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Solid-state batteries (SSBs) are rapidly advancing toward commercialization, with major companies like Toyota, Nissan, and Samsung SDI beginning pilot production and targeting GWh-level output by 2027. These batteries promise enhanced safety and higher energy density, yet face significant challenges related to high production costs and complex manufacturing processes. Despite these hurdles, manufacturers are progressing towards cost reductions through scaling, with TrendForce projecting costs to fall to USD 0.084–0.098 per Wh by 2035. Japanese companies, led by Toyota, are pushing for early mass production by 2026, while Chinese and South Korean firms follow closely, seeking to meet domestic demand for electric vehicles and energy storage.
Read more (https://www.trendforce.com/presscenter/news/20241031-12346.html)
SSBs are advancing towards commercialization as companies like Toyota, Nissan, and Samsung SDI begin pilot production, aiming to achieve GWh-level output by 2027. SSBs promise higher safety and energy density but face hurdles in production cost, complex manufacturing, and supply chain immaturity. Currently, semi-solid-state batteries, which have achieved GWh-scale deployment in EVs, cost over CNY 1/Wh (≈ USD 0.14/Wh), but TrendForce expects costs to drop below CNY 0.4/Wh (≈ USD 0.056/Wh) by 2035 with production advancements. All-solid-state batteries (ASSBs), progressing from prototypes to engineering-scale production, may see prices fall to CNY 0.6–0.7/Wh (≈ USD 0.084–0.098/Wh) by 2035 if demand scales above 10 GWh. Sulfide-based SSBs are particularly promising due to their high ionic conductivity, attracting major manufacturers despite challenges with cost and moisture sensitivity. Though current SSBs are not yet competitive with liquid lithium-ion batteries, TrendForce predicts cost reductions through scaling and strong government and capital support.
Atomic Layer Deposition (ALD) has become crucial for advancing solid-state batteries due to its ability to create uniform, pinhole-free, and conformal thin films on complex structures. For solid-state electrolytes (SSEs), ALD enables the deposition of materials like lithium phosphorus oxynitride (LiPON) with high ionic conductivity, which enhances overall battery performance by forming thin, conformal electrolyte layers. This technology also plays a significant role in interface engineering by modifying the interfaces between electrodes and electrolytes. ALD-deposited interlayers improve chemical compatibility, reduce interfacial resistance, and suppress unwanted reactions, thereby improving the durability and efficiency of solid-state batteries.
ALD is especially beneficial for the development of 3D battery architectures, where its conformal coating capability enables uniform deposition on high-aspect-ratio structures, increasing surface area and enhancing energy and power densities. In addition, ALD is used to apply protective coatings to electrode materials, which prevents degradation and enhances battery stability. Examples include ALD-grown lithium silicate films that serve as solid-state electrolytes with reliable ionic conductivity. Recent research highlights ALD’s essential role in producing high-performance ASSBs and SSBs, focusing on thin-film deposition precision and interface engineering to overcome challenges related to solid-state battery design and performance.
Key applications of ALD in sulfur-based SSBs include protective coatings on sulfur cathodes, enhancing solid electrolytes, and interface engineering. ALD can apply ultra-thin, conformal coatings on sulfur cathodes, which help to mitigate polysulfide dissolution—a common issue in sulfur-based systems that leads to capacity fading. By creating a barrier layer, ALD coatings help to prevent polysulfides from migrating, thereby enhancing cycle life and reducing degradation. For example, materials like Al2O3 and TiO2 deposited via ALD have been used to form stable interfacial layers that suppress undesirable reactions.
ALD is also utilized to improve the ionic conductivity of sulfide-based solid electrolytes, such as Li2S-P2S5, which are promising due to their high ionic conductivity and similarity to liquid electrolytes. ALD can deposit thin films of stabilizing materials on these electrolytes to prevent reactions with lithium and improve stability. Additionally, ALD helps create protective layers around sulfide electrolytes, which are highly sensitive to moisture and oxygen, reducing the need for stringent environmental controls.
Interface engineering is another important application of ALD, with the precision of ALD enabling the deposition of thin interlayers at the electrode-electrolyte interfaces, addressing the issue of poor contact and high interfacial resistance in sulfur-based SSBs. These interlayers help to form a stable “solid-solid” contact, minimizing interfacial impedance and enhancing ion transfer across the interface. Materials such as lithium phosphorous oxynitride (LiPON) or lithium silicate are often used in ALD processes to create these interlayers, leading to improved overall battery performance and stability.
Refernces:
https://www.frontiersin.org/journals/energy-research/articles/10.3389/fenrg.2018.00010/full
https://pubs.rsc.org/en/content/articlelanding/2021/na/d0na01072c
https://www.frontiersin.org/journals/energy-research/articles/10.3389/fenrg.2018.00010/full
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