Technology

Enhancing High-Energy Li-Ion Batteries for Commercial Applications

The demand for high-energy density lithium-ion (Li-ion) batteries is surging across critical sectors, including electric vehicles, consumer electronics, drones, and air taxis. Silicon (Si) has emerged as a leading candidate for next-generation Li-ion battery anodes, boasting a theoretical specific capacity of approximately 3,600 mAh/g—over ten times that of the current graphite anodes used in commercial batteries (350 mAh/g).
However, silicon's significant volume expansion (~300%) during the lithiation process presents challenges such as particle pulverization and rapid capacity loss, leading to shorter battery lifespans.
Moreover, silicon's lower electrical conductivity compared to graphite adversely affects power performance when integrated into batteries. Addressing these issues requires innovative modifications to silicon or the development of silicon-based composite materials.

Current Industry Solutions and Challenges

Academic research has explored various silicon-based composite structures, including buffer and porous designs. Despite their potential, these designs often encounter inherent drawbacks and practical limitations that impede their direct application in commercial batteries. On the commercial side, simpler products like silicon-graphite composites and silicon oxide (SiOx) are available from some manufacturers. However, their efficiency does not meet industry expectations. Existing silicon anode technologies fall short of commercial requirements due to performance limitations and challenges related to manufacturing costs and scalability. Additionally, incorporating 30-70% silicon into commercial batteries is challenging, as the limited anode volume restricts the accommodation of silicon expansion while maintaining profitability.

Nonetheless, some current efforts to design commercial products with high content of Si (> 70%) is worthy of notice. Porous Si structure may be a viable solution to overcome the limitations of non-porous SiC materials. Pre-existing pores will provide the volume needed for Si expansion. This battery with high energy density (1.5 times compared to general commercial products) demonstrated good cycle life with more than 2,000 cycles at a 1C rate. However, the technology’s complicated manufacturing processes, which results in high cost and low productivity, seriously hinder its commercialization capabilities.

Innovative Solutions and Strategic Direction

HKG Energy’s initiative focuses on developing a scalable manufacturing process for porous silicon-based anodes with high silicon loading (>70%). Our innovative anode design and fabrication method promise substantial improvements in next-generation batteries, offering high energy density, extended cycling stability, and rapid charging capabilities. As a contingency, we will optimize silicon utilization (20-30%) through an enhanced design featuring micron-sized silicon particles distributed within artificial and natural inner pores. This configuration minimizes overall particle expansion by accommodating most volume changes. Additionally, applying a conductive additive and lithium-titanate oxide (LTO) coating enhances fast charging performance and cycle longevity by facilitating rapid lithium ion transport and stabilizing the solid-electrolyte interphase (SEI) layer. The conductive carbon coating further supports efficient electronic and ionic transport within the silicon-based anodes.
Our strategy is poised to advance the rational design of silicon-based anodes, paving the way for their successful integration into industrial applications and meeting the growing demand for high-performance Li-ion batteries.

Together, let's unlock the potential of silicon and power a brighter tomorrow.

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