Publication date: 21st July 2025
Boosted after their commercialization in 2023, Sodium-ion batteries (SIBs) are well positioned to become the energy storage system of choice for stationary applications and complementary to Li-ion in electromobility. This is a sustainable and low-cost technology that does not rely on critical raw materials and guarantees widespread availability free of geopolitical constraints, hence avoiding most of the drawbacks of lithium-based technology. However, SIBs energy density has not yet reached the performance levels of LiFePO4-based lithium-ion batteries (LIBs), partially hindering their application in other sectors. One of the most promising cathode materials, namely the P2-type layered oxides, is affected by irreversible sodium consumption during solid electrolyte interphase (SEI) formation and low sodiation degree: about 2/3. These two factors are the main drawbacks behind SIB’s underperformance. Solutions to these problems have been attempted with limited success and significantly hindering the fabrication cost of Na-based cells. We had a look at quick and low-cost metallization processes used in low value products, such as candy wrapping, to develop a scalable and cost-effective sodiation process based on Na thermal evaporation. This method solves the incomplete sodiation degree of P2-type sodium layered oxides, thus overcoming the first irreversible capacity as demonstrated by manufacturing and testing all solid-state Na doped-Na~1Mn0.8Fe0.1Ti0.1O2ǀǀPEO-based polymer electrolyteǀǀNa full cells. This polymer has proven to be suitable for other cell configurations with sodium-deficient electroactive materials that will be presented here. The proposed sodium physical vapor deposition method opens the door for an easily scalable and cost-efficient strategy to incorporate any metal deficiency in the battery materials, pushing further the battery development.
BMBF Transition transferproject (FZK 03XP0533).
NGS-New Generation Storage (C644936001-00000045) with funding from the European Union NextGenerationEU (PRR).