Fabrication of 60μm-Thick Free-Standing Bilayer Solid Electrolytes for Solid-State Batteries Using Solution Processing and Lamination

Abstract

Development of solid-state batteries with a high voltage cathode and lithium metal anode could enable high energy density while avoiding safety issues of flammable liquid electrolytes. However, the solid electrolyte (SE) should meet multiple requirements, including 1) electrochemical stability at both the cathode and anode side interfaces, 2) small thickness (tens of μm) to maximize energy density of the cell, and 3) fabrication with a scalable manufacturing method. Using bilayer SEs with different electrochemical stability windows could enable stability at both cathode|SE and anode|SE interfaces. In this work, we developed a manufacturing process to fabricate thin (60 μm) free-standing bilayer SE films from slurry casting and lamination, which can be used for large scale manufacturing of SSBs.Halide SE (Li3InCl6) and sulfide SE (Li6PS5Cl) were slurry casted on different substrates, and then were dried in vacuum before being laminated onto each other to make a free-standing bilayer film. The parallel slurry casting approach eliminates cross-compatibility requirements of the solvents used for slurry preparation. The resulting bilayer films after densification were pin-hole free without intermixing between the two phases. The ionic conductivity of the bilayer SE film was ~70% of the bilayer SE pellet (1 mm thickness in total) made with a conventional powder pressing method. However, because the thickness of bilayer SE film (60 μm) was much smaller than the bilayer SE pellet (1 mm), the bilayer SE film had ~10x lower area-specific resistance (ASR) compared to the bilayer SE pellet. Because of the lower total cell resistance, the cell made with the bilayer SE film had a better rate capability compared to the reference cell in pellet geometry.The strategy developed in this work could be integrated into current manufacturing infrastructure of battery fabrication as it is based on slurry casting, which is already a well-established fabrication method for lithium-ion batteries. Moreover, it could be used to fabricate multi-layered solid-state architectures in general, which are challenging to manufacture due to solvent compatibility issues during slurry casting. The study will assist the progress of solid-state battery manufacturing by providing a scalable manufacture method to prepare thin free-standing bilayer SEs.