FMRG: Eco: Dry manufacturing of Solid-State Sodium Batteries for Energy STorage at large scale (S3-BEST)

建筑、风能和太阳能农场以及电网的储能系统在缓解能源、可持续性和气候变化挑战方面发挥着越来越重要的作用。人们希望可充电电池具有高安全性、低成本、长寿命和对环境变化的高弹性。如今的锂离子电池（lib）已经无法满足这些要求，因为易燃液体电解质存在安全问题，而且通常用于制造锂离子电池的关键材料（如钴、镍、锂）存在结垢挑战。钠（Na）全固态电池（NaSSB）被认为是LIB的一种有前途的替代技术，用于新兴的大规模存储应用。然而，NaSSB中使用的固态电解质（sse）具有有限的离子电导率，空气/水分敏感性以及与电池中其他组件的界面不稳定性。开发高效环保的制造工艺面临的主要挑战是：1)精确控制电极和ssi的厚度、孔隙度和均匀性；2)混合轧制速度快，缺陷低；3)高纯度的回收材料，其性能与原始材料相同。该未来制造研究基金（FMRG） ecommanufacturing项目将开发新知识，帮助将当今的NaSSB电池制造转变为基于干式制造工艺的闭环、环保、高精度和高产量技术。它还将使制造过程更安全，更便宜，因为增加了电池能量密度，消除了腐蚀性有机溶剂以及相关的安全预防措施。不仅限于固态电池，在这个项目中开发的新概念和知识可以用来提高生产效率，降低当今LIB制造的成本。因此，它有可能使能源储存更容易被接受和负担得起，这将有助于能源行业转向更多的可再生能源，从而实现碳中和社会。与此同时，将制定新的教育、培训和劳动力发展计划，以改善制造业大学预科生、本科生和研究生的平等和机会。该项目的目标是开发一种范式转换的干式制造方法，使安全、低成本和弹性的大型储能系统的nassb的环保制造成为可能，以帮助美国实现可持续发展目标。该项目将汇集化学工程、纳米工程、化学、材料科学、生命周期分析/技术经济分析、机器学习和数据科学方面的专业知识，以及社区学院和工业界的合作者，共同开发新的制造工艺、先进材料和新的电池原型，这些原型可能用于广泛的大规模存储系统。该研究将专注于通过四个高度协同的重点来填补NaSSB制造的科学和知识空白：1)阴极、固态电解质和阳极的干制造工艺设计，使NaSSB电池结构具有高容量负载和长循环；2)综合技术经济和生命周期分析，指导和改进制造步骤，材料进步和回收过程。3)通过材料界面工程和制造过程的在线分析进行多尺度质量控制和标准化；4)闭环无废回收的设计与论证。这项研究创造的新知识和工具将在大规模系统中实现环保、低成本和安全的能源存储，从而实现可持续的能源基础设施。这个未来制造项目由工程理事会的电气、通信和网络系统（ECCS）、化学、生物工程、环境和运输系统（CBET）、土木、机械和制造创新（CMMI）、教育和人力资源理事会的本科教育司（DUE）和国际科学与工程办公室（OISE）共同资助。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

Energy storage systems for buildings, wind and solar farms, and electric grids are playing an increasingly important role in mitigating the energy, sustainability and climate change challenges. Rechargeable batteries with high safety, low cost, long life and high resilience to environment changes are desired. Today’s lithium-ion batteries (LIBs) can no longer meet these requirements because of the safety issues associated with flammable liquid electrolytes and scaling challenges for critical materials (e.g., cobalt, nickel, lithium) that are typically used for making them. The sodium (Na) all-solid-state battery (NaSSB) is considered a promising alternative technology to LIB for emerging large-scale storage applications. However, solid-state electrolytes (SSEs) used in NaSSB have limited ionic conductivity, air/moisture sensitivity and interface instability with other components in the battery. The major challenges towards the development of efficient and eco-friendly manufacturing process are the achievement of: 1) precision control of the thickness, porosity, and uniformity of electrodes and SSEs; 2) high-speed mixing and rolling with low defects; and 3) high-purity of recycled material with the same level of performance as pristine materials. This Future Manufacturing Research Grant (FMRG) EcoManufacturing project will develop new knowledge to help transform today’s NaSSB battery manufacturing to a closed-loop, eco-friendly, high-precision, and high-yield technology based on a dry fabrication process. It will also make the manufacturing process safer and cheaper because of the increased cell energy density, and the elimination of caustic organic solvents as well as the related safety precautions. Not only limited to solid-state batteries, the new concept and knowledge developed in this project can be leveraged to improve the production efficiency and lower the cost of today’s LIB manufacturing. Therefore, it has the potential to make energy storage more acceptable and affordable, which will help the energy industry to shift towards more renewable sources, leading to a carbon-neutral society. In parallel, new education, training and workforce development programs will be developed to improve equality and opportunities for pre-college, undergraduate and graduate students in the manufacturing industry.The goal of this project is to develop a paradigm-shift dry fabrication approach to enable eco-friendly manufacturing of NaSSBs for safe, low-cost and resilient large energy storage systems to help the United States meet the sustainable development goal. This project will assemble expertise in chemical engineering, nanoengineering, chemistry, materials science, life-cycle analysis/technoeconomic analysis, machine learning and data science, as well as collaborators in community colleges and industry to develop new fabrication processes, advanced materials and new battery protypes that can potentially be used for a wide range of large-scale storage systems. The research will focus on filling the science and knowledge gaps in NaSSB manufacturing through four highly synergistic thrusts: 1) Dry fabrication processes design for cathode, solid-state electrolytes and anode to enable NaSSB cell architecture with high-capacity loading and long-cycling; 2) Integrated technoeconomic and life-cycle analysis to guide and improve manufacturing steps, materials advancement and recycling process. 3) Multiscale quality control and standardization through materials interfacial engineering and inline analysis for the fabrication process; 4) Design and demonstration of closed-loop and waste-free recycling. The new knowledge and tools created from this research will enable eco-friendly, low-cost and safe energy storage in large scale systems for a sustainable energy infrastructure.This Future Manufacturing project is jointly funded by the Divisions of Electrical, Communications and Cyber Systems (ECCS), Chemical, Bioengineering, Environmental and Transport Systems (CBET), and Civil, Mechanical and Manufacturing Innovation (CMMI) in the Directorate of Engineering, the Division of Undergraduate Education (DUE) in the Directorate for Education and Human Resources, and the Office of International Science and Engineering (OISE).This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.