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Completed TRL 3 (started at 1, targeting 5)
The Solid-state Architecture Batteries for Enhanced Rechargability and Safety (SABERS) activity aims to develop high specific energy solid-state batteries that can safely operate at high temperatures, without the flammability concerns that are common with the use of current state-of-the-art Lithium-ion batteries. The SABERS batteries were designed with four key foundational principles in mind: performance, safety, sustainability, and supply chain. To accomplish these foundational principles, the SABERS team performed a detailed systems level analysis coupled to an exhaustive computational modeling effort to determine the best electrochemical system to meet these criteria. It was determined that the sulfur-selenium cathode chemistry coupled to a solid-state battery architecture would meet these foundational principles. Sulfur is known for its ultrahigh theoretical energy density, as well as its low cost (currently priced at 2 cents per kilogram), its abundance, (it is a waste by product of oil refinement), and its wide accessibility within the U.S. (currently the U.S. is the second largest producer of sulfur in the world). The SABERS chemistry does not require the use of nickel or cobalt, both of which are now in short supply. This means that SABERS chemistry is both sustainable and eliminates supply chain concerns. Solid-state chemistry was chosen due to its inherent non-flammability and high temperature operation (up to 150 °C operation) which significantly enhance the safety of SABERS batteries.
The SABERS team has demonstrated very exciting results at both the coin cell and pouch cell levels. With optimized cathode composition and processing conditions, and the use of NASA-invented holey graphene, SABERS coin cells exhibit a specific energy as high as 543 Wh/kg, with still much design space to improve further. The team is currently scaling-up the technology to make larger scale pouch cells in both rectangular and circular shapes by engineering solid electrolyte separator and cathode fabrication techniques. Preliminary results suggest that these pouch cells will have a similar level of performance to the coin cells.
SABERS cells can safely operate in a wide temperature range from 0 to 150 °C and can be stored at colder temperatures without affecting their performance. With regard to safety, some SABERS pouch cells have been cut into smaller pieces and the pieces continue to operate without producing a flame nor an increase in temperature.
The team recently successfully demonstrated a bipolar stack individual cells, separating each cell in the stack with a lightweight membrane. This unique arrangement eliminates the complexity and added weight of individually packing each cell, which ultimately improves the specific energy of the stack.
Currently, SABERS cells are at a TRL level of 3-4 because the cells are fabricated and tested at the lab scale. The team is still improving cell manufacturing techniques for pouch cell scale-up. The team projects that the SABERS cells will move from TRL 4 to 6 through FY26 as validation of the cells will occur through flight demonstrations.
The application space for the SABERS batteries is vast, ranging from electric aviation, space applications, and military applications to electric vehicles and personal electronic devices. Safety is paramount: the SABERS cells are non-flammable and continue to operate even when damaged. SABER's high temperature operation coupled with non-flammability reduces the complexity and weight of thermal-management and battery-management systems, ultimately improving performance and safety compared to current state-of-the-art lithium ion battery packs.
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