Enhanced Electrode Performance for Energy Storage Applications Enabled by Direct Write Additive Manufacturing

Completed TRL 2 (started at 1, targeting 2)

Description

The innovation will focus on the design and additively manufacturing of 3D battery electrode to enhance the power density, in the process improving the battery energy density, durability and decreasing the weight. Nano-scale Lithium Iron Phosphate LiFePO4 (LFP) powders and various high conductivity nano-Carbon particles will be procured. Nano-powders with different constituents’ ratios will be mixed with a solvent to synthesize printable inks. The ink solid loading will be optimized to enhance the electrode electrical conductivity, ion-diffusion paths and the resulting power density. The designed electrode will be fabricated by direct write additive manufacturing (DWAM) method using N-Scrypt 3Dη-300 machine in the Ceramic and Polymer Composites Branch.The lightweight multifunctional structures will be an advancement over conventional designs utilized in industry. They will replace simple interdigitated structures that have limited surface area and durability. The additive manufacturing of complex electrodes is also an advancement over conventional approaches which rely on extensive machining to form electrodes while generating a lot of wastes and requiring multiple parts, fabrication steps, and extensive labor. Electrode sintering will be performed to remove inactive materials and further increase the electrode surface area. Afterwards, the microstructure of the fabricated electrode will be examined using scanning electron microscopy and the electrode electrochemical performance will be tested and characterized in a coin cell. Finally, the enhancement in surface area due to the 3D design, surface morphology and porosity network along with the improvement in durability will be demonstrated.

Benefits

Most conventional electrode materials have relatively low electronic conductivity and slow diffusion speeds of lithium ions, resulting in low charge/discharge rate and power density of batteries. Fabrication of thicker electrodes is a method for enhancing the energy density and areal capacitance which can significantly raise the active material loading while preserving rapid ion diffusion. However, the electron transport distances, and overall electrical impedance of the thick electrode will inevitably increase, resulting in reductions of power density and rate capability. Three-dimensional structures can yield shorter diffusion pathways and lower resistance during the ion-transport process, as well as providing increased energy density by creating porous structures with larger surface areas that can improve electrode reaction and ion transfer while efficiently using the limited space in a compact battery. The main objective of this project is to utilize advanced materials synthesis and 3D additive manufacturing to increase batteries power density by more than 50% which can enable more rapid energy discharge that is necessary for craft landing, takeoff and emergencies. Additional objectives are to increase the energy density, enhance the batteries durability and life under cycling, decrease the overall weight and determine the feasibility for in-space manufacturing and moon to mars space missions applications. Aeronautic applications can also benefit from this technology. In particular, the favorable power and energy densities and reduced weight that will be demonstrated by this technology can enable all electric aircraft propulsion (EAP), advanced power systems, and urban air mobility (UAM).

Details

Technology area	Materials, Structures, Mechanical Systems, and Manufacturing > Materials > Materials for Electrical Power Generation, Energy Storage, Power Distribution, and Electrical Machines
Program	Center Innovation Fund: GRC CIF (GRC CIF)
Lead organization	Glenn Research Center, Cleveland, OH
Start date	2020-10-01
End date	2021-09-30

Project contacts

Listed on TechPort itself — the most direct way to ask about this specific project.

Amjad S Almansour — amjad.s.almansour@nasa.gov

How to get involved

This is early/mid-stage (TRL 2) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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