Tape Casting Method Research Articles

Thin alumina wafer fabrication by vat photopolymerisation based additive manufacturing

In VAT Photopolymerization (VP), a ceramic slurry is cured layer by layer under light (200–760 nm) to fabricate ceramic parts from a 3D CAD model. Lithography-based Ceramic Manufacturing (LCM) a VP process presents a significant advancement over traditional tape-casting methods in the production of thin ceramic substrates. While tape casting is limited in its ability to produce substrates in a single step, with thickness in the range of 100s of microns, typically necessitating the lamination of multiple tapes to achieve greater thicknesses. LCM overcomes this limitation, and it offers precise control over layer thicknesses, ranging from 10 to 100 microns, and is capable of directly printing substrates in the range of several hundred microns. This capability not only streamlines the manufacturing process but also ensures more consistent quality and greater flexibility in substrate thickness, making LCM a superior technique for producing thin ceramic substrates. However, the main challenge in LCM is to make these substrates without any warpage. This study aims to nail down the root cause of the warpage by employing various characterization techniques (including FTIR, nano-indentation, SEM and TGA), and by identifying factors that contribute to the warpage. It is observed that layer-wise fabrication leads to a curing gradient owing to the multiple exposures of already cured layers, causing the final layers to cure less than the initial ones. Due to this, mechanical properties such as hardness and modulus are significantly different for the initial and final layers. In thin parts (<300 microns), a significant proportion of under-cured layers contribute to pronounced warpage. To make a warpage-free substrate, a post-curing strategy is proposed and examined. It is concluded that 80 % of the warpage can be reduced by the proposed post-curing method.

Preliminary characterization of glycerin, gelatin, propylene glycol, and cellulose based substrates for application in green microelectronics

In this study, the potential of biopolymer-based films for printed electronics was investigated. Three different tapes were prepared using a modified tape casting method, with compositions including glycerin, propylene glycol, and cellulose combined with gelatin. The films were evaluated for their temperature resistance, dielectric properties, and water absorption. The results indicated that the film with propylene glycol exhibited the highest temperature resistance, making it suitable for further application in electronic devices. Additionally, the dielectric properties were stable across the tested frequency range, and further research on biopolymer based biodegradable substrates is recommended for environmentally friendly electronics.

The synergistic effect of cold sintering and reaction sintering on BST tape casting sheets

In this paper, the tape casting method was used to prepare BST (Barium Strontium Titanate) thin films and the effect of combining cold sintering and reaction sintering processes on the properties of BST sheets was explored. A comparison was made between cold sintering and direct BST sintering combined. The combined process yielded high-density BST sheets with significantly improved dielectric properties (the resulting BST sheets displayed a low dielectric loss of less than 0.02 with a dielectric constant of 720) at a reduced sintering temperature of 950 °C. The underlying mechanisms for this enhanced performance are explored through structural and sintering analysis.

Flexible and anisotropically conductive film by assembly of silicone rubber and cobalt-coated glass fiber composites

In this study, we prepared electromagnetic cobalt-coated glass fiber (Co@GF) composites via an electroless plating method. Subsequently, a conductive sandwich flexible film consisting of Co@GF composites and liquid silicone rubber (RTV-2) was successfully formed using the tape casting method at room temperature. Based on the perfect coating and excellent electrical conductivity of the Co@GF composites, the resultant RTV-2/Co@GF/RTV-2 sandwich flexible film showed a low volume resistivity of 0.264 Ω·cm and could stretch to 100% (of 4.40 Ω·cm) without obvious fracture. When a magnetic field was applied during the curing process, the electromagnetic Co@GF composites were aligned automatically in the RTV-2 matrix because of their ferromagnetic nature. The as-prepared film exhibited anisotropy in its electrical performance. The volume resistivity parallel to the magnetic field direction is approximately two times lower than that in the perpendicular direction. The maximum difference in the volume resistivity (ρ∥ = 0.768 Ω·cm and ρ⊥ = 1.549 Ω·cm) was obtained at a magnetic field intensity of 800 mT. In addition, a magnetic field intensity of 100 mT helps improve the electrical conductivity of the as-obtained sandwich film. The anisotropic RTV-2/Co@GF/RTV-2 sandwich flexible film is considered a promising flexible electronic sensor, where discrepant inductive sensitivity is required in orthogonal directions.

Polyvinylidene fluoride‐co‐hexafluoropropylene polymer gel electrolyte‐enabled dye‐sensitized solar cell for sustainable energy

AbstractDeveloped specifically to address leakage and stability concerns inherent in liquid electrolytes, this study presents a significant advancement in polymer gel electrolyte (PGE) formulation by combining potassium iodide (KI), ammonium iodide (AI) salts, and polyvinylidene fluoride‐co‐hexafluoropropylene (PVDF‐co‐HFP) as a host polymer. The tape casting method was employed to deposit the standard TiO2 paste as the photoanode and platinum paste as the counter electrode. N3 dye was incorporated, and PVDF‐co‐HFP was used as the PGE between the electrodes. The conductivity of PGE was measured by using a digitized conductivity meter. The quasi solid‐state solar cell (QS‐DSSC) assembled using single salts (KI, and AI), and mixed cations PGE was examined via photocurrent–voltage characteristics, and electrochemical impedance spectroscopy. The augmented ionic conductivity directly influences the efficiency of DSSCs. Notably, incorporating a mixed salt (KI + AI) within the PGE enhances ionic conductivity compared to single‐salt‐based counterparts. The resultant DSSCs using mixed salt PGE exhibit a Voc of 600 mV, Jsc of 1.01 mA/cm2, FF of 0.6089, and an efficiency of 0.369%, outperforming those using KI or AI. This highlights the perceptible advantages of employing this innovative electrolyte composition to enhance solar cell performance.

Optimizing energy storage performance of lead zirconate-based antiferroelectric ceramics by a phase modulation strategy

Dielectric energy storage has gained considerable significance owing to the high energy requirements of human society. Lead zirconate-based (PZ) antiferroelectric materials have received much attention due to their fast discharge rate, high power density, and low cost. Nevertheless, their low energy storage density seriously limits their practical applications. To overcome this limitation, the phase modulation strategy via chemical modification was adopted to optimize the breakdown strength and phase switching field. Specifically, the antiferroelectric ceramics of (Pb0.97−xGd0.02Srx)(Zr0.87Sn0.12Ti0.01)O3 were prepared by the tape-casting method. An apparent multistage phase transition behavior revealed for x ≥ 0.05 is rarely discussed in reported Sr2+ modified PZ system. This is attributed to the coexistence of the main orthorhombic phase and the tetragonal phase. Although the transition near the lower field reduces the energy storage slightly, the disruption of the long-range order stabilizes the antiferroelectricity of the orthorhombic phase, hence elevating its transition field. In addition, the tetragonal phase with lower polarization suppresses the electrostrain thus improving the breakdown strength. Consequently, an ultrahigh recoverable energy storage density of 14.5 J/cm3 with a high energy efficiency of 81 % is achieved at a high electric field of 717 kV/cm for (Pb0.92Gd0.02Sr0.05)(Zr0.87Sn0.12Ti0.01)O3. Moreover, the fatigue resistance of this composition is excellent within 26,000 fatigue cycles. Besides, it exhibits a high discharge energy density of 9.4 J/cm3 and a great power density of 387 MW/cm3. These results confirm that the energy storage properties of PZ-based antiferroelectric materials can be effectively optimized via a phase modulation strategy.

(Invited) Innovating Sustainable, Cost-Effective, and Durable Redox Flow Battery Membranes

In the quest to integrate renewable energy sources like solar and wind into the electric grid efficiently, the development of long-duration energy storage (LDES) systems is paramount. The U.S. Department of Energy's Long Duration Storage Shot initiative is at the forefront of this endeavor, aiming to reduce the costs of grid-scale energy storage by 90% for systems with over 10 hours of operation. A key player in this mission is the non-aqueous redox flow battery (RFB), known for its use of earth-abundant materials and potential to meet these cost-reduction goals. However, the commercial viability of RFBs hinges on the development of high-performance, cost-effective membranes, which are crucial for their functionality and affordability. These membranes' ionic conductivity is vital for the power density of RFBs, while their ion selectivity and solvent uptake greatly influence the batteries' cycle life.Our team has made groundbreaking advancements in membrane technology for non-aqueous flow batteries. We've addressed the challenge of balancing ionic conductivity with mechanical strength in polymer electrolytes. Our findings reveal that enhanced solvent uptake while boosting membrane ionic conductivity, can compromise mechanical integrity. To counter this, we've employed two strategies: selective plasticization of the ion-conductive block in block copolymers and reinforcing the membrane's mechanical strength through hydrogen and ionic bonds with an inorganic scaffold. Significantly, we've also reduced the crossover of redox-active species in our membrane designs, notably decreasing polysulfide species crossover in a Na metal – polysulfide hybrid flow battery. This has led to improved capacity retention, Coulombic efficiency, and extended cycle life compared to traditional porous membranes.Our latest innovations include the development of hydrocarbon single-ion conductors, demonstrating enhanced conductivity and stability. We've also introduced crosslinking chemistry to control solvent uptake more effectively, thus improving ionic conductivity while preserving mechanical strength. Lastly, our pioneering tape casting method for producing ceramic-polymer composite membranes represents a major leap in scalable membrane production, paving the way for the practical application of non-aqueous redox flow batteries in long-duration energy storage. Acknowledgment This research was conducted at Oak Ridge National Laboratory, managed by UT Battelle, LLC, for the U.S. Department of Energy (DOE) and is sponsored by the U.S. Department of Energy through the Energy Storage Program in the Office of Electricity. We acknowledge Dr. Jagjit Nanda SLAC National Accelerator Laboratory for the fruitful discussions.

Low-temperature co-fired PNN-PZT-based multilayer piezoelectric actuator with low cost and high reliability

Developing low-temperature co-fired MLAs for the commercial application of micro-nano actuation and manipulation has recently become a research highlight. To simultaneously achieve high piezoelectric response and low co-firing temperature below 960 °C, a PNN-PZT-0.02 Sr piezoceramic incorporated with Li2O-Bi2O3-CuO sintering additives and its MLA with the dimension of 7×7×3 mm3 were prepared using tape-casting and subsequent co-firing methods. The piezoceramic mainly composed of a triple phase (M, R, and T) co-existence shows a dense microstructure, indicating a good sintering-assistance effect. Even sintering at 920 °C, the piezoceramic possesses d33 ∼ 683 pC/N and kp ∼ 0.64, possibly surpassing most reported PZT-based piezoceramics. The MLA co-fired at 940 °C possesses a good Ag-ceramic interface without holes, aggregation or delamination. Also, it shows high maximum displacement (≥ 20 μm), high stiffness (118.5 N/μm @ 150 V), excellent thermal stability and 109-cycle reliability. A flat and defect-free electrode morphology is conducive to decreased leakage current. However, high tanδ primarily induced by the residual glassy phase and (Pb, Bi) oxides is the drawback. These findings give a novel paradigm for low-cost and high-reliability MLAs using pure Ag as inner electrodes by triple-phase controlling and nano-heterogeneity.

Superior energy storage performance achieved in tungsten bronze SBCN-based ceramics through tape-casting

Simultaneously integrating outstanding energy storage density and good energy storage efficiency in advanced ferroelectrics is crucial to implementing the application of dielectrics in high-power pulse devices. In this work, (Sr0.5Ba0.5)2Ca0.5Nb5-xSbxO15 ceramics were designed and prepared by adopting the B sites substitution engineering together with combining strategies of tape-casting method and two-step sintering process. Benefiting from the refined grain size and high density, the breakdown field of (Sr0.5Ba0.5)2Ca0.5Nb4.8Sb0.2O15 (SBCNS0.2) was promoted to 400 kV/cm. By the substitution of Sb5+ in the B sites, the weaker interaction force of Sb-O bond in BO6 octahedral polar unit induced the occurrence of polar nanoregions (PNRs) at room temperature to strengthen the dielectric relaxation behavior. Then it is noteworthy that SBCNS0.2 ceramics simultaneously obtained excellent recoverable energy density (Wrec, 3.9 J/cm3), energy storage efficiency (η, 90.5 %), power density (PD, 156.0 MW/cm3), and current density (CD, 1356.7 A/cm2). In addition, the SBCNS0.2 ceramics exhibited an ultrafast discharge time (t0.9, 67 ns). These results reveal prospective potential of unfilled tungsten bronze SBCNS0.2 ceramics in power capacitor applications and provide an effective strategy for improving excellent energy storage properties from the perspective of preparation methods.

Conductivity and Chemiresistive H2S Gas Sensitivity of Graphene (75 wt%)/ Cu (25 wt%) Composite Thin Film

This paper studies the conductivity and chemiresistive H2S gas sensitivity of graphene (75wt%)-Cu(25wt%) composite thin film, using self-made chamber and common laboratory apparatus. The method adopted involves mixture of 2 drops of ethanol with the synthesized composite and prepared on a glass substrate by tape casting method. Two small copper metal sheets were used as electrodes for clipping of crocodile which were also connected to digital meter for resistance readings and its changes. The X-ray Diffraction (XRD) shows thatannealing temperature reduced the crystallite sizes. The Fourier Transform Infrared Radiation (FTIR) spectra show the functional groups present to be transition metal carbonyls or aromatic combination bands, terminal alkyne (monosubstituted), isothiocyanate and that between 2300 and 2400 cm-1 indicates N=C=S functional group and evidence of CO2 interaction with external surface of the material or intercalating in the interlayer of the host material Also, increase in the conductivity was observed due to decrease in resistivity. The response/sensitivity peak of the sensor to hydrogen sulfide was seen to rise proportionally as temperature rose with percentage 3.97% for as grown, annealed at 200°C is at 12.98% while the annealed at 400°C is at 27.34%.

Fabrication framework for metal supported solid oxide cells via tape casting

Among the different solid oxide cells (SOCs) designs, metal supported SOCs (MSOCs) offer important advantages such as enhanced mechanical robustness, improved thermal resilience and lower material costs. The conventional tape casting method, which is used for the commercial multilayer ceramic technology, is also attractive for the fabrication of MSOCs due to its inherent scalability and cost-efficient fabrication methodology while offering a reliable product without compromising critical microstructural aspects and electrochemical performance during operation.This study is aimed at addressing the main challenges in the fabrication of MSOCs using tape casting, to provide a robust framework for the fabrication parameters, allowing the technology to advance to a more mature stage. It was shown that the dispersion of the powder particles and the physical and chemical characteristics of the binder are found to play a crucial role in obtaining defect free MSOCs and are discussed in detail. Different architectural designs of the cells (asymmetric and symmetric) and electrode configurations (ceramic and metal-ceramic composites) are studied, highlighting their strengths and challenges. The framework established within this work allowed to fabricate, reproduce and test MSOC that exhibited electrochemical performance comparable to state-of-the-art solid oxide cells (electrolysis current density of 0.6 A/cm2 at 1.3 V at 700oC, 50 % steam in H2 at fuel side and air at the oxygen side).

Properties of tape cast (Na, K, Li) (Nb, Sb, Ta)O3 -based ceramics sintered in reduced atmosphere and its application in triaxial piezoelectric accelerometer

In this study, we utilized the tape-casting method to produce Pb-free (Na0·52K0·4425Li0.0375) (Nb0·8925Sb0·07Ta0.0375)O3 + 2 mol% MnCO3 + y mol% LiF (y = 0 to 3) piezoelectric ceramics. We investigated the impact of LiF sintering in a reduced atmosphere on microstructure, dielectric properties, impedance spectroscopy, and piezoelectric performance. By analyzing the degree of diffuse phase transition, we observed increased density and enhanced long-range order in the sample doped with 1 mol% LiF, which exhibited optimal piezoelectric properties (d33 = 265 pC/N and kp = 0.437) and a minimal diffusion parameter. Moreover, LiF doping enabled sintering at 1020 °C under low PO2, facilitating potential co-firing with Cu inner electrodes to further enhance the piezoelectric performance. Using the optimized parameters, we fabricated a cross-type triaxial piezoelectric accelerometer, demonstrating sensitivities of 2.33, 2.44, and 10.6 mV/g along the X, Y, and Z axes, respectively, with a resonance frequency of ∼2600 Hz and frequency range of ∼1300 Hz. This accelerometer holds promise for vibration measurements in low-frequency mechanical systems.

Excellent energy storage properties in ZrO2 toughened Ba0.55Sr0.45TiO3-based relaxor ferroelectric ceramics via multi-scale synergic regulation

Lead-free ceramic capacitors offer ultrahigh power density and ultrafast discharging rates, making them critical energy storage components for advanced pulsed power systems. However, the greatest obstacle to broader applications remains the relatively low energy storage density. In this study, a relaxor ferroelectric ceramic based on (0.6-x)Ba0.55Sr0.45TiO3-0.4Bi0.5Na0.5TiO3-xSrZrO3 ((0.6-x)BST-0.4BNT-xSZ) is prepared using the tape casting method, resulting in an excellent energy density (Wrec ≈ 10.0 J cm−3) and high energy storage efficiency (η ≈ 91 %). The solid solution of linear dielectrics SrZrO3 synergistically regulates both relaxor properties and breakdown strength. The variation of relaxor property was explored utilizing New Glass model and the multi-polarization model, with confirmation provided by piezoresponse force microscopy. Furthermore, the breakdown strength could be attributed to improvements in electric insulation and the widening of the bandgap. As SrZrO3 content increases, the in-situ emergence of the second phase ZrO2, accompanied by a martensitic transformation, not only improves the fracture toughness of ceramics but also serves to elongate the breakdown path. Encouragingly, x = 0.20 ceramics also achieve excellent temperature stability (−95–125 ℃), frequency stability (1–1000 Hz), cycling reliability (1–106 cycles), and great charging-discharging properties. This multiscale synergic regulation strategy plays a guiding role in the screening of high-performance energy storage dielectric materials.

Superior Heat and Mass Transfer Performance of Bionic Wick with Finger-like Pores Inspired by the Stomatal Array of Natural Leaf.

The thermal management of electronics has gained significant attention, with loop heat pipes (LHPs) emerging as an attractive solution for heat dissipation. The heat transfer performance of LHPs is influenced by the heat and mass transfer processes within the wick. However, designing the pore diameter of the wick is challenging due to the different requirements of flow resistance and capillary force. Specifically, the working fluid needs large pores to reduce resistance, while the liquid suction requires small pores to provide a large capillary force. To address this issue, we drew inspiration from the stomatal array of natural leaves used for transpiration and developed an alumina ceramic bionic wick with finger-like pores using the phase-inversion tape casting method. The finger-like pores in the wick resemble the straight hole structure of stomata, which increases the gas-liquid interface area within the wick. This design allows for timely discharge of water vapor generated by boiling, thereby reducing mass transfer resistance. Additionally, numerous micrometer-sized small pores surrounding the finger-like pores provide sufficient capillary force to replenish liquid for the gas-liquid evaporation interface. Experimental results demonstrate that the introduction of finger-like pores in the wick increases gas and water permeabilities by 2.4 and 5.2 times, respectively. Furthermore, the superior heat and mass transfer performance of the bionic wick was demonstrated with an LHP. This work effectively addresses the conflicting demands of capillary force and flow resistance, enhancing the heat transfer performance of LHPs, which holds great promise for addressing heat dissipation challenges in high power density electronic chips and has potential applications in aviation, aerospace, and microelectronics for efficient thermal management.

Sintering behaviors, microstructure and properties of CaO–B2O3–SiO2 glass-ceramics for LTCC applications

The aim of this work was to investigate the impacts of MgO on the crystalline behaviors, microstructure, and properties of CaO–B2O3–SiO2 (CBS) glass-ceramics. In the study, the CBS samples with various MgO contents were developed via the melting and quenching route. Subsequently, a CBS casting tape and a multi-layered LTCC microcircuit module were created by using the tape casting method. Results indicated that MgO could break the glass network and promote the formation of liquid phase during the sintering process. A suitable amount of MgO additive promoted densification during firing process and improved the properties of the CBS materials. The CBS sample with 1.5 wt% MgO fired at 875 °C exhibited outstanding properties, including a dielectric constant (εr) of 6.5 (at 10 GHz), a dielectric loss (tan δ) of 8 × 10−4, a flexural strength of 167 MPa, a coefficient of thermal expansion (CTE) of 6.8 ppm/°C, and a thermal conductivity (λ) of 2.2 W/mK. In addition, this LTCC material demonstrated good co-firing compatibility with silver electrodes and superior temperature stability, showing its great potential for microelectronic applications.

A multifunctional flexible composite phase-change film with excellent solar driven thermal management

The development of multifunctional films with integrated temperature regulation, photothermal conversion, and bendability is urgently needed for personal thermal management products. In this paper, aminated multi-walled carbon nanotubes modified phase-change microcapsules (ACNTs-PCMC) were synthesized. Subsequently, a flexible polyvinyl alcohol (PVA)/graphene/ACNTs-PCMC composite film (PGAMF) with a three-dimensional sandwich structure was prepared by a simple tape-casting method. The obtained PGAMF films possessed a phase-change enthalpy of 45.5 ± 0.7 J/g. The designed sandwich structure can fix the ACNTs-PCMC microcapsules inside the PGAMF films through the bonding effect of the PVA to prevent them from falling off and sliding, so that the PGAMF composite films have the proper mechanical properties and excellent flexibility. More importantly, the PGAMF composite films had a high photothermal conversion efficiency of 88.8 %. In the cold environment, the center temperature of the PGAMF composite film adhered to the fiber fabric driven by a low solar radiation was 14.5 ± 0.5 °C higher than that of the fiber fabric without the PGAMF composite film. Therefore, the multifunctional composite films with flexibility, heat storage and solar-to-heat conversion prepared in this study have broad application scenarios in heat preservation in low temperature areas and solar-driven thermal management engineering.

The study of BMN cubic pyrochlores based multi-layer capacitors

The multi-layer ceramic capacitor (MLCC) is prepared with Bi1.5MgNb1.5O7 (BMN) pyrochlores, which has medium dielectric constant, large dielectric tunability, and especially the very small dielectric loss. The multilayer ceramic capacitors with Bi1.5MgNb1.5O7 as the dielectric material are prepared by a tape-casting method. The dielectric constant of the BMN thick film was observed to be superior to that of the bulk material, indicating its potential application in electronic devices. The increase in dielectric constant during the preparation of multilayer ceramic capacitors was explained by investigating the interdiffusion between the ceramic thick films and the electrodes. The BMN thick films and Ag0.7/Pd0.3 electrodes showed a dense microstructure and serial interfaces when sintering at 1050 °C for 1.5 h. The capacitor exhibited good temperature stability with a dielectric constant temperature coefficient of −249.94 ppm/°C, a relative dielectric constant of 216, and a dielectric loss of 0.00036. Provides insights for the development and optimization of high-performance dielectric tunable electronic device.

Remarkable enhancement in piezoelectric performance of [001] textured Na0.4K0.1Bi0.5TiO3 ceramic

This study explores the dependence of dielectric and piezoelectric properties on the grain morphology, orientation, and electric field in the [001] textured Na0.4K0.1Bi0.5TiO3 (NKBT-T) piezoceramics, fabricated via reactive template grain growth and tape-casting methods. A high degree of [001] texturing with Lotgering factor (f) of ∼0.92 was confirmed by X-ray diffraction, electron backscattered diffraction, and bulk texture measurements. A large average plate length of ∼8.5 ± 1 μm with an aspect ratio of ∼11 was achieved in NKBT-T ceramic. An extremely large value of piezoelectric voltage coefficient (g33) of ∼100×10−3 Vm/N was observed in poled NKBT-T ceramics, originating from a low dielectric constant (∼230) and high piezoelectric charge coefficient (d33 ∼205 pC/N). The transduction coefficient (d33•g33) of NKBT-T ceramic was estimated at ∼20,000 × 10−15 m2N−1 and the mechanical energy harvesting responses of ∼1.8 µA and ∼4 V were recorded in the NKBT-T ceramic-based piezoelectric device.

Multi-scale parallel and texture interface to enhance thermoelectric performance of p-type Ca3Co4O9 semiconductor materials

Ca3Co4O9 is considered as an attractive material for high-temperature area application. The correlation between structure modulation and electric-thermal transport properties is an important prerequisite to optimize thermoelectric performance of Ca3Co4O9 materials. p-type Ca3Co4O9-based ceramics with texture interface were successfully prepared by tape casting method. The different content of template seeds was added into the Ca3Co4O9 semiconductor, successfully constructing the parallel interfaces. The “brick-wall” structure was formed due to the liquid film existed at grain boundaries. The sample with 15 wt% template seeds additives yielded ∼60 % rise in power factor with a peak value of 0.33 mW/(m·K2), and the low thermal conductivity of 0.97 W/(m·K) was obtained at 800 ℃. Additionally, the ZT value reached 0.34 due to the presence of multi-scale parallel interfaces among the stripe-like grains, which effectively scattered the long-wave, middle-wave and short-wave phonons and strengthened the charge carrier transporting. This texturing method offered a meaningful way for enhancing thermoelectric properties of oxides thermoelectric materials.

Processing-structure-property relationships in practical thin solid-electrolyte separators for all-solid-state batteries

Scalable processing of thin and robust solid-electrolyte (SE) separators is key for the commercialization of high-energy all-solid-state batteries (ASSBs). Herein, we report the preparation of Li6PS5Cl-based thin SE separators incorporating suitable binders for potential use in ASSBs by two scalable wet processing techniques: tape-casting with nitrile-butadiene rubber (NBR) and calendering with carboxylated nitrile butadiene rubber (XNBR). By means of tensile testing and electrochemical impedance spectroscopy, the influence of processing on the mechanical as well as the electrochemical properties of the resulting thin SE separators is investigated. A trade-off between the mechanical and electrochemical properties is observed, which is due to the inextricably linked microstructures (particle size, binder content and distribution, and porosity) induced by the two different processes. Thin SE separators prepared using the tape-casting method with the more well-distributed binder network demonstrate superior tensile mechanical properties compared to the ones prepared by the calendering method. The results provide insights into the processing-structure-property relationships of the thin SE separators, which will contribute to advancing the application of practical thin solid electrolytes in ASSBs.