SiFAB Advanced Silicon Anode Technology

#AdvMfgExpoInformation Classification: General

#TheBatteryShow #EVTechExpo

SiFAB Advanced Silicon

Anode Technology

Bruce Zoitos

1

Novel fiber-based anode offering:

• High energy density (>1000 mAh/g)

• Manufacturing flexibility: drop in to current cell manufacturing

• Performance: cycle life, high rate charge/discharge

• Commercial scale production coming in 2022, further capacity in 2023

Introducing…SiFABTM Silicon Fiber Anode Battery Technology

Visit us in Booth 1431

2

Unifrax is a Leading Global Supplier of High-performance Specialty Fibers

Unifrax is a global leader in high-performance specialty fibers and inorganic materials used in high-temperature industrial, automotive, and fire protection applications. We are committed to producing superior products that help our customers save energy, reduce pollution, and improve fire safety.

Quality Certifications: ISO 9001:2015 IATF 16949:2016

Greener.Lower fuel costs, higher operational efficiency, and significant energy savings.

Cleaner.High-performance, environmentally friendly solutions.

Safer.Maximum fire protection – for your people and your equipment.


3

FyreWrap® LiB Papers FyreWrap® LiB Coatings

FyreWrap® LiB Films & Enhanced Films Offering Blast ResistanceFyreWrap® LiB Boards & Felts

We Supply LiB Technology For Industry Leading OEMs

Cell-to-Cell Thermal Runaway Propagation Barriers

Module Passive Fire Protection

Heat Shielding

Battery Pack Passive Fire Protection


Unifrax Quality Certifications: ISO 9001:2015, IATF 16949:2016

4







Heat Shielding


LiB Battery Separator


5




Presentation Focus



Heat Shielding


LiB Battery Separator

Advanced Silicon Anode Technology

High capacity, silicon dominant anode resistant to swelling



6

A Simple, Novel, Scalable Approach to Silicon Anode.

High performance fiber…

• Ultra high-capacity silicon dominant anode• Unique geometry allows drop-in use to anode slurries• Allows better particle-particle contact• Offers better options for anode microstructure

Nanostructured…

• 30% open volume to accommodate swelling• Controlled high surface area to facilitate Li transfer• Short internal diffusion distances to minimize swelling stress

Highly scalable…• Manufacturing process uses established, large scale methods• Unifrax has a 75-year track record of supplying specialty fibers• Tested in Roll 2 Roll

SiFAB Nano Porous Fiber Structure

Artist rendition of SiFAB at nano scale

SiFAB on R-T-R anode

STEM of Si-C composite structure


7

SiFAB Manufacturing Expansion

Process Design is Modular & Scalable

Widnes, EnglandPrimary Fiber Production Plant


New Carlisle, Indiana Secondary Process Facility Online 2022

8

We Are Rapidly Scaling SiFAB Production to Hundreds of MT By 2023 Following 5 Years of Product Development

2017 2018 2019 2020 2021 2022 2023

First material synthesized

Internal R&D

1st Production Line

Fully dedicated plant

Performance testing with third party labs

Half cells Full coin cellsPouch &

cylindrical cells

Production Scale(Annual capacity)

Commercialization Timeline

Today

KG Samples available now

Data to be shared today

1,000 MT100s of MT capacity

by 2023

20 MT

Will continue to add scale ‘24 -25


9

High Capacity in Silicon Dominant Anode

Composite Reversible Capacity

>1000 mAh/g

Si / SiOx

SiFAB(Current Composition)

35%

65%

Carbon

Si/SiOx/C composite material design with high capacity

• Chemistry and process may be tuned to alter material base characteristics

• Can alter %Si, porosity, open volume % carbon

• Tailor desired capacity, other performance parameters, to end user need

• % Si -- capacity

• Porosity & carbon level to impact other parameters

• Following data is based on A single target structure


10

Roadmap to Enabling SiFAB in Lithium-Ion Batteries

SiFAB Development program

• Key base performance metrics

• SiFAB drop-in development

• Roll 2 roll process development

• Prelithiation studies

• High throughput cell optimization studies

• Swelling testing

• Large cell development


11


SiFAB technical programs are moving fast fully characterizing SiFAB

Anode Capacity up to 725 mAh/gAnode Capacity >1000mAh/g

Depends on customers’ current technology roadmap

Very High Capacity High Load w/ Prelithiation

Blended with Graphite


12

Prelithiation in 100% SiFAB Anode Study Details

2

2.5

3

3.5

4

0 20 40 60 80 100 120 140 160 180 200

Vo

ltag

e(V

)

Specific Discharge Capacity (mAh/g)

Voltage(V), vs. Specific Discharge Capacity (mAh/g)

Anode Capacity 1199 mAh/g

FCE = 89.2%

NMC 532 Cathode

Full cell, first cycle results • 100% SiFAB anode

• SiFAB anode externally pre-lithiated to 3 cycles in half cell

• Half cell anode capacity 1200 mAh/g

• Full cell FCE 89.2%, much attributable to NMC 532

Conclusion:

• Full Cell FCE 89.2%• Anode half cell capacity of 1200 mAh/g

realized by anode. (100% Si)

Based on cathode (pos-limited)


FCE 89.2%

Anode capacity 1200 mAh/g

13

Prelithiation in Composite Anode Study Details

• Composite anode: 69% SiFAB/31% Graphite

• SiFAB anode externally pre-lithiated to 25% capacity

• Full cell first cycle reversible anode capacity >900 mAh/g. (947 mAh/g in half cell)

• Full cell FCE ~89%, much attributable to NMC 622

Conclusion:

• Full cell FCE 89% • Full cell anode capacity of 900 mAh/g

(69Si / 31Graphite blend)

Full Cell, First Cycle Results

NMC 622//UF Si+Gr (Preli 25%)

25°C

2.5-4,3V

Cy1: C/20 CC, C/50 CV


FCE 89%

Anode capacity ~900 mAh/g

14

Commercial Scale Lithiation in Practice

Unifrax Worked with who have developed and enabled Commercial Scale

Lithiation Systems in a Tightly Controlled Turnkey Continuous Process Design.

In this Prototype work SiFAB containing cells achieved:

>90% FCE on roll to roll electrodes

Reversible Capacity >1000mAh/g

Up to 20% increase in modeled Gravimetric Energy Density

15

Full Cell Energy Density via PrelithiationModeling Results

Energy Density Improvement

Anode Wh/l

Graphite

SiFAB-925 mAh/g*

SiFAB-1200 mAh/g

661

758

824

* 69% SiFABTM blend with graphite


500

600

700

800

900

Vo

lum

etr

ic E

ne

rgy

De

nsi

ty

Graphite

SiFAB 925

SiFAB 1200

25%

* 100% SiFABTM

vs NMC 622

Can be >900 Wh/l using NMC 811

16


SiFAB technical programs are moving fast fully characterizing SiFAB

Anode Capacity up to 725 mAh/gAnode Capacity >1000mAh/g

Very High Capacity High Load w/ Prelithiation

Blended with Graphite


17

72

74

76

78

80

82

84

86

88

90

0 20 40 60 80 100

% F

irst

Cyc

le E

ffic

ien

cy

%SiFAB Blended with Graphite

SiFAB Can Be Easily Blended With Graphite

• Proven FCE increase with Graphite blend

• SiFAB easily incorporated into blended electrode

• Graphite blends up to 40% SiFAB demonstrate >80% FCE

• Reversible capacity up to 725mAh/g can be accessed at >80% FCE w/ up to 40% SiFAB

• Pouch cells are being tested for swelling


Half cellVs. Li foil

18

72

74

76

78

80

82

84

86

88

90

0 20 40 60 80 100

% F

irst

Cyc

le E

ffic

ien

cy

%SiFAB Blended with Graphite

SiFAB Can Be Easily Blended With Graphite

Up to 40% SiFABFCE > 80%

Reversible capacity up to 725mAh/g

80%

• Proven FCE increase with Graphite blend

• SiFAB easily incorporated into blended electrode

• Graphite blends up to 40% SiFAB demonstrate >80% FCE

• Reversible capacity up to 725mAh/g can be accessed at >80% FCE w/ up to 40% SiFAB

• Pouch cells are being tested for swelling



19

Anode StructureBlended SiFAB/Graphite Electrode Structure

50% SiFAB; 50% Graphite100% SiFAB; 0% Graphite 19% SiFAB; 81% Graphite

SiFAB readily blends with graphite and provides a bridging, connected structure


20

C/2 cycling studies indicate 250 cycles for

highest load (75% SiFAB)

Lower loadings projected to >500 cycles

Binders and electrolyte being optimized

for cycle life via high throughput studies.

Cycling in Single Layer Pouch Cells

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

0 50 100 150 200 250 300 350 400 450 500

% R

ETA

INED

CA

PAC

ITY

CYCLE #

9.4% SiFAB

19.4% SiFAB

29.4% SiFAB

50% SiFAB

75% SiFAB

SiFAB composite cells

Full Cell

NMC 532

C/2 cycling


75% SiFAB: 250 cycles to 80% Capacity

50% SiFAB: projected 500 cycles

21

Cycle Characteristics of SiFAB

60 cycles in half cell

>150 cycles half cell

As formed anode

0

500

1,000

1,500

0 40 80 120 160

Re

vers

ible

Cap

acit

y, m

Ah

/g

Cycle #

100% SiFAB AM showing stable cycling performance in half cell

Structurally stable: No evidence of anode pulverization



22

Overall cell swelling for cycle 1 (post

formation) and cycle 200.

Swelling measured at full charge and full

discharge—expansion on each cycle.

Swelling remains in defined band. Cells

do not show progressive expansion with

cycling.

Swelling Measurements of Pouch Cell

0

1

2

3

4

5

6

7

8

9

10

0 10 20 30 40 50 60 70 80

% E

XPA

NSI

ON

SiFAB LOADING (%)

Cycle 1

CELL SWELLING (%)D [TOC – BOC]


23

Overall cell swelling for cycle 1 (post

formation) and cycle 200.

Swelling measured at full charge and full

discharge—expansion on each cycle.

Swelling remains in defined band. Cells

do not show progressive expansion with

cycling.

Swelling Measurements of Pouch Cell

0

1

2

3

4

5

6

7

8

9

10

0 10 20 30 40 50 60 70 80

% E

XPA

NSI

ON

SiFAB LOADING (%)

Cycle 1

Cycle 200

CELL SWELLING (%)D [TOC – BOC]


24

High Rate Charge/Discharge Performance

SiFAB was tested in full cells for high rate performance The top binder systems from a previous study were tested At 4C, Discharge rate retention >74% was achieved and >60% Charge Rate Retention

0

20

40

60

80

100

120

0 1 2 3 4 5

CA

PAC

ITY

% C

/10

C-RATE

RATE CAPABILITY: CHARGING

0

20

40

60

80

100

120

0 1 2 3 4 5

CA

PAC

ITY

% C

/10

C-RATE

RATE CAPABILITY: DISCHARGE


60% CAPACITY AT 4C CHARGE RATE

74% CAPACITY AT 4C DISCHARGE RATE

FULL CELLSVs. NMC 6223 mAh/cm2

25

Key Takeaways & Next Steps

What we discussed Next Steps

SiFAB silicon dominant anode material showing high capacity and versatility

Tested with third party labs to establish optimal use

To learn more and request a material sample:

• Visit us in Booth 1431

• Go to sifab.com and join our mailing list

Unifrax partnering with OEMs and Cell Makers and have 1Kg samples available

75+ years of experience Large scale manufacturing

of SiFAB in 2022


#AdvMfgExpoInformation Classification: General

Thank you!

Questions?

#TBS19#TBS20#TheBatteryShow #EVTechExpo

Date post:	13-Feb-2022
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SiFAB Advanced Silicon Anode Technology

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