The increasing number of fire/explosion incidents related to lithium-ion batteries (LIBs) for mobile devices and electric vehicles (EVs) in the recent years have raised significant concerns regarding their safety and reliability. The use of solid electrolytes provides a technical solution to address the safety issues of lithium-ion batteries and enables a bipolar design of high-voltage and high-energy battery modules. The bipolar design avoids unnecessary components and parts for packaging and electrical connection; therefore, it facilitates an increase in the volumetric energy density of the battery, while enabling easy build-up of total output voltage. Here, we report the design and construction of a multi-layered bipolar ASSB using a hybrid solid electrolyte (HSE) membrane. The HSE membrane proposed in this work consists of inorganic Li0.29La0.57TiO3 (LLTO) perovskite and poly(ethylene oxide) (PEO). The perovskite-structured LLTO was selected as an inorganic solid electrolyte specifically as a result of its high Li+ conductivity, excellent mechanical strength, and high chemical stability against moisture. The hybridization of LLTO with PEO allows for the fabrication of thin and large-area electrolyte membranes with high ionic conductivity, without the need for high-temperature sintering. Moreover, the soft and adhesive PEO improves the interfacial contact between the electrolyte and electrode, resulting therefore in enhanced electrochemical performance of the prepared ASSBs. Although the concept of hybridization between inorganic material (garnet-Li7La3Zr2O12 and NASICON-Li1.5Al0.5Ge1.5(PO4)3) and polymer has been proposed previously, the focus in these earlier studies has been predominantly on optimizing the electrolytes to improve their Li+-conducting and/or mechanical properties and/or demonstrating their applications in the monopolar-type, small-sized ASSB. By contrast, little attention has been given to the design and fabrication of bipolar ASSBs with HSEs, which is essential for demonstrating the feasibility of HSEs in large-scale ASSBs with high voltage and energy. In this study, the HSE membranes based on LLTO and PEO were synthesized in the form of flexible and freestanding sheets with a thickness of ~30 mm using a simple casting method. The optimized HSE membrane exhibits remarkably enhanced Li+ conductivity, electrochemical window, and thermal stability when compared to a solid PEO-only membrane, facilitating reversible charge–discharge operations of ASSBs. Finally, a proof-of-concept bipolar ASSB comprising three unit cells connected in series was designed and constructed using the HSE membrane, and its electrochemical performance was investigated.
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