Robust interface and reduced operation pressure enabled by co-rolling dry-process for stable all-solid-state batteries

Dong Ju Lee, Yuju Jeon, Jung-Pil Lee, Lanshuang Zhang, Ki Hwan Koh, Feng Li, Anthony U. Mu, Junlin Wu, Yu-Ting Chen, Seamus McNulty, Wei Tang, Marta Vicencio, Dapeng Xu, Jiyoung Kim and Zheng Chen ()
Additional contact information
Dong Ju Lee: San Diego
Yuju Jeon: San Diego
Jung-Pil Lee: Ltd. LG Science Park
Lanshuang Zhang: University of California, San Diego
Ki Hwan Koh: San Diego
Feng Li: San Diego
Anthony U. Mu: San Diego
Junlin Wu: University of California, San Diego
Yu-Ting Chen: University of California, San Diego
Seamus McNulty: San Diego
Wei Tang: San Diego
Marta Vicencio: San Diego
Dapeng Xu: San Diego
Jiyoung Kim: Ltd. LG Science Park
Zheng Chen: San Diego

Nature Communications, 2025, vol. 16, issue 1, 1-12

Abstract: Abstract The dry-process is a sustainable and promising fabrication method for all-solid-state batteries by eliminating solvents. However, a pragmatic fabrication design for thin and robust solid-state electrolyte (SSE) layers has not been established. Herein, we report a dry-process approach that enhances mechanical stability of SSE layers from film fabrication to cell operation. By co-rolling thick SSE and positive electrode feeds, a uniform, thin SSE layer (50 µm) and a high loading positive electrode layer (5 mAh cm−2) with high active material ratio (80 wt%) are simultaneously achieved. This SSE-positive electrode integrated film exhibits enhanced physical properties and cyclability (> 80% retention after 500 cycles) at low stack pressure (2 MPa) compared to the freestanding counterparts, attributed to reinforced and intimate SSE-positive electrode interface constructed during co-rolling process. Additionally, an all-solid-state pouch cell with high stack-level specific energy (310 Wh kg−1) and energy density (805 Wh L−1) operating at 30 °C and 5 MPa is demonstrated.

Date: 2025
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DOI: 10.1038/s41467-025-59363-4

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