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Engineering Materials for Next Generation Energy Storage
James Trevey Ph.D
NDIA JSPE May 4, 2017
Break-out Session #19452
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Forge Nano’s proprietary technologyand manufacturing processes makeangstrom-thick surface coatings fast,affordable and commercially viablefor a wide range of materials,applications and industries includingLithium-Ion batteries.
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ALD Enabled Lithium Ion batteries
Performance• Increased power density • Increased cycle life • Increased energy density
Cost• Less material• Improved Processing• Fewer replacements
Safety• Greater abuse tolerance• Reduced warranty risk
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Innovative Products
ALD
Nano CoatingsConductive InksCatalysts
CapacitorsLi-ion Batteries
Fuel CellsAdvanced Ceramics
RawMaterials
Scientific Reports | 6:26532 | DOI: 10.1038/srep26532
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Atomic Layer Deposition
Particle coatings Multilayers Nano-islands
• Gas phase process • Self limiting• No line-of-sight
restrictions• Sub-nanometer control• Pinhole free
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Forge Nano’s Patented Continuous Particle ALD
Process is Fast and Economical
Particle ALD Invented(Russia)
19772011
20122013
20142015 & 2016
Forge NanoTech Validation
3 kg/hrPrototype
DOE SBIRPhase I & II
Pilot LineCoated 2.5 t/yr
Conventional ALD has been Historically Slow and ExpensiveLack of Manufacturing Innovation Hindered Commercial Adoption
300 ton/year Light CommercialPlant Undergoing Validation
2017
Fluidized Bed ALD ImplementedIn Europe
1992
Forge Nano’s Technology Breakthrough
Production ScaleLab Scale
The Only Proven High Throughput ALD Production Tool
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Decreasing costs with increasing throughput
$1,000’s/kg
10-30 tons/year 300-1000 tons/year >1000 tons/year1-3 tons/year
Prototype Pilot Light Commercial Commercial
2013/2014 2015/2016 2017/20182016/2017
Forge Nano ALD Processing
Scale-up Tool Roadmap
$100’s/kg $10’s/kg $1’s/kg
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Our Patents
• ALD Manufacturing Apparatus: US 9,284,643• ALD Manufacturing Process: US 9,546,424 • Comprehensive ALD Battery IP: Coated cathode, anode, solid
electrolyte, and separatorsForge Nano Filed: 3 additional pending patentsLicensed IP: 13 issued and pending patents with exclusive licenses
• Non-Battery IP: 1 additional pending patent for coated metal uses
• Ongoing Research & Licensing with National Labs / Universities: Batteries, Fuel Cells, MLCCs, Supercapacitors, Conductive Inks, Catalysts
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Li-Ion Batteries: Behind the Innovation Curve
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Safety Pressures
Cost to Samsung - $5.3 BillionCost to Boeing - $600 Million
Titanium Shields- Adds Cost & Weight
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Cost Pressures
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ALD Enabled Cathode Materials
Performance
• Higher voltage
• Higher rate
• Increased robustness
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ALD Enabled CathodeMaterials
Lifetime
• Reduced capacity fade
• Reduced overbuild
• Reduced warranty risk
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ALD Enabled CathodeMaterials
Safety
• Lower resistance • Reduced heat generation
during cycling• Suppression of thermal
runaway• Abuse tolerance • Improved nail penetration
performance• Resistance to dendrite
growth
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Processing Improvements
Processing
• Lower viscosity• Less NMP• Faster drying
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Results:
• Al2O3 and TiO2 coatings improved NCA
capacity retention during high rate (1 C/−1
C) cycling.
• Al2O3 coating improved NMC capacity
retention during low rate (0.3 C/−0.3 C) and
high rate (1 C/−1 C) cycling.
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ALD Enabled Anodes
50% Lifetime Improvement at 45°C with 1C Cycling
Results from 2 Ah pouch cells with ALD-Enabled Anode Materials
45°C, 1C-1C cycling; full NMC-532:Graphite coin cells using pristine NMC
*Projected by linear fit to last 25 cycles
Uncoated
GraphiteCoating 1 Coating 2 Coating 3 Coating 4
Cycles to 10% Discharge
Capacity Fade87 ± 11 156 ± 13 129 ± 27 118 ± 10 121 ± 3
Relative Cycle Life
Improvement0 79% 48% 35% 39%
Cycles to 120%
Discharge Capacity
Fade
180 ± 6 *293 ± 28 *265 ± 41 *232 ± 24 *274 ± 18
Relative Cycle Life
Improvement0 62% 47% 29% 52%
20%
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ALD Enabled Li-ion Batteries
Forge Nano Coatings Lower costs
• Reduced overbuild
• Improved Manufacturability
• Lower $/kWh for life of battery
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Benefits of ALD Enabled Li-ion BatteriesSummary
Performance• Increased power density • Increased cycle life • Increased energy density
Cost• Less material• Improved processing• Fewer replacements
Safety• Greater abuse tolerance• Reduced warranty risk
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20www.ForgeNano.com
James Trevey Ph.D1172 Century Drive, Suite 240
Louisville, CO 80027
303.469.3910
Engineering Materials for Next Generation Energy Storage
NDIA JSPE May 4, 2017
Break-out Session #19452