The SeNSE proposal aims at enabling next generation lithium-ion batteries with a silicon-graphite composite anode and a nickel-rich NMC cathode to reach 750 Wh/L. Cycling stability is the key challenge for the adoption of this cell chemistry. The objective is to reach 2000 deep cycles by (i) reducing the surface reactivity of the active materials by a combination of novel film-forming electrolyte additives and active materials coatings, (ii) compensating irreversible lithium losses during the first cycles employing pre-lithiated silicon and providing an on-demand reservoir of excess lithium in the cathode, (iii) identifying and controlling critical cycling parameters with data provided from in-cell sensors. Adaptive fast charging protocols will be integrated into the battery management system based on dynamic in-cell sensor data and by implementing thermal management concepts on materials and electrode level. To improve the sustainability of the battery and to lower production cost, the content of the critical raw materials cobalt and natural graphite will be reduced. Enabled by protective coatings, aqueous slurry processing will be developed for the cathode. Costs will be further lowered and energy density improved by the development of thinner textured current collector foils offering enhanced adhesion. The feasibility and scalability of the SeNSE battery technology with respect to the call targets will be demonstrated through 25 Ah pouch cell prototypes and a 1 kWh module. Scalability to the gigawatt scale and cost-effectiveness of the proposed solutions, including aspects of recycling and second-life use, will be continuously monitored via regular briefings led by Northvolt, which currently undertakes one of the most ambitious efforts to establish a European cell manufacturing plant at scale. To strengthen the European IP portfolio in the battery field, patent applications are the preferred way of dissemination of technology developed within SeNSE.

Electrochemical reactions in battery materials normally lead to structural changes, which may cause degradation and damage, and thus causing the loss of functionality of the battery with cycling. Next-generation electrode materials for lithium-ion batteries are especially prone to these failure mechanisms because they react with greater amounts of lithium and thus undergo more drastic structural changes. BAT4EVER refers to microscopic self-healing of the micro-damages generated during repetitive charging/discharging processes at the Silicon anodes, NMC-based cathodes and electrolytes aiming a significantly improved charge-discharge cycle and calendar life of the Li-ion batteries. These challenging tasks will be overcome by applying self-healing polymer coverage around Si-NPs on the anode side and by synthesizing core-shell structured and thus redox-stabilised cathode nano-particles that are embedded in M-ions and H-bonds induced polymers. Ionogel and covalent bonded gels will initiate curing ability to the electrolytes. These battery component development acts will be supported with extensive use of material and structure characterisation methods and with atomistic modelling and cell simulation efforts. The processing technologies will be transferred to the scaling team of the consortium for prototype manufacturing. The prototypes will be tested under varies environmental and in next-generation cell phones as a case study.

This proposal describes the third stage of the EC-funded part of the Graphene Flagship. It builds upon the results achieved in the ramp-up phase (2013 - 2016) and the first core project (2016 - 2018), and covers the period April 2018 - March 2020. The progress of the flagship follows the general plans set out in the Framework Partnership Agreement, and the second core project represents an additional step towards higher technology and manufacturing readiness levels. The Flagship is built upon the concept of value chains, one of which is along the axis of materials-components-systems; the ramp-up phase placed substantial resources on the development of materials production technologies, the first core project moved to emphasise components, and the second core project will move further towards integrating components in larger systems. This evolution is manifested, e.g., in the introduction of six market-motivated spearhead projects during the Core 2 project.

Si-DRIVE will develop the next generation of rechargeable Li-ion batteries, allowing for cost competitive mass market EVs by transformative materials and cell chemistry innovations, delivering enhanced safety with superior energy density, cycle life and fast charging capability using sustainable and recyclable components.The technology encompasses amorphous Si coated onto a conductive copper silicide network as the anode with polymer/ionic liquid electrolytes and Li-rich high voltage (Co-free) cathodes via processes that are scalable and demonstrably manufacturable within Europe.The components have been demonstrated at TRL3 through preliminary lab-scale analysis, with a clear component improvement strategy to arrive at a TRL5 prototype demonstration by the end of Si-DRIVE. Comprehensive theoretical and experimental studies will probe and control interfacial processes that have heretofore limited Li-ion technologies to incremental gains, guiding materials design and eliminating capacity fade mechanisms.The Si-DRIVE technology will exceed the stringent demands of EV batteries where safety is paramount, by dramatically improving each component within the accepted Li-ion platform and achieving this in a market competitive process with whole of life considerations. The technology will also demonstrate suitability for 2nd life applications at reduced energy density beyond the primary EV lifetime, prior to cost effective materials recycling, consistent with a circular economy.The Si-DRIVE consortium boasts the required academic and industrial partner expertise to deliver this technology and spans material design and synthesis, electrochemical testing, prototype formation and production method validation, life cycle assessment and recycling process development.

The core technological approach of the HYDRA project consists of using hybrid electrode technology to overcome the fundamental limits of current Li-ion battery technology in terms of energy, power, safety and cost to enter the age of generation 3b of Li ion batteries. HYDRA, taking its name from the mythological beast, will use a multi-headed integrative approach: In addition to novel material development and scale-up of components and battery cells manufacturing, assisted by modelling, HYDRA will build a synergy with strong investments by the project’s industrial partners and foster reaching and keeping a significant market share for Europe. The necessary competitiveness will be obtained by hybridizing high energy with high power materials. These materials will be implemented at the cell/electrode level, via sustainable, eco-designed scaled-up manufacture and safe electrolyte systems, demonstrated in pilot scale to TRL6, and will be ready for commercialisation 3 years after the project end. To reach this target, HYDRA mobilizes a strong industry commitment: the partners include a strong value-chain of suppliers with global competitiveness for xEV batteries and a direct liaison to the market in sectors such as automotive and maritime transport, ensuring a fast-uptake of results, with an added value of 1BN € in the next decade. Ecological and economical sustainability also keep a strong importance, as HYDRA will be performing life cycle assessments and value-chain analyses on local and global scales. All aspects from raw materials via battery cell production and end-use/market to recycling and 2nd life usage will be evaluated. The HYDRA concept uses abundant electrode materials like iron, manganese and silicon, and eliminates the use of the CRMs cobalt and natural graphite, with a net CRM reduction of >85%. The new materials will be produced in an environmentally friendly, energy-efficient manner, and using water in place of organic solvents.