Xerion Advanced Battery Corp. has developed two novel technologies for use in the production of advanced rechargeable batteries: DirectPlate™, a manufacturing process, and StructurePore™, a nano-structured material.

DirectPlate™ is a patented electroplating process that when used to make battery electrodes - anodes and cathodes - removes the need for binders and conductive additives. This results in batteries with higher energy and higher power that are lower cost. DirectPlate™ has been demonstrated with various substrate and plating materials, including various 2D foil substrates and variations of our 3D StructurePore™ substrate. In addition, when used with 2D foil substrates, the result can be a very flexible - bendable - battery.

StructurePore™ is a patented nano-structured 3D conductive foam that replaces the 2D foil as the current collector. This results in batteries with higher power, higher energy, and longer cycle life, that charge faster, run longer between charges, and run cooler, that are safer, lighter weight, and lower cost. StructurePore™ has been demonstrated in both the anode and cathode, and with various battery chemistries. It has also been used in 3D printed micro-batteries.

The combination of DirectPlate™ and StructurePore™ support flexible manufacturing in that batteries with different energy and power characteristics may be produced on a single production line without the need to retool.

Xerion is currently producing manufacturing representative pouch cells in a range of commercial li-ion chemistries. These prototypes can be rapidly customized to meet customer needs.