Synthesis and Processing of Battery Materials: Giving it the Plasma Touch

Abstract Li‐ion batteries (LIBs) are currently the most preferred energy storage devices in portable applications. Recent surge in the production of electric vehicles in the wake of the current global warming scenario has strongly increased the demand for LIBs, thereby reinforcing the need for new battery chemistries as well as making the existing production chain more efficient and sustainable. Several new technologies are explored to achieve these goals. Among them, plasma technology has the potential to simplify the synthesis and modification of battery materials, enable ‘dry’ and ‘green’ processing that eliminate the need for solvents that are often toxic, expensive, flammable, and energy‐intensive. In this review, we have attempted to provide an overview of state‐of‐the‐art (scientific) research and development with respect to the application of plasma‐based processes in the synthesis and modification of materials for battery components. We have explored various applications wherein plasma‐based processes have been demonstrated in the processing of electrode materials, electrolytes, and separators in addition to the recent developments in the context of solid‐state and flexible batteries. Our analysis shows that plasma‐based technologies are slowly but steadily gaining attention in these areas. Several technical and conventional issues remain, which require innovations at the conceptual as well as engineering levels. Technical issues include the selection of appropriate plasma type and precursors, plasma density, selectivity, and a preferable shift from vacuum to atmospheric conditions. The conventional issues include the practical difficulties in converting or adapting the assembly lines to plasma‐based technology. From a business perspective, all that matters is the cost per mAh g−1 of energy produced, for which, unfortunately, we do not have sufficient quantitative data yet with regard to the materials processed by plasma‐based technologies. However, the battery manufacturing sector is now open for innovations like never before. Therefore, it remains to be seen how plasma technologies embrace this opportunity and penetrate the battery production sector, where the key parameters are efficiency and cost‐effectiveness. Would ‘giving it the plasma touch’ bring added value to the battery manufacturing processes? That is the question we try to address in this review.