118

 

      5.1.6 Pouch Cell Production Process: NEDO Standard Cell -119

 

      5.1.7 Pouch Cell Production Process : NEDO demonstration cell -120

      5.1.8 Production of NEDO Large Area Laminated Demonstration Cell-121

 

      5.1.9 First Generation Solid State Demonstration Cell LIB -122

 

      5.1.10 Japan NEDO : Next Generation Solid State Demonstration Cell LIB-123

 

      

      5.2 Cell Manufacturing Technology

 

      5.2.1 Advantages and disadvantages as per solid state battery type -124

 

      5.2.2 Suitable manufacturing method according to solid electrolyte type 125

 

      5.2.3 Comparison of CIP, WIP, HIP -126

 

      5.2.4 Suitable methods according to solid electrolyte type -127

 

      5.2.5 Densification process of electrode/electrolyte layer-128

 

      5.2.6 Production of composite electrodes and separators -129

 

      5.2.7 Lamination & Stacking Process -130

 

      5.2.8 Slurry/solution casting process -131

 

      5.2.9 Extrusion process-132

      5.2.10 Tape casting process -133

 

      5.2.11 Electrolyte infusion process -134

 

      

      5.3 Cell Manufacturing Process

 

      5.3.1 Common LIB production process -135

 

      5.3.2 Solid state cells : Production of cathode -136

 

      5.3.3 Solid state cells : Production of anode -137

 

      5.3.4 Solid state cells : Production of cell -138

 

      5.3.5 Solid state cells : Cell conditioning -139

 

      5.3.6 Solid state cells  : Cell processing cost -140

 

      5.3.7 Solid state cells : Process comparison -142

 

      5.3.8 Entire Flow of Cell Production -144

 

      5.3.9 Solid Electrolyte Separator Manufacturing Process Flow -145

 

      5.3.10 Details of Solid Electrolyte Separator Manufacturing Process -146

 

      5.3.11 Manufacturing process of solid electrolyte separator (on composite cathode) -147

 

      5.3.12 Anode production process flow 148

 

      5.3.13 Details of anode production process -149

 

      5.3.14 Lithium foil manufacturing process -150

 

      5.3.15 Composite Cathode : Main production process flow -151

      5.3.16 Composite cathode production process (in detail) -152

 

      5.3.17 Composite cathode production process and equipement -153

 

      5.3.18 Main process flow of cell assembly -154

 

      5.3.19 Main process of cell assembly (in detail) -155

 

      5.3.20 Cell assembly : Stack production process -156

 

      5.3.21 Comparison of advantages / disadvantages of each manufacturing process -157

 

      5.3.22 Production Process of Oxide Solid Electrolyte-Applied Cells -158

 

      5.3.23 Manufacture of cathode and anode for SSB by using LIB process 160

 

      5.3.24 Post-Process of Solid State Cells by using LIB Process --161

 

 

      5.4 Cell manufacturing method

 

      5.4.1 Limits of plane press and roll press -162

 

      5.4.2 Difference of HIP(Hot Isostatic Pressing) and Hot Pressing 163

 

      5.4.3 Comparison: solid electrolyte treated by conventional sintering method vs HIP -164

 

      5.4.4 Wet manufacturing method of cathode material --166

      5.4.5 Coating the surface of cathode active material 169

 

      5.4.6 Forming active material composite and shaping spherical form -170

 

 

 

6.     Manufacturing Technology in Major Companies

 

 6.1 TOYOTA

 

      6.1.1 Identifying cause of performance degradation of Toyota's solid state battery-172

 

      6.1.2 Performance degradation in long cycle -173

 

      6.1.3 Toyota's counter-measures for the performance degradation -174

 

      6.1.4 Counter-measures and Solutions --175

 

      6.1.5 Toyota's Step of Applying Solid State Batteries -176

 

      6.1.6 Toyota's Solid State Battery Manufacturing: Pressing 177

 

      6.1.7 Toyota's Solid State Battery Manufacturing : Sublimable filler 180

 

      6.1.8 Toyota's Solid State Battery Manufacturing : HIP -181

 

      6.1.9 Toyota's Solid State Battery Manufacturing : Resin packaging -183

 

     

 

   6.2 HONDA

 

      6.2.1 Hondas Direction of Solid State Cell Manufacturing -188

      6.2.2 Hondas Direction of Solid State Cell Manufacturing 189

 

      6.2.3 Honda's Solid State Battery Manufacturing Process: Mixing -190

 

      6.2.4 Honda's Solid State Battery Manufacturing Process: Electrode Coating --91

 

      6.2.5 Solid State Battery Manufacturing Process : Bonding roll pressing -192

 

      6.2.6 Solid State Battery Manufacturing Process : Electrode slitting -193

 

      6.2.7 Solid State Battery Manufacturing Process : Bonding roll pressing -194

 

      6.2.8 Solid State Battery Manufacturing Process : Stacking --195

 

      6.2.9 Solid State Battery Manufacturing Process : Tab welding, assembly, sealing -196

 

      6.2.10 Solid State Battery Manufacturing Process : Aging, Inspection -197

 

 

 

  6.3 Nissan

 

      6.3.1 Direction of Solid State Cell Manufacturing -198

 

      6.3.2 Overview of Solid State Battery Manufacturing Process -200

 

      6.3.3 Solid State Battery Manufacturing Process -201

 

 

 

  6.4 SES

 

      6.4.1 SES Overall cell structure -206

 

      6.4.2 Cell Performance -207

 

      6.4.3 SES cell P/P line major processes -208

 

 

 

6.5 Solid Power

 

      6.5.1 Solid state battery structure and development line-up --209

 

      6.5.2 Solid state cell manufacturing process --210

 

      6.5.3 Roadmap of Si Anode Solid State Batteries --211

 

      6.5.4 Roadmap of Li Anode Solid State Batteries -212

 

      6.5.5 Solid State Battery Production Roadmap -213

 

 

 

   6.6 Blue Solution

 

      6.6.1 LMP® Solid state battery structure --214

 

      6.6.2 Manufacturing process of Blue Solution -215

 

      6.6.3 Solid state battery roadmap -216

 

 

 

   6.7 QuantumScape

 

      6.7.1 Cell performance of solid state batteries -217

 

      6.7.2 Solide state cell manufacturing process and cell characteristics-218

 

      6.7.3 Solide state battery roadmap --219

 

 

 

 

 

   6.8 ProLogium

 

      6.8.1 Solid state battery cell structure -220

 

      6.8.2 Solid state battery structure and performance -221

 

6.8.3 Solid state battery production line -222

 

      6.8.4 Solid state battery production process-223

 

 

 

  6.9 Johnson Energy Storage

 

      6.9.1 Cell information and related characteristics-224

 

      6.9.2 Slurry coating process 225

 

      6.9.3 Co-extrusion process -227

 

 

 

  6.10 TaiyoYuden(太陽誘電)

 

      6.10.1 MLCC Type solid state cell structure--229

      6.10.2 MLCC Type solid state cell production process --230