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Robust interface and reduced operation pressure enabled by co-rolling dry-process for stable all-solid-state
Dong Ju Lee1, Yuju Jeon1, Jung-Pil Lee2
1Aiiso Yufeng Li Family Department of Chemical and Nano Engineering, University of California, San Diego, 9500 Gilman Drive, La Jolla, CA, 92093, USA.
Nature Communications
|May 6, 2025
Summary
A novel dry-process enhances solid-state battery fabrication by co-rolling electrolyte and electrode layers. This method yields thin, robust solid-state electrolyte layers with improved mechanical stability and battery performance.
Area of Science:
- Materials Science
- Electrochemistry
- Sustainable Manufacturing
Background:
- Dry-processing offers a solvent-free, sustainable route for all-solid-state battery (ASSB) fabrication.
- A key challenge remains the development of pragmatic fabrication designs for thin, mechanically robust solid-state electrolyte (SSE) layers.
Purpose of the Study:
- To develop a dry-process approach for enhancing the mechanical stability of SSE layers throughout fabrication and cell operation.
- To achieve simultaneous fabrication of thin SSE layers and high-loading positive electrodes using a co-rolling technique.
Main Methods:
- Co-rolling of thick SSE and positive electrode feeds to create integrated films.
- Characterization of the physical properties, interface integrity, and electrochemical performance of the fabricated SSE-positive electrode films.
- Assembly and testing of an all-solid-state pouch cell using the integrated films.
Main Results:
- Simultaneous achievement of a uniform, thin SSE layer (50 µm) and a high-loading positive electrode (5 mAh cm⁻²).
- The integrated SSE-positive electrode film demonstrated enhanced physical properties and superior cyclability (>80% retention after 500 cycles) at low stack pressure (2 MPa).
- An all-solid-state pouch cell achieved high stack-level specific energy (310 Wh kg⁻¹) and energy density (805 Wh L⁻¹).
Conclusions:
- The co-rolling dry-process effectively enhances the mechanical stability and performance of SSE layers by creating a reinforced and intimate SSE-positive electrode interface.
- This integrated film approach is crucial for advancing practical, high-performance all-solid-state batteries.
- The demonstrated pouch cell performance highlights the potential of this dry-process for scalable and sustainable battery manufacturing.
