Next-Generation Battery Chemistries

Particle size distribution (PSD) is more than a material specification in all-solid-state batteries; it links solid-state electrolyte (SSE) chemistry with wet processing, manufacturability, and cell performance. This talk will explore modeling, generative AI, and inverse-design approaches for optimizing PSDs and SSE property windows. Particular emphasis will be placed on compatibility between active-material and electrolyte particle populations and on translating processing, cell-performance, and customer requirements into particle-level design targets. These approaches can support manufacturing robustness, reduce experimental search space, and accelerate development of scalable SSE products.

Lithium-sulfur and sodium-sulfur batteries are appealing due to the high abundance and low cost of sulfur and sodium that can ease supply-chain challenges. However, their commercialization is hampered by polysulfide dissolution and shuttling between the two electrodes. One way to overcome this persistent challenge is to replace liquid electrolytes with a solid-state electrolyte. This presentation will focus on the design of sulfur cathode architectures and lithium-rich alloy anodes with an operating voltage similar to that of lithium metal that enable solid-state cells with high sulfur utilization, fast reaction kinetics, high capacity, and long cycle life at low stack pressures.

X-Ray microscopy enables the direct visualization of internal structures nondestructively in 3D. Tomography and laminography are two methods for measuring 3D images for different sample geometries. We will present our latest results using lab- and synchrotron-based X-ray tomography and laminography to study how different processing parameters modify the architecture of catholytes and solid electrolytes such as the distribution of active material, density or pore volume, and cathode particle fracturing.

Thermally stable sodium-ion chemistry offers benefits that extend beyond the cell. It creates an opportunity to rethink the grid storage system. Built around an NFPP cathode and hard carbon anode, Peak Energy’s system eliminates active cooling components and associated failure modes, simplifying thermal management, safety design, and permitting. These advantages improve reliability and reduce project costs and total cost of ownership, delivering compelling economics before further cell cost reductions.

Solid-state lithium batteries promise two things: safety and energy density. On safety, aqueous chemistry remains the gold standard; some 20 to 25 million NiMH hybrids have shipped since 1997 without a reported field fire. But water's narrow stability window caps aqueous cells near 80 Wh/kg, while Li-ion's energy density comes with flammable electrolytes. PolyPlus' aqueous Li-ion/sulfur grid battery bridges the two: LATP ceramic decouples lithium-based anodes from aqueous catholytes, delivering lithium voltage with water-based safety. Sulfur is sourced from waste H2S, and dissolved lithium is recovered by simple precipitation, driving active-material cost toward zero and enabling lithium leasing rather than consumption.

This presentation highlights the advantages of vertical extrusion for continuous manufacturing of dry components, including optimized material flow, precise temperature control, flexible multi-zone dosing, and enhanced mixing performance. It also demonstrates reductions in both capital and operating costs through a much smaller dry room footprint and reduced waste. It will also outline ongoing research for optimizing anode dry coating and separator production while advancing the understanding of polymer–active material interactions.

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.