Qualification of the atmospheric plasma spraying process for the coating of copper current collectors on (solid-state) battery components
Duration: 01.03.2025 – 31.08.2027
Research objective
The CoCoBatt project is investigating the suitability of the atmospheric plasma spraying process for the production of copper current collectors for anode-free solid-state batteries (AFSSB). The aim is to deposit a thin copper layer non-destructively on ceramic solid electrolyte and to produce an optimized interface contact that enables repeated deposition of anode material. Particular attention is paid to the problem of the high mechanical pressure exerted on the brittle electrolyte ceramic in foil-based processes. This often leads to cracks within the ceramic, which favor the growth of lithium dendrites. These dendrites can quickly penetrate the cell and lead to a short circuit, which significantly reduces long-term stability. The plasma spraying process offers a low-pressure alternative that maintains the structural integrity of the separator while optimizing interfacial contact. In addition, the project analyzes the effects of mechanical stresses on battery life and the stability of the copper layers under cyclic loads. Finally, it is being investigated whether a symmetrical cell can be realized by coating both sides of the solid electrolyte without delamination or mechanical failure. The plasma spraying process is intended to enable economical large-scale production and increase the performance of solid-state batteries. At the same time, it should make it easier for small and medium-sized enterprises (SMEs) to get started with innovative battery technology. The research results will be published in scientific publications and implemented in practice in close cooperation with project partners.
Demonstrator CoCoBatt
Description
The use of the atmospheric plasma coating process addresses the technical, economic and ecological bottlenecks in the production of anode-free solid-state batteries. By investing in a plasma coating system, SMEs can carry out a process step with high added value without having to invest in battery production lines, cathode material laboratories or complete cell production facilities that are prohibitively expensive for them. Instead, the project concentrates on a defined process step that can be clearly separated economically and locally from the production of a full cell. After the coating process, there is still no metallic lithium or sodium in the semi-finished product (solid electrolytic ceramic plasma-coated with copper current collector). This means that the semi-finished product can be shrink-wrapped and stored in large quantities, and can be sold on to an end user or processor. The project deals with the anode side of a battery. After the process step, the method is cathode-independent and allows an end user to apply any cathode to the back of the coated electrolyte, thereby increasing the customer market. There is a general desire in the literature for metallic lithium or sodium to be deposited on the anode side of a solid-state battery [5].
can be deposited [5]. The production of a battery cathode has a much larger number of variables: The cell chemistry and its exact synthesis and the production of specially shaped cathode particles, which are influenced by the selection of suitable base particles. Their shape, size distribution, sintering time and temperature steps, as well as coating with suitable coating paste, influence the properties of the cathode particles. This is followed by the selection of suitable electrolytes. These are processes that can only be mastered by large industrial groups, such as BASF in Schwarzheide in Europe in the near future for cathode material production and the subsequent cell production of automotive OEMs. The CoCoBatt project offers an SME the opportunity to
to work on a technological leap in battery development and production without having to invest the kind of capital that is usually only affordable for international stock corporations. Since the current collector can be produced with little plant and process engineering effort, provided the parameters and process windows – which are to be determined in this project – are known. In addition, the plasma coating system does not have to be designed for a specific ceramic material or substrate geometry, but can be used for large and small-area coatings or for large and small series production by adapting the workpiece carrier with the appropriate configuration
Research institutes and contact persons
For further contact details, please contact the office. E-Mail to office
- FAU Erlangen-Nürnberg Lehrstuhl für Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik
- Fraunhofer-Institut für Keramische Technologien und Systeme IKTS
