Upscaling of Thin Film Coating
AGC Plasma Technology Solutions is partnering with several energy start-ups to scale up next-generation thin film coating technologies that enhance battery and electrolyser performance.
One initiative focuses on upscaling AGC’s PlasmaMAX© PECVD process to an industrial Roll-to-Roll platform, enabling high-volume production of 100% silicon anodes. These anodes, developed by GDI, dramatically increase both volumetric and gravimetric energy density in lithium-ion cells. The PECVD process itself is environmentally sustainable, relying on abundant precursor materials and avoiding wet-chemical steps.
A second collaboration, with ABEE, explores thermal evaporation to produce ultra-thin lithium metal layers without contamination—an advanced alternative to foil lamination by extrusion. This method also allows the integration of protective coatings via magnetron sputtering in a single pass.
A third project addresses solid-state batteries, where AGC is advancing the sputtering of insulating solid electrolytes such as LiPON. Achieving this with DC power—instead of radio frequency—marks an important step toward industrial scalability.
Finally, in the field of Proton Exchange Membrane (PEM) electrolysers, AGC has upgraded one of its pilot coaters to apply protective platinum coatings using HiPIMS. This enables dense, well-adhered layers on titanium fibre substrates, ensuring durability in demanding electrochemical environments.
Key Takeaways:
- Scalable Silicon Anodes – Roll-to-Roll PECVD enables sustainable mass production of 100% silicon anodes, boosting lithium-ion energy density.
- Innovative Lithium Deposition – Thermal evaporation offers a cleaner, more efficient route for lithium metal layers, with integrated protective coatings.
- Advanced Solid Electrolyte Coatings – DC sputtering of LiPON supports industrial-scale solid-state battery development.
- Protective PEM Coatings – HiPIMS delivers robust platinum layers for enhanced PEM electrolyser durability.
