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High-Performance, Roll-to-Roll Fabricated Scaffold-Supported Solid Electrolyte Separator for Practical

Seok Hun Kang1, Hyobin Lee2, Young-Jin Hong3

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Summary
This summary is machine-generated.

Researchers developed a thin, robust solid electrolyte separator (SES) for all-solid-state batteries (ASBs). This innovation enables higher energy densities, paving the way for safer, next-generation energy storage solutions.

Keywords:
all‐solid‐state batterieshigh energy densitylaser‐drilled scaffoldroll‐to‐roll fabricationsolid electrolyte separator

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Area of Science:

  • Materials Science
  • Electrochemistry
  • Energy Storage

Background:

  • All-solid-state batteries (ASBs) offer enhanced safety and higher energy density potential compared to traditional lithium-ion batteries (LIBs).
  • A key challenge for practical ASBs is the development of thin, mechanically stable solid electrolyte separators (SESs) capable of supporting high energy densities.

Purpose of the Study:

  • To fabricate a thin, mechanically robust SES using a scalable tape casting method for high-performance ASBs.
  • To evaluate the ionic conductivity, mechanical properties, and performance of the fabricated SES in a prototype battery cell.
  • To investigate the impact of scaffold porosity and pore distribution on ion transport and plating behavior through simulations.

Main Methods:

  • Fabrication of a 27 µm thin SES using a tape casting method, combining Li6PS5Cl solid electrolyte (SE) with a laser-drilled porous polyimide (PI) scaffold (69% porosity).
  • Characterization of the SES's ionic conductance (146 mS cm⁻²) and mechanical properties (7.15 MPa tensile stress at 6% strain).
  • Assembly and testing of a LiNi0.83Co0.11Mn0.06O2||Li-In pouch cell using the fabricated SES and simulation studies on ion flux and plating.

Main Results:

  • The SES achieved high ionic conductance and demonstrated mechanical integrity suitable for roll-to-roll manufacturing.
  • The prototype pouch cell exhibited high gravimetric (322 Wh kg⁻¹) and volumetric (571 Wh L⁻¹) energy densities.
  • Simulation results emphasized the critical role of scaffold porosity and pore distribution in ensuring uniform ion flux and preventing lithium plating.

Conclusions:

  • The developed thin and robust SES is a viable component for high-energy-density ASBs.
  • The scalable fabrication method, including a 4m long prototype, confirms the potential for industrial-scale production.
  • Optimizing scaffold design is crucial for maximizing the performance and safety of scaffold-supported SESs in ASBs.