Robust interface and reduced operation pressure enabled by co-rolling dry-process for stable all-solid-state...

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.