Solid-State Batteries Get Closer to Mass Manufacture

­I’ve been writing about solid-state batteries for a while now, both in this column and in my weekly blogs. The problem with battery technologies is that you are often writing about innovation that may not come to market for a number of years or even decades, if at all. Now, it seems that solid-state batteries are finally about to enter the mainstream. Several companies have announced that production batteries will be included in vehicles, as soon as the end of this year. Perhaps the most eye grabbing headline was from Huawei, when the company claimed that its new solid-state battery had the potential to provide EVs with a range of 3000 km, with energy density of up to 500W/kg, and a charging time of 5 minutes. The materials that Huawei uses are very expensive, and the charging infrastructure would need a massive upgrade to reach that recharge time, so that battery may prove more of a concept than an actual production device. However, other companies are far closer to market with more economical solid-state batteries. These include, CATL, Panasonic, Factorial, QuantumScape, and Toyota, who are all very close to mass production. Toyota promises to have an EV with a range of 1,200 km, a charging time of ten minutes, and a lifetime of 30 years, launched in 2027. Stellantis says it will incorporate Factorial’s solid-state batteries into a demonstration fleet by 2026, and closer still, Hyundai claims that it will have pilot vehicles with solid-state batteries later this year. These batteries will still be expensive and mainly used in top of the range vehicles initially, but the price should fall quickly as manufacturing scales up.

Solid-state batteries normally use similar materials to regular Li-ion batteries but have a solid electrolyte instead of a liquid one. The solid electrolyte makes them inherently safer than normal Li-ion batteries. The reason for this is that the liquid electrolyte is caustic, and Li-ion batteries can explode of spontaneously combust if not handled correctly. Those safety issues usually mean that Li-ion batteries are encased in a thick metal casing to stop leaks, prevent them taking damage, and try to contain any fires. As solid-state batteries do not face these problems, there’s no need for that thick casing, meaning that more cells can be fitted together in a similar space, increasing energy density. In addition, Li-ion batteries often need equipment to stop them overheating and expanding. Those are generally unnecessary with solid-state batteries, making the vehicles even lighter or providing room for additional cells, and therefore range.

Although EVs are the target area for many of the manufacturers of solid-state batteries, other areas will also benefit. For example, Maryland based ION Storage Systems has begun shipping its Cornerstone battery, the first commercial generation of ION's solid-state technology, to leading consumer electronics companies. The multilayer cells are designed for integration into smartphones, laptops, wearables, and other small products.