Solar Energy
Finding key to low-cost, fast production of solid-state batteries for EVs
A new fabrication technique could allow solid-state automotive lithium-ion batteries to adopt nonflammable ceramic electrolytes using the same production processes as in batteries made with conventional liquid electrolytes.
The melt-infiltration technology developed by materials science researchers at the Georgia Institute of Technology uses electrolyte materials that can be infiltrated into porous yet densely packed, thermally stable electrodes.
The one-step process produces high-density composites based on pressure-less, capillary-driven infiltration of a molten solid electrolyte into porous bodies, including multilayered electrode-separator stacks.
“”While the melting point of traditional solid state electrolytes can range from 700 degrees Celsius to over 1,000 degrees Celsius, we operate at a much lower temperature range, depending on the electrolyte composition, roughly from 200 to 300 degrees Celsius,” explained Gleb Yushin, a professor in the School of Materials Science and Engineering at Georgia Tech. “At these lower temperatures, fabrication is much faster and easier. Materials at low temperatures don’t react. The standard electrode assemblies, including the polymer binder or glue, can be stable in these conditions.”
The new technique, to be reported March 8 in the journal Nature Materials, could allow large automotive Li-ion batteries to be made safer with 100% solid-state nonflammable ceramic rather than liquid electrolytes using the same manufacturing processes of conventional liquid electrolyte battery production.
The patent-pending manufacturing technology mimics low-cost fabrication of commercial Li-ion cells with liquid electrolytes, but instead uses solid state electrolytes with low melting points that are melted and infiltrated into dense electrodes. As a result, high-quality multi-layered cells of any size or shape could be rapidly manufactured at scale using proven tools and processes developed and optimized over the last 30 years for Li-ion.
“Melt-infiltration technology is the key advance. The cycle life and stability of Li-ion batteries depend strongly on the operating conditions, particularly temperature,” Georgia Tech graduate student Yiran Xiao explained.
“If batteries are overheated for a prolonged period, they commonly begin to degrade prematurely, and overheated batteries may catch on fire. That has prompted nearly all electric vehicles (EV) to include sophisticated and rather expensive cooling systems.” In contrast, solid-state batteries may only require heaters, which are significantly less expensive than cooling systems.
Yushin and Xiao are encouraged by the potential of this manufacturing process to enable battery makers to produce lighter, safer, and more energy-dense batteries.
“”The developed melt-infiltration technology is compatible with a broad range of material chemistries, including so-called conversion-type electrodes. Such materials have been demonstrated to increase automotive cell energy density by over 20% now and by more than 100% in the future,” said co-author and Georgia Tech research scientist Kostiantyn Turcheniuk, noting that higher density cells support longer driving ranges. The cells need high-capacity electrodes for that performance leap.
Georgia Tech’s technique is not yet commercially ready, but Yushin predicts that if a significant portion of the future EV market embraces solid-state batteries, “This would probably be the only way to go,” since it will allow manufacturers to use their existing production facilities and infrastructure.
“That’s why we focused on this project – it was one of the most commercially viable areas of innovation for our lab to pursue,” he said.
Battery cell prices hit $100 per kilowatt hour for the first time in 2020. According to Yushin, they will need to drop below $70 per kilowatt hour before the consumer EV market can fully open. Battery innovation is critical to that occurring.
The Materials Science lab team currently is focused on developing other electrolytes that will have lower melting points and higher conductivities using the same technique proven in the lab.
Yushin envisions this research team’s manufacturing advance opening the floodgates to more innovation in this area.
“So many incredibly smart scientists are focused on solving very challenging scientific problems, while completely ignoring economic and technical practicality. They are studying and optimizing very high-temperature electrolytes that are not only dramatically more expensive to use in cells but are also up to five times heavier compared with liquid electrolytes,” he explained. “My goal is to push the research community to look outside that chemical box.”
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800-mn-euro battery factory to be built in Finland
by AFP Staff Writers
Helsinki (AFP) Mar 20, 2025
A Chinese-Finnish company announced Thursday it would begin building a battery materials plant in Finland in April, the first of its kind in the Nordic country.
The plant will produce cathode active material, a key component in lithium-ion batteries used in electric vehicles and for energy storage, said Easpring Finland New Materials, a company co-owned by Finnish Minerals Group and Beijing Easpring Material Technology.
It said the investment was worth 800 million euros ($868 million).
The announcement came one week after a bankruptcy filing by Swedish battery maker Northvolt, which had planned to develop cathode production but dropped those plans to focus on battery cell production as it fought for survival.
Easpring Finland New Materials said commercial production was expected to begin in 2027.
The plant, to be located in Kotka in southeast Finland, will initially produce 60,000 tonnes of cathode active material annually.
At full production capacity, it could supply cathode material for the production of around 750,000 electric vehicles annually, the company said.
Matti Hietanen, the chief executive of Finnish Minerals Group, said the investment created an “entirely new kind of industry in Finland related to the production of lithium-ion batteries” and represented a European “spearhead project for the industry.”
The new plant will employ 270 people and an area of around 80 hectares had been reserved for its construction.
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Nanocellulose infused with red onion extract shields solar cells from UV degradation
by Robert Schreiber
Berlin, Germany (SPX) Mar 20, 2025
Researchers at the University of Turku in Finland have developed a bio-based film that provides high-performance UV protection for solar cells, utilizing nanocellulose treated with red onion skin extract. This marks the first comparative study of how various bio-derived UV filters perform over time.
Solar cells, susceptible to damage from ultraviolet radiation, are typically shielded by petroleum-derived films such as polyvinyl fluoride (PVF) or polyethylene terephthalate (PET). In an effort to reduce reliance on fossil fuels, researchers are exploring sustainable alternatives like nanocellulose, a material made by refining cellulose into nanoscale fibers that can be customized for UV blocking capabilities.
The study, conducted in collaboration with Aalto University in Finland and Wageningen University in the Netherlands, revealed that nanocellulose films dyed with red onion extract blocked 99.9% of UV rays up to 400 nanometres. This performance surpassed that of commercial PET-based filters, which served as a benchmark in the research.
“Nanocellulose films treated with red onion dye are a promising option in applications where the protective material should be bio-based,” stated Doctoral Researcher Rustem Nizamov from the University of Turku.
Researchers evaluated four types of nanocellulose films enhanced with red onion extract, lignin, or iron ions, all known for their UV-filtering properties. Among them, the film incorporating red onion extract demonstrated the most effective UV shielding.
Effective UV protection must be balanced with the ability to transmit visible and near-infrared light, essential for solar energy conversion. While materials like lignin excel in UV absorption, their dark hue hinders transparency. In contrast, the red onion-based film achieved over 80% light transmission at wavelengths between 650 and 1,100 nanometres, maintaining this level over extended testing.
To simulate prolonged outdoor use, the films were exposed to artificial light for 1,000 hours, equating to roughly one year of natural sunlight in central Europe. Researchers tracked changes in the films and solar cells through digital imaging.
“The study emphasised the importance of long-term testing for UV filters, as the UV protection and light transmittance of the other bio-based filters changed significantly over time. For example, the films treated with iron ions had good initial transmittance which reduced after aging,” tells Nizamov.
Tests focused on dye-sensitised solar cells, which are particularly prone to UV-induced deterioration. The findings also have broader implications for other solar technologies like perovskite and organic photovoltaics, where bio-based UV filters could play a crucial role.
“These results are also relevant for the UV protection of other types of solar cells, including perovskite and organic photovoltaics, as well as any application where the use of a bio-based UV filter is paramount,” Nizamov says.
Looking ahead, the researchers aim to create biodegradable solar cells that could serve as power sources in applications such as food packaging sensors.
“The forest industry is interested in developing new high-grade products. In the field of electronics, these may also be components for solar cells,” noted Kati Miettunen, Professor in Materials Engineering.
The University of Turku’s Solar Energy Materials and Systems (SEMS) group is exploring ways to integrate solar technologies into broader energy systems.
This work was part of the BioEST project, supported by the Research Council of Finland.
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Space Solar teams with MagDrive to boost in-orbit solar power systems
by Sophie Jenkins
London, UK (SPX) Mar 20, 2025
Space Solar, a leading force in the field of space-based solar power (SBSP), has formed a strategic alliance with UK propulsion technology company Magdrive to enhance the deployment of large-scale infrastructure in orbit. The agreement, unveiled during the Farnborough International Space Show (FISS), is formalized under the Space Propulsion and Infrastructure Innovation Initiative (SPI3), reflecting a concerted push to realize space-driven clean energy.
SPI3 is designed to help fulfil the UK’s long-term goal of producing scalable, sustainable energy directly from space. By integrating Magdrive’s advanced propulsion systems, the initiative addresses the complex challenge of transporting, assembling, and managing substantial SBSP infrastructure in orbit.
Space Solar plans to launch its first 30-megawatt SBSP platform within five years, and success hinges on the ability to control and maintain massive solar satellite structures. Magdrive’s propulsion solutions are poised to support upcoming demonstration missions by enabling essential orbital maneuvers, satellite assembly, and shape optimization.
“Innovation in propulsion is essential to making large-scale space infrastructure a reality,” said Sam Adlen, Co-CEO of Space Solar. “Space Solar and Magdrive share a vision of advancing sustainable space operations that benefit earth, and this collaboration will pave the way for new propulsion solutions that will be indispensable for space-based solar power and other large scale space infrastructure.”
This partnership is also set to strengthen the UK’s space sector by stimulating high-value job creation and technological advancement. It highlights the country’s dedication to leading innovation at the intersection of clean energy and aerospace.
As part of SPI3, both companies will collaborate on refining propulsion specifications tailored to SBSP systems and identify additional applications for these technologies within the broader context of UK-led space initiatives. The cooperation is a key step towards expanding the UK’s footprint in the global space economy and unlocking emerging opportunities in space-based energy markets.
“We’re excited to work with Space Solar, they’re building the future of space energy and infrastructure on a scale never seen before. By working together we’ll be propelling the space industry towards enabling sustainable life on earth. Here’s to the new space age!” said Mark Stokes, CEO, MagDrive.
United by a vision to deliver scalable energy solutions from space, Space Solar and Magdrive’s agreement represents a pivotal move toward the commercialization of SBSP. As Space Solar progresses toward critical mission milestones, incorporating Magdrive’s propulsion technology will bring the reality of space-derived clean energy closer than ever.
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