Lithium-ion Battery Chemistry

In this talk, we will present a) an advanced PEDOT coating technology at the particle level to fully protect the cathode, b) a novel nonflammable high-voltage electrolyte that is compatible with lithium metal, c) an Ni-rich low cobalt dual mode gradient, d) an Mn-rich multistage gradient structure cathode, and e) a silicon graphene composite anode with a novel pre-lithiation technology.

Solid state metal-sulfur batteries  have long suffered from poor performance due to the low reactivities of both elemental sulfur (S) and lithium sulfide (Li2S). To address these challenges, we have been exploring doping S and Li2S with halides and/or transition metals to enhance their ionic and electronic conductivity, alter reaction pathways, minimize volume changes, and even enable thermal annealing to reverse degradation.

This presentation highlights advances in molecular, liquid-state, and solid-state electrolytes for high-voltage lithium batteries operating across a wide temperature range, including low-temperature conditions. Key strategies include controlling ion solvation, engineering stable electrode–electrolyte interphases, and suppressing dendrite formation in lithium metal cells. Recent examples featuring dinitrile-, sulfone-, and ether-based electrolytes demonstrate improved safety, stability, ionic transport, and performance for next-generation high-voltage cathodes and lithium metal anodes.

Lithium-ion batteries are complex systems, and their development still depends heavily on physical experimentation. Wildcat’s high-throughput platform accelerates research by generating reproducible, cross-comparable data from both successful and unsuccessful tests. By augmenting this platform with AI, we aim to improve research efficiency and predictive modeling. This presentation highlights Wildcat’s approach, data system, and lessons learned from deploying machine-learning models.

Conventional LFP/LMFP synthesis via solid-state or hydrothermal routes demands fine precursors and slow, costly processing. Unlike oxide cathodes, LFP/LMFP has a low congruent melting point, enabling a homogeneous molten medium for rapid, thermodynamically-driven reactions. Our patented melt-synthesis process exploits this, achieving synthesis within minutes while tolerating diverse precursor chemistries, purities, and morphologies. This flexibility lowers environmental impact and simplifies recycling of off-spec and spent-battery materials.

Interfacial reactions in Li-ion cells almost always generate gases. By measuring the quantity and type of gases we can understand these reactions. At Dalhousie University we built a novel multi-channel Online Electrochemical Mass Spectrometer that can sample gases from up to six battery cells simultaneously and enable electrolyte additive screening. We will explain how this system helps us to understand the reaction mechanisms of new additives for high-voltage Li-ion cells.

Electrode performance is dependent on multiscale factors that modify ion and charge transport during cycling. Cross-sectioning of intact coin cells and electrodes with cryogenic electron microscopy workflows can identify cathode particle microstructure, degradation, and the formation of cathode–electrolyte interphases that can change the local charge transport pathways and lead to increased Li-ion transfer impedance. Our automation of these multiscale workflows is enabling rapid evaluation and feedback on battery design.

Energy density and rate capability have long been competing design goals in lithium-ion cells, with fast charge further limited by lithium plating. This talk presents a cell architecture developed over two decades that delivers fast charge and fast discharge while achieving ultra-high energy densities. We cover the design principles enabling this never-before-seen combination of specifications, the constraints that remain, and technology transfer to a manufacturing licensee.

Different from conventional slurry coating methods, we applied a new electrode fabrication directional ice templating. In this method, DI water is used as solvent which eliminates the need for hazardous NMP solvent. The exposure time between the aqueous solvent and electrode materials is strictly controlled to minimize potiential side reactions.

Lithium-ion battery growth is commonly viewed through cathode materials, yet every cell relies on graphite anodes. This presentation explores how battery-grade graphite production depends on petroleum coke, a refinery by-product with limited and competing end uses. Covering regional supply-demand dynamics, synthetic and natural graphite pathways, emerging anode technologies, and carbon intensity, the session highlights why petcoke availability may become a critical determinant of future battery supply chains.

The pace of advancements in intercalation-type lithium-ion batteries (LIBs) has significantly slowed as conventional electrode materials approached their theoretical limits. By inventing and successfully commercializing chemical vapor deposition (CVD)-enabled nanostructured silicon/carbon (Si/C) composite materials (US Patents with 2009-2013 priorities: US 8,889,295B2; US 2014/0057179 A1; US20230343939A1), our team unlocked a new performance standard. This Si/C technology is quickly replacing graphite in commercial phones, drones, power tools, transportation and even grid.

Lithium-rich, manganese rich (LMR) cathode materials have attributes that can result in highly advantaged lithium-ion cells, and this class of materials requires sometimes unexpected design attributes to achieve optimal performance. This talk explores how an advanced LMR CAM, LXMO produced by Stratus Materials, can be implemented in high-performance cells that allow for cells to be produced with the cost and safety of LFP along with NMC energy densities.

High-mass-loading cathodes are essential for achieving practical energy densities in all-solid-state batteries (ASSBs). However, their capacity utilization and rate capability are often limited by high tortuosity and sluggish lithium-ion transport through thick cathode architectures. In this work, we investigate lithium-ion transport limitations in high-loading ASSB cathodes using laser-induced breakdown spectroscopy (LIBS), which probes lithium distribution and transport behavior and shows clear evidence of nonuniform lithiation across the cathode thickness. We will present LIBS measurements on several different ASSB cathode thicknesses and discuss potential strategies to mitigate these transport limitations.