Rechargeable electrochemical storage systems are increasing in importance for many fields of daily life. High-capacity energy storage devices, such as lithium-ion (Li-ion) batteries are used in a growing number of applications, including portable electronics, medical, transportation, frequency regulation of grid-connected large energy storage and uninterruptible power supply (UPS). In each of these applications, the charge/discharge time and capacity of energy storage devices (Wh/L and Wh/kg) are key performance parameters. In addition, the size, weight, flexibility, and/or cost ($/kWh) of such energy storage devices are also key parameters. Further, safety is necessary for all applications and safety is managed both at the cell level, pack level and at the system level. One way to improve the cell safety is to incorporate high ion conducting non-flammable electrolyte such as solid electrolytes.
New inorganic and organic polymeric materials have been discovered recently showing promising ionic conductivities in the vicinity of liquid electrolytes. One of the key challenge is to integrate these new materials in a cost effective way replacing liquid/gel electrolytes. High volume manufacturing issue needs to be addressed to successful commercialization of non-flammable high ion-conducting materials. In this talk some of the manufacturing challenges will be addressed.