Critical Resources booms on solid-state battery breakthrough

Critical Resources has delivered a huge manufacturing breakthrough from its solid-state battery evaluation program, successfully depositing a complete cathode, solid-state electrolyte and conductive network layer in a single, dry step.

And the market would appear to agree, with the company’s share price surging as much as 42 per cent in early trade on the best turnover in almost three months.

The company says the achievement represents a streamlined pathway to building solid-state lithium-ion batteries, potentially slashing the cost and complexity of a process that is typically energy and capital-intensive.

The process, known as dry spray deposition, or “DSD”, essentially “3D prints” the battery’s core components in a single pass at room temperature. It completely removes the need for solvents, binders, drying ovens and furnaces, which are hallmarks of conventional battery manufacturing.

‘Doing it solvent free, at room temperature, points to a cleaner and simpler way of making these cells.’

Critical Resources managing director Tim Wither

In its latest trial, Critical’s program combined lithium iron phosphate cathode material, a lithium lanthanum zirconium oxide solid electrolyte and a carbon nanotube conductive network into a single composite layer.

The result was a dense, uniform coating about 15 microns thick, deposited on battery-grade aluminium foil. For comparison, a human hair is 60 microns thick.

Management says the single-step process tackles one of the hardest problems in the field, the interface between the cathode and the electrolyte. Poor contact between these two layers is a leading cause of solid-state cell failure.

By co-depositing them, Critical says it can build a stronger, more reliable connection directly into the material, rather than the usual process of joining the two elements after they have been manufactured.

The work is being conducted with the South Dakota School of Mines and Technology (SDSMT) as part of a US National Science Foundation-supported research program. Critical holds an exclusive option over a portfolio of solid-state battery patents being developed at SDSMT.

It is one of two parallel workstreams the company is advancing, with the other focused on developing its own proprietary amorphous solid-state electrolyte, or “ASE”, material.

Unlike conventional batteries that rely on a liquid electrolyte to transport lithium ions, Critical’s ASE enables ions to move more efficiently through a solid electrolyte, potentially delivering safer batteries that charge faster, store more energy and last longer.

Critical Resources managing director Tim Wither said: “Depositing solid electrolyte, cathode and a carbon-nanotube conductive network in a single step, is a genuine milestone for our program. The hardest part of a solid state battery is the join between the cathode and the electrolyte, and forming that join during manufacture, rather than pressing finished parts together afterwards.”

While the company is pushing the boundaries of battery technology, it also holds a diversified portfolio of more traditional exploration assets. Its flagship Mavis Lake lithium project in Ontario, Canada, could provide a potential future upstream supply line for its downstream battery ambitions.

The company also holds the Halls Peak base metals project in New South Wales and a growing gold portfolio in New Zealand. Recent reconnaissance sampling at its Croesus project in New Zealand confirmed a high-grade gold-antimony system, with rock chips returning up to 13.3 grams per tonne gold and 0.7 per cent antimony.

With the latest battery manufacturing milestone now under its belt, Critical’s focus will turn to testing the new composite layer. Electrochemical testing in a coin-cell battery format is now underway to establish a baseline performance.

From there, the program will aim to develop a full-format pouch cell for independent evaluation. A pouch cell battery uses a flexible foil bag instead of a rigid metal cylinder and can be stacked easily, fitting into tight spaces within gadgets such as mobile phones, laptops, electric cars and satellites.

The ultimate goal is to integrate its proprietary ASE electrolyte material into the DSD manufacturing process to create a fully in-house solid-state cell.

With this latest result, Critical has potentially demonstrated a simpler and cleaner way to build a solid-state battery. The company’s model is not to build the batteries itself, but to license the intellectual property.

By improving not only the materials but also the manufacturing process, the company is methodically building a case for its technology. With testing now underway, the market will likely be watching with interest to see what kind of performance improvements this patented one-step deposited electrolyte-conductor layer can deliver.

Is your ASX-listed company doing something interesting? Contact: mattbirney@bullsnbears.com.au