Energy storage will play a critical role in the success of future NASA missions that require batteries with higher energy density, higher power, and most critically improved safety. These performance requirements, which extend beyond those for electric automobile markets, must be satisfied to enable widespread adoption of electric aviation. One approach to improve battery safety and energy is to transition to non-volatile solid-state electrolytes (SSE) which promise many advantages over traditional flammable liquid electrolytes and may also be an enabling technology for next generation chemistries such as lithium-sulfur (Li-S). However, significant manufacturing challenges must be overcome before the adoption of such technology. This study will discuss development of solid electrolytes specifically designed to meet future NASA electric aviation targets. Separator films were processed with densified thickness between 20-30 microns using solvent processing techniques [1]. These films were produced 10-15 times thinner than comparable bulk pressed powder electrolytes and achieved thicknesses comparable to commercial polyolefin separators (25 micron) used in commercial liquid containing lithium-ion cells. Furthermore, design considerations and fabrication techniques of novel cathode composites optimized through the integration of experiment and particle dynamics modeling will be discussed [2] [3]. [1] Donald A. Dornbusch, Rocco P. Viggiano, John W. Connell, Yi Lin, Vadim F. Lvovich. Practical considerations in designing solid state Li-S cells for electric aviation, Electrochimica Acta, 2021, 139406, ISSN 0013-4686,[2] Vesselin I. Yamakov, April A. Rains, Jin Ho Kang, Lopamudra Das, Rehan Rashid, Ji Su, Rocco P. Viggiano, John W. Connell, Yi Lin. Pressure Dependence of Solid Electrolyte Ionic Conductivity: A Particle Dynamics Study. ACS Applied Materials & Interfaces 2023, 15 (22) , 27243-27252.[3] Elizabeth A. Barrios, April A. Rains, Yi Lin, Ji Su, John W. Connell, Rocco P. Viggiano, Donald A. Dornbusch, James J. Wu, and Vesselin Yamakov. Li-Ion Permeability of Holey Graphene in Solid State Batteries: A Particle Dynamics Study. ACS Appl. Mater. Interfaces 2022, 14, 18, 21363–21370.
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