The performance of composite solid electrolytes (CSEs) composed of poly(ethylene oxide) and ceramic oxide-type solid electrolyte fillers has been shown to be highly dependent on the available surface area of filler inside of the composite. This is due to the formation of new transport pathways in the polymer-ceramic interphase, a region some tens of nanometers between the bulk polymer and ceramic surface. The small volume of this interphase relative to the size of traditional particles presents a design problem: Using micron-scale filler particles, a nm-thick interphase can never occupy a meaningful volume fraction of the composite. Thus, nanoparticles are often used in CSEs. However, the inevitable agglomeration of nanoparticles prevents a continuous interphase from forming even in the best dispersion conditions. Therefore, efforts to explore and exploit this synergistic transport mechanism have so far relied on careful, slow, and expensive methods designed to yield a continuous polymer-ceramic interphase between electrodes, e.g., cast nanowires, infiltrated 3D-structures, or templating.In this work we report a ceramic solid electrolyte, Li1.3Al0.3Ti1.7(PO4)3 or LATP, with a multiscale hollow spherical microstructure, designed to maximize the available continuous interphase volume in the composite. The hollow spherical structure is achieved by synthesizing LATP particles onto 10-15 μm carbon spheres, then subsequently pyrolyzing the carbon to achieve micron-scale hollow spheres composed of nano-scale LATP particles. This structure effectively prevents the bulk agglomeration of individual LATP particles, while still allowing for long, continuous interphase pathways. Importantly, the non-directionality of the filler means that the manufacture of the films remains simple.The hollow spherical microstructure of the filler had significantly enhanced the room temperature conductivity of the composite solid electrolyte, to 1.64 x 10-4 S/cm – the highest reported for an LATP-containing CSE with micron-scale filler particles. The mechanical properties, thermal stability, and electrochemical stability of the composite solid electrolyte were also significantly enhanced. This approach is a promising method to exploiting the synergistic transport in composite solid electrolytes while maintaining their excellent manufacturability.
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