Recyclable and sustainable batteries are a prerequisite for a green energy revolution, as the rapidly increasing demand for batteries is driving up the consumption of rare raw materials like lithium.
Two spin-off ventures, stemming from various ETH Zurich research, are working to solve this problem by applying innovative production and manufacturing techniques in the battery domain.
BTRY, an ETH spin-off, creates ultra-fast-charging batteries that can withstand temperature changes and are appropriate for various uses. Another firm, 8inks, hopes to standardize a cutting-edge manufacturing process that will allow it to create customized batteries.
Ultra-fast charging, solid-state design
Liquid electrolytes are found inside conventional lithium-ion batteries, the kind that is currently found in notebook computers and smartphones.
Because of this, the batteries are susceptible to temperature changes and can quickly catch fire at high temperatures, for example. Additionally, it takes some time for traditional batteries to recharge.
As a result, BTRY has created a solid-state battery with thin layer construction that can significantly reduce charging times. When it comes to the components of their battery and the production method, the researchers completely eschew using liquids.
According to the BTRY team, the main benefit of its solid-state batteries is their extreme temperature resistance. As a result, they can be employed in applications that require them to function at extremely high or low temperatures, such as sensors that identify vapor leaks or during medication delivery.
Utilizing a coating technique derived from semiconductor production, BTRY’s battery design offers advanced efficiency. Within a vacuum, wafer-thin battery cells are meticulously stacked, creating a revolutionary design.
The team claims the innovation facilitates ultra-fast recharging, completing in approximately one minute. Moreover, the battery’s unique structure ensures a lifespan of approximately ten times longer than its conventional counterparts.
The resulting product resembles a thin foil, with coatings so delicate that the final thickness is thinner than a human hair.
The team sees the battery’s potential in various applications, such as consumer electronics, space operations, and Internet of Things sensors.
Multilayer coating innovation
ETH spin-off 8inks distinguishes itself from other battery producers with its cutting-edge manufacturing process. It seeks to replace the so-called slot die technology, a manufacturing standard for lithium-ion batteries that has essentially not altered in the last 30 years.
The team created a method known as “multilayer curtain coating.” The active substance that stores the lithium-ion can be applied in many thin layers to customize the coating process to the specific needs.
The approach supports, among other things, the scaling of solid-state batteries because of the variation in the thickness and material properties of the different layers. According to the team, the method also greatly accelerates the coating speed of the battery electrodes, making it ideal for meeting the increasing demand.
Currently, the 8inks staff is investigating various types, from coin batteries to pouch cells similar to those used in cellphones. For example, the technology for electric car batteries should be scalable to a greater industrial scale.
“We aim to use our manufacturing technique to develop solutions for the storage of renewable energies. This is the only way of meeting the enormous rise in demand for high-performance batteries in the long term,” said Paul Baade, founder of 8inks, in a statement.
