Impact of Particle Size Distribution and Densification on the Development of Solid-State Pouch Cells

Daniel Rettenwander^a

^aDepartment of Materials Science and Engineering, NTNU Norwegian University of Science and Technology, Trondheim, Norway

^bChristian Doppler Laboratory for Solid-State Batteries, NTNU Norwegian University of Science and Technology, 7034 Trondheim, Norway

Materials for Sustainable Development Conference (MATSUS)
Proceedings of MATSUS Spring 2025 Conference (MATSUSSpring25)

Advances in Li-Metal All-Solid-State Batteries: Processing, Manufacturing, and Integration - #AdvanceSSB

Sevilla, Spain, 2025 March 3rd - 7th

Organizer: Juan Carlos Gonzalez-Rosillo

Invited Speaker, Daniel Rettenwander, presentation 028
DOI: https://doi.org/10.29363/nanoge.matsusspring.2025.028
Publication date: 16th December 2024

Solid-state batteries are widely regarded as a promising next-generation technology, addressing critical limitations of conventional Li-ion batteries, particularly safety concerns related to the flammable liquid electrolyte. Moreover, they offer the potential for higher volumetric and gravimetric energy densities compared to Li-ion systems.[1] Despite substantial progress in the development of solid-state batteries, scaling up from successful lab-scale cells to commercially viable pouch cells remain a significant challenge, especially when utilizing inorganic solid electrolytes.[2],[3] For example, recent studies have demonstrated that the particle size ratio between the cathode material and the solid electrolyte plays a critical role in achieving low tortuosity, thereby enhancing power density.[5] However, commercially available materials often exhibit broad particle size distributions, with large particles that even exceed the thickness of the composite cathode, posing challenges for densification and leading to poor electrochemical performance.

In this talk, I will discuss our recent advances in optimizing the particle size distribution of Li₆PS₅Cl (LPSCl) electrolytes while maintaining their superior transport properties. Further, I will explore how particle size distribution affects the densification of slurry-cast LPSCl tapes and their corresponding Li-ion conductivities. Finally, I will share our progress in fabricating solid-state pouch cells with various cathodes (e.g., Si, LiIn), emphasizing the influence of LPSCl particle size distribution, pre-pressing conditions, and formation pressure on cell performance.

References:

[1] Janek, J.; Zeier, W. G. A Solid Future for Battery Development. Nat. Energy 2016, 1 (9), 1–4.

[2] Wang, C.; et al. Progress and Prospects of Inorganic Solid‐State Electrolyte‐Based All‐Solid‐State Pouch Cells. Adv. Mater. 2023, 35 (19), 2209074.

[3] Wang, C.; et al. All-Solid-State Lithium Batteries Enabled by Sulfide Electrolytes: From Fundamental Research to Practical Engineering Design. Energy Environ. Sci. 2021, 14 (5), 2577–2619.

[4] Shi, T.; et al. High Active Material Loading in All‐Solid‐State Battery Electrode via Particle Size Optimization. Adv. Energy Mater. 2020, 10 (1), 1902881.

Acknowledgements:

I acknowledge financial support by the Austrian Federal Ministry for Digital and Economic Affairs, the National Foundation for Research, Technology and Development and the Christian Doppler Research Association (Christian Doppler Laboratory for Solid State Batteries).

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