All-solid-state lithium batteries (ASSBs) have several advantages over lithium-ion batteries (LIBs) such as higher safety thresholds associated with solid electrolytes (SEs) and the possibility of using lithium metal or silicon anodes to achieve comparatively higher energy and power density. The SE can also prevent chemical interactions with dissolved active materials, and thus solve the issue of long-term instability of LIBs. However, there are also challenges associated with ASSBs manufacturing, such as local stress and contact-loss between SE and active materials in cathodes due to active material “breath”, poor contact and high ionic resistance at the SE-cathode interface, difficulty in fabricating thin SEs, and the absence of scalable and cost-effective manufacturing processes (J. Janek and W.G. Zeier, Nature Energy 8 (2023): 230-240). A key to tackling these issues begins with ink formulation for electrolyte and cathode coating, including ink compositions and rheological properties.In this study, we report the influence of ink preparation methods and conditions on the solid-state electrolyte and cathode coating qualities, where lithium lanthanum zirconium oxide (LLZO) and lithium nickel manganese cobalt oxide (NMC) are used as model systems. Various mixing methods, such as acoustic wave mixing, high-speed off-axis mixing, and thin film mixing, are compared. Their influence on ink viscosity and particle dispersion, coating thickness and microstructure uniformity, and electrolyte and electrode electrochemical properties will be discussed.
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