High‐Performance, Roll‐to‐Roll Fabricated Scaffold‐Supported Solid Electrolyte Separator for Practical All‐Solid‐State Batteries
Seok Hun Kang, Hyobin Lee, Young‐Jin Hong, Sang-Wong Myoung, Hyewon Seo, Jaecheol Choi, Sung‐Min Yoon, Ju Young Kim, Dong Ok Shin, Myeong Ju Lee, Young‐Sam Park, Young‐Gi Lee, Yong Min Lee
All-solid-state batteries (ASBs) are promising candidates for next-generation energy storage systems due to their enhanced safety and potential for higher energy densities. However, achieving practical ASBs with energy densities surpassing those of state-of-the-art lithium-ion batteries (LIBs) requires the development of thin, mechanically robust solid electrolyte separators (SESs). In this study, a scalable tape casting method is employed to fabricate a thin SES with a thickness of 27 µm and a high ionic conductance of 146 mS cm<sup>-2</sup>. The SES, composed of Li<sub>6</sub>PS<sub>5</sub>Cl SE and a laser-drilled porous polyimide (PI) scaffold with a high porosity of 69%, exhibits a tensile stress of 7.15 MPa at 6% strain, demonstrating the mechanical integrity necessary for commercial roll-to-roll fabrication. Due to its reduced thickness, the LiNi<sub>0.83</sub>Co<sub>0.11</sub>Mn<sub>0.06</sub>O<sub>2</sub>||Li-In pouch cell achieves outstanding estimated cell-level gravimetric and volumetric energy densities of 322 Wh kg<sup>-1</sup> and 571 Wh L<sup>-1</sup>, respectively, demonstrating its practical viability. Additionally, simulation studies highlight the importance of optimizing the porosity and pore distribution of porous scaffolds to minimize Li-ion flux heterogeneity and prevent non-uniform Li plating in scaffold-supported SESs. Finally, a 4 m long, double-side coated SES is successfully manufactured using an industrial-level comma coater, demonstrating the feasibility of the approach for large-scale SES production and the forthcoming commercialization of ASBs.
https://doi.org/10.1002/smll.202502996
Separator (oil production)
Solid-state
Materials science
Electrolyte
Scaffold
Fast ion conductor
Nanotechnology
Chemical engineering
Biomedical engineering
Electrode
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