Exploring key processing parameters for lithium metal anodes with sulfide solid electrolytes and nickel-rich NMC cathodes in solid-state batteries

Research output: Contribution to journalResearch articleContributedpeer-review

Contributors

  • Maria Rosner - , Chair of Inorganic Chemistry I, Fraunhofer Institute for Material and Beam Technology (Author)
  • Karsten Mehr - , Chair of Inorganic Chemistry I, Fraunhofer Institute for Material and Beam Technology (Author)
  • Stephanie Mörseburg - , Fraunhofer Institute for Material and Beam Technology (Author)
  • Sahin Cangaz - , Fraunhofer Institute for Material and Beam Technology (Author)
  • Felix Hippauf - , Fraunhofer Institute for Material and Beam Technology (Author)
  • Sebastian L. Benz - , Justus Liebig University Giessen (Author)
  • Susanne Dörfler - , Fraunhofer Institute for Material and Beam Technology (Author)
  • Thomas Abendroth - , Fraunhofer Institute for Material and Beam Technology (Author)
  • Holger Althues - , Fraunhofer Institute for Material and Beam Technology (Author)
  • Jürgen Janek - , Justus Liebig University Giessen (Author)
  • Stefan Kaskel - , Chair of Inorganic Chemistry I, Fraunhofer Institute for Material and Beam Technology (Author)

Abstract

The integration of lithium metal anodes (LMAs) into solid-state batteries (SSBs) offers a promising route toward significantly increased energy densities. However, the mechanical and electrochemical instability of the Li|solid electrolyte (SE) interface remains a major challenge for practical long-term cycling stability. This study systematically examines key parameters affecting the interface formation, including contact pressure, holding time, and the microstructure of the sulfide-based SE using electron microscopy and electrochemical impedance spectroscopy (EIS). To enable the use of thin electrolyte layers in larger cell formats, the SE is fabricated using a scalable slurry-based process with hydrogenated nitrile butadiene rubber (HNBR) binder. Long-term cycling over 300 cycles with a coulombic efficiency (CE) exceeding 99.5% is demonstrated in application-oriented pouch cells with a LMA and a nickel manganese cobalt oxide (NMC) cathode. The cells are assembled with a precompressed SE film with a thickness of 230 μm and a high-pressure compression step of 360 MPa. Applying the adapted pressurization method enables stable cycling performance with thin SE layers (90 μm thickness). The presented findings identify critical parameters for LMA-based SSB with thin sulfide SE layers and provide practical guidelines for the processing and assembly of lithium metal–based solid state prototype pouch cells.

Details

Original languageEnglish
Article number176023
JournalChemical engineering journal
Volume536
Publication statusPublished - 15 May 2026
Peer-reviewedYes

Keywords

Keywords

  • All-solid-state batteries, Impedance spectroscopy, LiPSCl, Lithium metal anode, Sulfide electrolytes