I-Corps: Translation potential of a manufacturing platform for high-performance thick battery electrodes using liquid crystal- or gel phase-regulated assembly

Award ID: 2627379

This I-Corps project is based on the development of a scalable manufacturing platform for producing high energy density battery electrodes. Currently, conventional battery manufacturing methods have challenges producing thick, high-loading electrodes with reliable mechanical integrity and electrochemical performance, which limits energy density and increases costs. This technology introduces a small amount (110 vol%) of liquid crystal or gel polymer during thermomechanical processing to guide particle self-assembly and densification. The method enables thick, high-loading electrodes with significantly higher areal capacity and energy density while remaining compatible with existing roll-to-roll battery manufacturing equipment. The target is manufacturers of lithium-ion batteries for electric vehicles, grid-scale storage, aerospace systems, and advanced energy platforms. This technology may provide measurable improvements in energy density, manufacturing yield, and cost reduction to support next-generation batteries for electric vehicles, grid-scale energy storage, and aerospace applications. This I-Corps project utilizes experiential learning coupled with first-hand investigation of the industry ecosystem to assess the translation potential of liquid crystal or gel phaseregulated manufacturing to produce thick battery electrodes. The dominant industrial method today is slurry coating, in which active materials are mixed with solvent and binder, coated onto a current collector, and dried. While this process is scalable, solvent evaporation creates pore gradients and stresses when electrodes become thick, leading to cracking and non-uniform binder distribution. As a result, commercial electrodes are typically limited to about 100 microns in thickness. This technology uses liquid crystal or gel phase during thermomechanical processing, enabling fabrication of electrodes with thicknesses ranging from 200 to 500 micrometers and improved structural uniformity. Ongoing efforts focus on evaluating scalability and compatibility with industrial roll-to-roll production methods. This technology may accelerate the commercialization of advanced battery manufacturing processes, while supporting broader deployment of renewable energy systems and electrified transportation and contributing to a resilient energy economy. 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.

NSF Program Director: Ruth Shuman