Integrating Polymer Electrolytes-Based Thick Composite Cathodes in All-Polymer Solid-State Lithium Metal Batteries

Abstract

High energy density solid-state batteries require high areal loading composite cathodes (>4 mAh/cm2). However, increasing the cathode loading or thickness can introduce additional challenges apart from the expected rate capability limitations, which are much less pronounced in low loading or thin composite cathodes. These include greater volume changes during cycling at the cell level, which can introduce stresses at the various interfaces. While there are many successful reports showing long-term stable cycling of high loading composite cathode in all-inorganic solid-state cells, these cells are typically cycled under high pressures (>10 MPa), which may be impractical to commercialize. Such high pressures can alleviate the interfacial contact loss issues generated due to volume changes during cycling. Polymer electrolytes are non-rigid and can potentially accommodate strains to maintain contact at the interfaces during cycling, given sufficient adhesion. In this work, we will show some of the design strategies that were implemented to alleviate the contact loss issue at the polymer electrolyte separator/composite cathode interface in order to achieve stable cycling with thick polymer electrolyte-based composite cathodes in coil-cell configuration. Nickel-rich NMC (LiNixMnyCozO2) cathodes (NMC811 or 622) were used as the active materials. Since polymer electrolytes are known to be unstable with high voltage cathodes such as NMCs, the contribution of oxidative instability to the overall capacity decay will also be discussed by comparing two polymer electrolytes with different oxidative stability (a PEO-based dual-ion polymer electrolyte, and a single-ion polymer electrolyte). This research was sponsored by the U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy for the Vehicle Technologies Office’s Advanced Battery Materials Research Program (Simon Thompson, Program Manager). A part of this research was sponsored by the Laboratory Directed Research and Development Program of Oak Ridge National Laboratory (ORNL), managed by UT-Battelle, LLC for the U.S. Department of Energy under Contract No. DE-AC05-00OR22725. The SEM in this work was performed and supported at the Center for Nanophase Materials Sciences in Oak Ridge National Lab, a DOE Office of Science user facility.