To be more clear, my guess is that
the number one and quickest benefit of Maxwell’s technology is to allow for a thicker cathode layer and hence a higher active materials volume ratio and higher cell energy densities even with existing cathode chemistry.
The cathode energy density is generally the limiting factor in cell energy density so obviously increasing the % of cathode material in a cell is the easiest way to increase cell energy density. In fact I understand this has been the key driver of battery cell improvements over the past 20 years – “The gradual improvement in energy density over the last 20 to 25 years was mostly due to cell engineering, which has increased the volume ratio of active materials from ~20% in early Li-ion cells to ~45% in today’s state-of-art cells [7,8]. Thickening electrodes in cell stacks while making current collectors and separators thinner is one effective approach to continuously increasing the active material content for higher energy density and lowcost Li-ion batteries.”
Understanding limiting factors in thick electrode performance as applied to high energy density Li-ion batteries (Journal Article) | OSTI.GOV
The problem with this simple approach is increasing cathode thickness beyond a certain amount can lead to underutilisation of the cathode materials and also lower power density. So you get diminishing returns and counterproductive effects after a certain thickness.
I think this is why the focus shifted to solid state batteries – lithium metal anodes have a much higher energy density so they allow for much thinner anode and hence a higher % of cathode in the overall cell (solid state can theoretically have other potential benefits like faster charge time, increased cycles, less flammable etc). The solid state electrolyte is mainly just there as requirement to safely manufacture lithium metal anodes.
It looks like Maxwell is increasing cathode thickness c.50% within the current 18650 cell design. So they must be reducing thickness of the electrolyte, anode or separators etc a corresponding amount (anode thickness reduction would require a new anode chemistry with higher energy density). If they manage to fully utilize the full thickness of this cathode material without adverse impact to power density, safety, cycle life etc, they should get a significant increase in cell energy density without changing the cathode chemistry while remaining viable for quick deployment in EVs.
I think Tesla’s battery breakthrough approach may end up looking very much like their Camera vs Lidar approach for Autonomy. Everyone else spends 5 years trying to bring Lidar costs down from $100k to $10k while Tesla gets further just using cameras which were $100 all along. Everyone else spends 5-10 years trying to commercialise new solid state battery designs while Tesla specs beat solid state just from iterating the current technology.
Also, I'm not a battery cell expert, i've only followed the tech for a while and read a bunch of papers, so someone correct me if any of this is wrong.