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The first technique improves electrolyte densification, which is essential for ion conductivity and battery reliability overall. The process involves the use of a sintering aid (e.g., sulfur) to achieve denser and more stable electrolytes than are achievable through more common, high-temperature processes. Electrolytes that are denser and less porous have higher ion conductivity (thus better performance), longer cycle lives, and lower volatility. Aside from densification, this technique also significantly increased the base electrolyte's lithium wettability. The second innovation is a new cathode and electrolyte design using a mixed conducting material that can carry both ions and electrons, which simplifies the cathode’s composition by eliminating the need for separate ion and electron conductors. This catholyte is a composite that utilizes a mixed conducting material, replacing both the ion and electron conductors with a single material thus simplifying solid state cathode design from a 3-component to 2-component composite. The mixed material is composed of a metal chalcogenide, such as titanium disulfide (TiS2), which can act as a mixed conductor and contributes to energy storage. The addition of sulfur boosts energy capacity up to 33% compared to traditional cathode designs. Reducing single-conduction phases simplifies energy transport pathways and improves efficiency, making solid-state batteries easier to produce and safer to use. These two innovations work together to improve the state of the art, creating solid-state batteries with higher temperature tolerances and up to five times more energy capacity than current lithium-ion batteries. They stand together at a TRL 4 and are available for patent licensing individually or as part of the larger SABERS (LEW-TOPS-167) or SABERS 2.0 portfolio (LEW-TOPS-188).

The original SABERS portfolio established foundational materials and architecture for solid-state lithium-sulfur batteries through innovations in graphene-based cathodes, solid electrolytes, and bipolar plate designs. Building on this foundation, SABERS 2.0 addresses critical challenges that have limited the practical implementation and scalability of solid-state batteries: cathode efficiency and electrolyte performance, anode interface stability, and cell-level packaging optimization. The SABERS 2.0 portfolio comprises four complementary innovations that work together to improve solid-state battery performance and manufacturing viability. Major licensable technologies in the SABERS 2.0 portfolio include: • Mixed Conducting Cathodes and Dense Electrolytes (LEW-TOPS-186): Two complementary innovations in electrolyte densification and catholyte formulation that simplify manufacturing and improve energy capacity, ion conductivity, and battery reliability. • Solvent-Free Anode Interlayer (LAR-TOPS-405): A dry-processed interlayer that prevents dendrite formation, maintains stable interfaces, and enables cost-effective, environmentally friendly manufacturing. • Isostatically Pressurized Cell Case (LEW-TOPS-187): A lightweight pressure vessel system that provides uniform compression to solid-state cells, eliminating the need for heavy machinery while enhancing performance and longevity. These technologies may be licensed independently, as part of the SABERS 2.0 suite, or in custom combination with the technologies in the original SABERS suite (LEW-TOPS-167).

This technology is based upon a 120-watt IR laser is coupled to a fiber optic cable that is routed from the output of the laser into a series of focusing optics which directs energy onto a battery cell mounted to a test stand. When activated, heat from the laser penetrates the metal housing, heating the internals of the cell. At a specific temperature, the separator in the first few layers of the cell melts allowing the anode and cathode to make contact and initiates an internal short circuit. The internal short circuit then propagates throughout the battery eventually causing thermal runaway. The lower the wavelength of the laser used to produce the thermal runaway, the more heat-energy will be absorbed into the cell producing a faster result. The fiber optic cable can be terminated into a series of optics to focus the laser at a specific target, or the fiber optic cable can be stripped bare and placed next to the target to heat an isolated location. This method can also be used on a wide variety of cells, including Li-ion pouch cells, Li-ion cylindrical cells and Li-ion Large format cells. The innovation Triggering Li-ion Cells with Laser Radiation is at TRL 6 (which means a system/subsystem prototype has been demonstrated in a relevant environment) and the related patent application is now available to license and develop into a commercial product. Please note that NASA does not manufacture products itself for commercial sale.