Key Findings
The STAR Lab at Oak Ridge National Laboratory (ORNL) is undertaking a crucial investigation into the scalability of manufacturing processes for all-solid-state batteries, with a particular emphasis on sulfide solid electrolytes. The research directly confronts significant barriers to commercialization, including how to sustain robust contact between electrodes and the solid electrolyte during battery operation, and mitigating issues arising from the inherent moisture sensitivity of sulfide materials during processing. By addressing these fundamental challenges, ORNL aims to pave the way for more efficient and cost-effective large-scale production of these next-generation batteries.
Technical / Clinical Details
Researchers at STAR Lab are systematically evaluating both dry and liquid-based manufacturing methodologies for solid-state batteries. The dry processing approach, which avoids the use of solvents, offers environmental benefits and simplifies certain steps, but presents difficulties in achieving uniform material distribution and dense packing. Conversely, liquid-based methods can facilitate better material homogeneity but introduce complexities related to the sulfide electrolyte’s reactivity with solvents and moisture. The lab is meticulously studying how these different processing choices impact critical material properties, such as ionic conductivity, interfacial resistance, and ultimately, the battery’s overall performance metrics including cycle life and power output. Understanding these interdependencies is vital for optimizing manufacturing protocols.
Background & Context
All-solid-state batteries are heralded as a transformative technology for energy storage due to their enhanced safety profiles, higher energy densities, and longer lifespans compared to conventional lithium-ion batteries. They are particularly promising for electric vehicles (EVs) and grid-scale energy storage. However, the path to mass production is fraught with challenges, primarily stemming from the complexity and high cost of current manufacturing techniques. Sulfide solid electrolytes are attractive for their high ionic conductivity but demand precise control during fabrication. ORNL’s involvement underscores the strategic importance of overcoming these manufacturing hurdles to accelerate the deployment of advanced battery technologies and strengthen the U.S. competitive position in the global battery supply chain.
Strategic Significance & Outlook
The work at STAR Lab is foundational for developing scalable and cost-effective manufacturing techniques for solid-state batteries. The insights gained from this research will not only accelerate the practical application of sulfide-based all-solid-state batteries but will also contribute significantly to the broader adoption of EVs and the integration of renewable energy sources. By elucidating the profound impact of manufacturing choices on material interfaces and overall battery performance, this research is expected to provide definitive guidelines for future battery design and production strategies, marking a critical step towards unlocking the full potential of solid-state energy storage.
Source: https://www.ornl.gov/news/star-lab-tests-whether-battery-advances-can-scale
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