CARTS 2013 Novel Ceramic and Metal Materials for Energy Storage and Clean Tech

1. CARTS 2013Novel Ceramic and Metal Materials for Energy Storage and Clean Tech Brian Foster & Dr. Gordon Dayton Foster Rush Electronics, Nano Technology and Clean Tech

2. Outline • Introduction • Fuel Cell Materials • Lithium Ion Battery Materials • Solar Cells • Conclusions

3. Introduction • Passive component value chain trends: • Passive component price erosion continues to outpace unit growth by 5-10%/year • Component miniaturization • Migration of manufacturing to low cost geographic regions • Aggressive competition for high value component market space • Increasing raw material costs • Consolidation in the electronic materials supply chain • Supply/demand imbalance • Competition among end use applications • Macro-economic pressures • Continuation of European economic malaise • Reduced growth expectations for US • Moderation of growth rate in China

4. Introduction • Search for Adjacent Market Spaces • New and Trending • Not commoditized • Value-added materials • Leverage existing technology platforms and manufacturing competencies to maximize return on investment • Benefit from development incentives • Candidate Markets: • Clean Technology (SOFC, Solar Cells) • Energy Storage (Li Batteries)

5. Heated Solid Oxide Fuel Cells • 1930’s development • Early versions difficult to commercialize • Clean technology trends are driving new development • Byproducts: H2O, O2-depleted Air, electricity • Potential for small, highly efficient source of clean energy

6. Heated SOFC • Fuel: hydrocarbon gas (i.e., methane) • Air (Oxygen source) • Electrolyte: ZrO2-based (YSZ, ScSZ, GDC) • Anode: Ni-ZrO2 Cermet • Cathode: (La,Sr)MnO3 • Temperature: 500-1000C • Cathode is bulk material

7. Hydrothermal Zirconia Process • High purity raw materials • Co-doping possible • Low-temperature precipitation • Synthesis at ~400C • PSD can be tailored by process conditions • Potential for low-agglomeration CA 102447125A

8. Hydrothermal ZrO2 Properties

9. Sinocera Hydrothermal YSZ • High surface area • Fine particle size • Highly dispersed • Easily handled • Easily processed

10. Sinocera YSZ Ceramic • Uniform microstructure • High density • Fine grain size • Low firing temperature • Forming: 100 Mpa • Tsinter: 1360 oC • Density: 6.03 g/cc

11. Lithium Ion Battery Technology • Applications: • Consumer Electronics – established/expanding • Military/Aerospace – growing • Electronic Vehicle – development (huge potential) • Advantages • High energy density • No memory effect • Low static drain

12. Lithium Ion Battery (LIB) • Cathodes: • Li,Co-Oxide* • Li,Fe-Phosphate • Li,Mn-Oxide, • Li,Mn,Ni,Co-Oxide • Anode: Graphite • Separator: permeable membrane** • Electrolytes: Li-salts *LCO cathode is preferred for energy density, but has safety issues, especially if damaged **Separator must be permeable to liquid electrolytes to facilitate charge/discharge

13. LIB Separator Technology • Porous polymer Membrane • Typically Polyethylene or Polyproplyene • Porosity > 40% • Not developed solely for LIB applications • Prone to development of Li-dendrites

14. LIB Separator Failure Mode • Separator Matrix: • Polyethylene • Polypropylene • Other: PVDF, etc. • Separator Porosity • > 40% • Failure mode • Li dendrite growth • Electrical shorting • Overheating • Separator melting / fire EP1401037 Lithium metal precipitates in porous membrane and forms dendrites under EMF - EP1401037, Mar 2010

15. Lithium Ion Battery Risks

16. LIB Composite Separators

17. LIB Separator Filler Materials • Limit growth of Li-dendrites • Established options: • CaCO3, SiO2, Al2O3, TiO2, SiS2, SiPO4 • Development: high K filler enhances electrolyte dissociation • BaTiO3

18. High Purity BaTiO3 for Fillers • High purity raw materials • Fine control of reactant ratio • Low-temperature reaction • Highly crystalline output powder Samsung Oxalate BaTiO3 Process

19. Samsung Fine Chemical Oxalate BaTiO3 - SBT Powder

20. Samsung Fine Chemical Oxalate BaTiO3 Properties

21. Solar Cell Technology • Established Technology • Trend for clean energy • Potential for off grid or grid connected applications • Recent government subsidies drive growth • Competition in material market for cost and performance • Aluminum backside conductor • Highly engineered silvers for front conductor

22. Solar Cell Technology • Front Conductor • Silver powder ink • Cell Material • Doped silicon wafer • Back Conductor • Silver powder ink • Aluminum powder ink

23. Silver conductor Technology • Fine powders for conduction efficiency • Good adhesion to Si-wafer • “Ohmic” contact critical to efficiency • Resinate additives improve function • Lower processing temperature • Increase network development

24. Daiken Chemical Company Resinate Technology

25. Typical Resinate Performance • Low temperature sintering • Halogen and sulfur free to eliminate corrosive decomposition products • Thin film formation on a nano scale • Homogeneous mixing at molecular level for conductive paste additive applications

26. Conclusions • High price pressure on passive component value chain • Adjacent markets may offer profitable opportunities • Leveraging existing core competencies combined with development incentives offers attractive return on investment • Follow global megatrends • Market examples include: • Clean Technology: SOFC, Solar • Ceramic Fuel Cells alliance with Chaozhou Three Circle Group • Murata Ag paste for solar cell (metal wrap through technology) • Energy Storage: Li Batteries • EnerSys and Ioxus joint development agreement