SBIR-STTR Award

The objective of this proposal is to demonstrate the feasibility of producing novel electrochemical cells with energy density of >500 Wh/kg, capable of recharge rates of 1C, with a robust safety profile. To accomplish this, we plan to use our patented carbon technology to synthesize C/Si composites for the anode and C/S composites (lithiated) for the cathode (all other components will be commercially sourced). During Phase I, we will synthesize and test the C/Si materials (4 different combinations of Si content and particle size). We have already measured >500mAh/g on our C/Si composite with 10% Si (and will design the final composite for this application using that information as an input). The deliverables include electrochemmical test data on all the C/Si combinations synthesized during this phase of the project. We also plan to synthesize the C/S cathode materials and perform initial materials characerization testing on these. The goal here is to develop a one-pot process from the carbon and sulfur salt precursors to synthesize a C/S cathode with all the precursors being converted into the final components of the composite. Farad Power's process to synthesize carbons utilizes polymerization of a furfuryl alcohol carbon precursor in the presence of additives. Furfuryl alcohol is a liquid organic compound that is derived from agricultural waste (namely sugarcane bagasse and/or corn cob). It is readily available, inexpensive, and derived from a renewable source. We have studied this system in great detail and have synthesized >100 batches of carbon and carbon composites using this method in our labs. We have already been granted 8 patents on the technology and have filed several more. The data obtained from Phase I will be used to synthesize and test C/S cathodes during Phase II - with a goal towards fabricating coin and pouch cells using the C/Si and C/S electrode materials synthesized using our method. The main advantages of our method include ability to form very uniform and homogeneous mixtures of the C/S and C/Si composites. This is due to the fact that we use a liquid carbon precursor and mixing a solid powder into a liquid will result in a much homogeneous mixture than mixing two solid powders. Also, using a liquid carbon precursor with a Si powder will result in a complete coating of the Si particles with a carbon layer (formed after polymerization and carbonization of the furfuryl alcohol precursor).

This proposal aims to develop a better-performing battery pack for an EV vehicle that is part of a fleet of electric vehicles maintained by the 412 MXG group at Edwards AFB, CA. We plan to build this battery using our high-capacity proprietary and patented anode and cathode materials technology to give us cell-level specific energy of up to 500 Wh/Kg. To accomplish this, we plan to use our carbon technology to synthesize a Carbon/Silicon composite anode material with >800 mAh/g capacity and a Carbon/Sulfur cathode material with a capacity of >750 mAh/gm. During Phase I, we confirmed the suitability of using our process (polymerization of furfuryl alcohol– in the presence of Si particles and other additives) to synthesize Carbon/Silicon composite materials that were suitable for high-capacity LIB anode applications. Our Carbon technology (polymerization of furfuryl alcohol) represents a simple, robust and low carbon-footprint method of replacing graphite in traditional LIB cells - at an attractive price-point. Specifically, we demonstrated an initial capacity of >550 mAh/g with - with a Carbon/Silicon composite - as tested by our university sub-contractor (Pennsylvania State University) in ½ cell configurations. Our planned Phase II development work will use a smaller Silicon particle size and an increased ratio of Silicon-to-Carbon to achieve our goal of >800 mAh/gm. Several promising Si nanoparticles will be evaluated, along with several additives (to improve electrical performance and pre-lithiation of the anode powders). This proprietary anode material will be combined with commercial off-the-self cathode materials and electrolytes to construct our first next-generation LIB product offering. We also plan development work on a carbon-sulfur cathode material using the same approach (polymerization of furfuryl alcohol in the presence of S-based salts and other additives). This is anticipated to yield cathode materials with >750 mAh/g capacity. To construct our LIB cells, along with our proprietary electrode materials, we plan to use other commercial off-the-shelf components required to complete the cells. Farad Power's electrode materials synthesis process utilizes the polymerization of a furfuryl alcohol carbon precursor in the presence of additives. Furfuryl alcohol is a liquid organic compound derived from agricultural waste (namely sugarcane bagasse and corn cob). It is readily available, inexpensive, and derived from a renewable source. We have studied this system in great detail and have synthesized hundreds of batches of carbon and carbon composites using this method in our laboratories. We have already been granted ten patents on the technology and have filed several more.