Insight into the Microstructure and Ionic Conductivity of Cold Sintered NASICON Solid Electrolyte for Solid-State Batteries

Scalable Dry Process for Fabricating a Na Superionic Conductor-Type Solid Electrolyte Sheet

The cost reduction and mass production of oxide-based solid electrolytes are critical for the commercialization of all-solid-state batteries. In this study, an environmentally friendly, low-cost, and high-density oxide-based Na superionic conductor-type solid electrolyte sheet was fabricated via a dry process without the use of any solvent. The polytetrafluoroethylene (PTFE), used as a binder, was transformed into thin thread-like structures via shear force, resulting in a flexible solid electrolyte sheet. The solid electrolyte powder quantity was limited to 50 wt % for fabricating a uniform green sheet via the wet process. However, when the dry process was employed for green sheet fabrication, the solid electrolyte powder quantity could be increased to values exceeding 95 wt %. Therefore, the green sheets produced by using the dry process demonstrated a higher density than those fabricated by using the wet process. The binder content and particle size affected the ionic conductivity of a solid electrolyte sheet fabricated via a dry process. The sheet obtained via the blending of 3 wt % PTFE binder with a solid electrolyte powder, finely ground using a planetary ball mill, which exhibited the highest total ionic conductivity of 1.03 mS cm-1.

Facile Route to Synthesize a Highly Sinterable Li1.3Al0.3Ti1.7(PO4)3 Solid Electrolyte

NASICON-type Li1.3Al0.3Ti1.7(PO4)3 (LATP) is a widely used solid electrolyte in solid-state lithium batteries, owing to its excellent chemical stability against moisture and high total ionic conductivity. However, traditionally, densification of LATP has been achieved through a high-temperature sintering process (approximately 1000 °C) owing to its poor sinterability. Herein, we report a facile synthesis route to obtain highly sinterable LATP solid electrolyte using tetrabutyl titanate (C16H36O4Ti) as the titanium source and incorporating the traditional solid-state reaction method. The synthetic LATP powder mixed with a low ratio of LiTiPO5 exhibited a hybrid crystalline-amorphous phase structure, which facilitated grain fusion, promoted structural homogeneity, and facilitated structural densification under low-temperature sintering. The sintered LATP pellet, which exhibited an interconnected structure and indistinct grain boundaries, achieved a relative density of >90% and an ionic conductivity of 0.667 mS/cm at a sintering temperature of only 750 °C. Additionally, we systematically studied and demonstrated the synthesis reaction mechanism, sintering behavior, and ionic diffusion kinetics of LATP electrolytes. Our study paves the way for synthesizing highly sinterable LATP solid electrolytes using a simple, additive-free, and cost-effective method.

Borohydride and halide dual-substituted lithium argyrodites

Solid electrolyte is a crucial component of all-solid-state batteries, with sulphide solid electrolytes such as lithium argyrodite being closest to commercialization due to their high ionic conductivity and formability. In this study, borohydride/halide dual-substituted argyrodite-type electrolytes, Li7-α-βPS6-α-β(BH4)αXβ (X = Cl, Br, I; α + β ≤ 1.8), have been synthesized using a two-step ball-milling method without post-annealing. Among the various compositions, Li5.35PS4.35(BH4)1.15Cl0.5 exhibits the highest ionic conductivity of 16.4 mS cm-1 at 25 °C when cold-pressed, which further improves to 26.1 mS cm-1 after low temperature sintering. The enhanced conductivity can be attributed to the increased number of Li vacancies resulting from increased BH4 and halide occupancy and site disorder. Li symmetric cells with Li5.35PS4.35(BH4)1.15Cl0.5 demonstrate stable Li plating and stripping cycling for over 2,000 hours at 1 mA cm-2, along with a high critical current density of 2.1 mA cm-2. An all-solid-state battery prepared using Li5.35PS4.35(BH4)1.15Cl0.5 as the electrolyte and pure Li as the anode exhibits an initial coulombic efficiency of 86.4%. Although these electrolytes have limited thermal stability, it shows a wide compositional range while maintaining high ionic conductivity.

Enabling long-term oxide based solid-state lithium metal battery through a near room-temperature sintering process

The huge Li ion transport resistance through the grain boundaries (GBs) among rigid oxide particles forces the adoption of high-temperature sintering (HTS) process over 1000 °C. Nevertheless, the severe side reactions and uncontrollable lithium loss are always companied during the high-cost HTS process, which slows down the pace of oxide solid electrolyte (OSE) for practical application and accelerates the exploration of a new OSE sintering process. Herein, a near-room-temperature (60 °C) cold-sintering process is proposed by filling the GBs with a low-melting-point plastic crystal electrolyte (PCE). Due to the soft property and high-ionic conductivity of PCE, the Li ion transport rate through the GBs is 10 times faster than the bulk phase, endowing the OSE (Li1.5Al0.5Ge1.5(PO4)3 chosen as a representative) with a room temperature ionic conductivity of 0.25 mS cm-1. As proof of the concept, the assembled Li symmetrical cells perform a low over-potential of 50 mV with a capacity of 1 mA h cm-2 and full cells delivers a capacity retention of roughly 70% after 820 cycles (1.5 years) at 0.1C.

Engineering and regulating the interfacial stability between Li1.3Al0.3Ti1.7(PO4)3-based solid electrolytes and lithium metal anodes for solid-state lithium batteries

InCl3@Li1.3Al0.3Ti1.7(PO4)3-F (InCl3@LATP-F) solid electrolyte powders are designed and fabricated by coating a uniform InCl3 layer on the surface of F--doped Li1.3Al0.3Ti1.7(PO4)3 (LATP-F) solid powders via a feasible wet-chemical technique. The assembled Li/InCl3@LATP-F/Li cell can undergo longer cycles of 2500 h at 0.4 mA cm-2 without obvious increases in the overvoltage compared to 1837 h for the Li/LATP-F/Li cell, and the interfacial resistance demonstrates a sharp decrease from 3428 to 436 Ω for the Li/InCl3@LATP-F/Li cell during the first 500 h. Importantly, the assembled LiCoO2/InCl3@LATP-F/Li cell delivers a high discharge specific capacity of 126.4 mAh g-1 with a 95.42% capacity retention ratio after 100 cycles at 0.5 C, and the value easily returns to 112.9 mAh g-1 when the current density is abruptly set back to 0.1 C after different rate cycles. These improved results can be mainly attributed to the fact that the InCl3 layer with a lithiophilic nature can react with lithium metal to form a Li-In alloy, which can guarantee homogeneous lithium ion flux to avoid the accumulation of ions/electrons across the interface and suppress the growth of lithium dendrites. Moreover, the InCl3 layer can prevent direct contact of the LATP-F solid electrolyte and lithium metal to effectively alleviate the reduction reaction of Ti4+ and preserve the structural stability of the composite electrolyte. Therefore, this work may provide an effective strategy to engineer and regulate the interfacial stability between LATP solid electrolytes and lithium metal anodes for LATP-type solid-state lithium batteries.

Thermally Stable Ceramic-Salt Electrolytes for Li Metal Batteries Produced from Cold Sintering Using DMF/Water Mixture Solvents

The cold sintering process (CSP) for synthesizing oxide-based electrolytes, which uses water transient solvents and uniaxial pressure, is a promising alternative to the conventional high temperature sintering process due to its low temperature (<200 °C) and short processing time (<2 h). However, the formation of amorphous secondary phases in the intergranular regions, which results in poor ionic conductivity (σ), remains a challenge. In this study, we introduced high-boiling solvents of dimethylformamide (DMF, b.p.: 153 °C) and dimethyl sulfoxide (DMSO, b.p.: 189 °C) as transient solvents to develop composite electrolytes of Li1.5Al0.5Ge1.5(PO4)3 (LAGP) with bis(trifluoromethane)sulfonimide lithium salt (LiTFSI). Our results show that composite electrolytes processed with the DMF/water mixture (CSP LAGP-LiTFSI DMF/H2O) yield a high σ of 10-4 S cm-1 at room temperature and high relative densities of >87%. Furthermore, the composite electrolytes exhibit good thermal stability; the σ maintains its initial value after heat treatment. In contrast, the composite electrolytes processed with the DMSO/water mixture and water alone show thermal degradation. The CSP LAGP-LiTFSI DMF/H2O composite electrolytes exhibit long-term stability, showing no signs of short circuiting after 350 h at 0.1 mAh cm-2 in Li symmetric cells. Our work highlights the importance of selecting appropriate transient solvents for producing efficient and stable composite electrolytes using CSP.

Polycationic doping of the LATP ceramic electrolyte for Li-ion batteries

All-solid-state Li-ion batteries (LIBs) with a solid electrolyte instead of a liquid one demonstrate significantly higher safety in contrast with the conventional liquid-based LIBs. An inorganic NASICON-type Li conductor Li_1.3Al_0.3Ti_1.7(PO₄)₃ (LATP) is a promising solid electrolyte with an ionic conductivity of up to 10^-3 S cm^-1 at room temperature. However, LATP gradually degrades in contact with Li metal because of reduction of Ti⁴⁺ to Ti³⁺, resulting in a lower ionic conductivity at the electrolyte-electrode interface. Cation doping is a promising approach to stabilize the LATP structure and mitigate the Ti reduction. Here, we report our findings on the alternative polycationic doping strategy of the LiTi₂(PO₄)₃ (LTP) structure, when a heterovalent cation is added along with Al. In particular, we studied the effect of tetravalent and divalent cation dopants (Zr, Hf, Ca, Mg, Sr) of LATP on the Li-ion conduction and Ti reduction during interaction with lithium metal. The samples were prepared by molten flux and solid-state reaction methods. The structure, morphology, and ion-transport properties of the samples were analyzed. The activation energy of Li-ion migration in all synthesized systems was calculated based on the electrochemical impedance spectroscopy (EIS) data retrieved for a temperature range of 25-100 °C. From the obtained results, the tetravalent doping (Zr⁴⁺ and Hf⁴⁺) appeared to be a more promissing route to improve the LATP electrolyte than the divalent doping (Mg²⁺, Ca²⁺, and Sr²⁺). The X-ray photoelectron spectroscopy analysis of the samples after their contact with lithium provided the data, which could shed light on the effect of the incorporated dopants onto the Ti reduction.

Li-Ion Conductive Li1.3Al0.3Ti1.7(PO4)3 (LATP) Solid Electrolyte Prepared by Cold Sintering Process with Various Sintering Additives

The density, microstructure, and ionic conductivity of solid electrolyte Li_1.3Al_0.3Ti_1.7(PO₄)₃ (LATP) ceramics prepared by cold sintering using liquid and solid sintering additives are studied. The effects of both liquid (water and water solutions of acetic acid and lithium hydroxide) and solid (lithium acetate) additives on densification are investigated. The properties of cold-sintered LATP are compared to those of conventionally sintered LATP. The materials cold-sintered at temperatures 140-280 °C and pressures 510-600 MPa show relative density in the range of 90-98% of LATP's theoretical value, comparable or higher than the density of conventionally sintered ceramics. With the relative density of 94%, a total ionic conductivity of 1.26 × 10^-5 S/cm (room temperature) is achieved by cold sintering at the temperature of 200 °C and uniaxial pressure of 510 MPa using water as additive. The lower ionic conductivities of the cold-sintered ceramics compared to those prepared by conventional sintering are attributed to the formation of amorphous secondary phases in the intergranular regions depending on the type of additives used and on the processing conditions selected.

Nanoscale interface engineering of inorganic Solid-State electrolytes for High-Performance alkali metal batteries

All-solid-state metal batteries (ASSMBs) have been regarded as the ideal candidate for the next-generation high-energy storage system due to their ultrahigh specific capacity and the lowest redox potential. However, the uncontrollable chemical reactivity during cycling which directly determines the growth behaviour of metal dendrites, the low coulombic efficiency and the safety concerns severely limit their real-world applications.. Crystallographic optimization based on solid-state electrolytes (SSEs) provides an atomic-scale and fundamental solution for the inhibition of dendrite growth in metal anodes, which has attracted widespread attentions. From this perspective, we summarize the recent advance of the crystallographic optimization for various classes of solid-state electrolytes. We highlight the recent experimental findings of crystallographic optimization for a new generation of all-solid-state batteries, including lithium-ion batteries, sodium-ion batteries, magnesium-ion batteries, with the aim of providing a deeper understanding of the crystallographic reactions in ASSMBs. The challenges and prospects for the future design and engineering of crystallographic optimization of SSEs are discussed, providing ideas for further research into crystallographic optimization to improve the performance of rechargeable batteries.

Enhancing ionic conductivity in solid electrolyte by relocating diffusion ions to under-coordination sites

Solid electrolytes are highly important materials for improving safety, energy density, and reversibility of electrochemical energy storage batteries. However, it is a challenge to modulate the coordination structure of conducting ions, which limits the improvement of ionic conductivity and hampers further development of practical solid electrolytes. Here, we present a skeleton-retained cationic exchange approach to produce a high-performance solid electrolyte of Li₃Zr₂Si₂PO₁₂ stemming from the NASICON-type superionic conductor of Na₃Zr₂Si₂PO₁₂. The introduced lithium ions stabilized in under-coordination structures are facilitated to pass through relatively large conduction bottlenecks inherited from the Na₃Zr₂Si₂PO₁₂ precursor. The synthesized Li₃Zr₂Si₂PO₁₂ achieves a low activation energy of 0.21 eV and a high ionic conductivity of 3.59 mS cm^-1 at room temperature. Li₃Zr₂Si₂PO₁₂ not only inherits the satisfactory air survivability from Na₃Zr₂Si₂PO₁₂ but also exhibits excellent cyclic stability and rate capability when applied to solid-state batteries. The present study opens an innovative avenue to regulate cationic occupancy and make new materials.

Reaction of Li1.3Al0.3Ti1.7(PO4)3 and LiNi0.6Co0.2Mn0.2O2 in Co-Sintered Composite Cathodes for Solid-State Batteries

All solid-state batteries offer the possibility of increased safety at potentially higher energy densities compared to conventional lithium-ion batteries. In an all-ceramic oxide battery, the composite cathode consists of at least one ion-conducting solid electrolyte and an active material, which are typically densified by sintering. In this study, the reaction of the solid electrolyte Li_1.3Al_0.3Ti_1.7(PO₄)₃ (LATP) and the active material LiNi_0.6Co_0.2Mn_0.2O₂ (NCM622) is investigated by cosintering at temperatures between 550 and 650 °C. The characterization of the composites and the reaction layer is performed by optical dilatometry, X-ray diffractometry, field emission scanning electron microscopy with energy dispersive X-ray spectroscopy, time-of-flight secondary ion mass spectrometry, as well as scanning transmission electron microscopy (STEM). Even at low sintering temperatures, elemental diffusion occurs between the two phases, which leads to the formation of secondary phases and decomposition reactions of the active material and the solid electrolyte. As a result, the densification of the composite is prevented and ion-conducting paths between individual particles cannot be formed. Based on the experimental results, a mechanism of the reactions in cosintered LATP and NCM622 oxide composite cathodes is suggested.

Densification of a NASICON-Type LATP Electrolyte Sheet by a Cold-Sintering Process

A NASICON-type Li_1.3Al_0.3Ti_1.7(PO₄)₃ (LATP) electrolyte sheet for all-solid-state batteries was fabricated by a cold sintering process (CSP). The microstructure of the LATP sheet was controlled to improve the wettability which is an essential factor in CSP. The porous sheets of LATP were prepared by calcination the green sheets to remove the organic components and form the porous structure. By the CSP using the porous sheets, the densification of grain boundary was observed and further densified with increasing reaction time. The total conductivity of the prepared LATP sheet was improved from 3.0 × 10⁻⁶ S/cm to 3.0 × 10⁻⁴ S/cm due to the formation of necks between the particles at the grain boundary.

Quasi-solid electrolyte developed on hierarchical rambutan-like γ-AlOOH microspheres with high ionic conductivity for lithium ion batteries

Upgrading liquid electrolytes with all-solid-state electrolytes (ASEs) or quasi-solid-state electrolytes (QSEs) for solid-state batteries (SBs) have emerged not only to address the intrinsic disadvantages of traditional liquid lithium ion batteries, but also to offer more possibilities for the development of new battery chemistries. In this work, a novel rambutan-like yolk-shell-structured porous γ-AlOOH microsphere with a large specific surface area of 262.92 m² g^-1 was firstly obtained by a simple hydrothermal synthesis route, which was then utilized as a robust framework to assemble QSE via encapsulating abundant liquid electrolyte (LE). The obtained γ-AlOOH-QSE exhibits a high ionic conductivity of 4.0 × 10^-3 S cm^-1, a large lithium ion transference number (t_Li⁺) of 0.76, as well as a wide electrochemical window of 4.72 V vs. Li/Li⁺. Moreover, the assembled cell of LiFePO₄/γ-AlOOH-QSE/Li could maintain a high specific capacity of 144.4 mA h g^-1 even after 120 cycles with almost negligible capacity decay, which could be mainly attributed to the excellent interfacial compatibility, prominent performance in suppressing lithium dendrite growth upon cycling (rigid characteristic), as well as the high ionic conductivity of γ-AlOOH-QSE (intrinsic advantage). This work could not only expand the applications of QSE with cost-effective aluminum-based oxides with facile fabrication strategy, but also will shed light on the construction of SEs with more integrated QSEs and ASEs in the field of advanced energy storage.

Comparison of LiTaO3 and LiNbO3 Surface Layers Prepared by Post- and Precursor-Based Coating Methods for Ni-Rich Cathodes of All-Solid-State Batteries

Surface coating is essential for the cathode materials applied in all-solid-state batteries (ASSBs) based on sulfide electrolytes because of the instability of the cathode/sulfide interface. In contrast with those for general lithium ion batteries (LIBs) using a liquid electrolyte, the coating materials for ASSBs require different functional properties such as high ionic conductivity, low reactivity with sulfide electrolytes, and low electronic conductivity. In addition to LiNbO₃, which is the most popular coating material for ASSBs, LiTaO₃ is another highly promising coating material, and both materials mostly satisfy these requirements. In this work, LiTaO₃ and LiNbO₃ were used to coat the surface of LiNi_0.82Co_0.12Mn_0.06O₂ cathodes for ASSBs. Further, the effects of two different coating methods, postcoating and precursor-based (PB) coating, were characterized and compared. The postcoating method simply forms a coating layer, whereas the PB coating method offers an additional doping effect owing to the diffusion of coating ions into the cathode structure. Surface coating considerably increased the capacity of the ASSB cathodes under all experimental conditions. With the same coating amount and method, the effect of the LiTaO₃ coating was similar or superior to that of the LiNbO₃ coating. Compared with the postcoating method, however, the PB coating method resulted in a superior rate capability and cyclic performance, which was mostly attributed to the doping effect of Ta or Nb. An X-ray photoelectron spectroscopy analysis confirmed that both the LiTaO₃ and LiNbO₃ coatings suppressed side reactions. Among the coatings we examined, the LiTaO₃ coating prepared by the PB method most effectively enhanced the electrochemical performance of the cathodes for sulfide electrolyte-based ASSBs.

Combined wet milling and heat treatment in water vapor for producing amorphous to crystalline ultrafine Li1.3Al0.3Ti1.7(PO4)3 solid electrolyte particles

Bulk-type all-solid-state batteries (ASSBs) consisting of composite electrodes of homogeneously mixed fine particles of both active materials and solid electrolytes (SEs) exhibit a high safety, high energy density, and long cycle life. SE nanoparticles are required for the construction of ion-conducting pathways as a response to the particle size reduction of active materials; however, simple and low-cost milling processes for producing nanoparticles cause a collapse in the crystal structure and eventually amorphization, decreasing the conductivity. This study develops a heat treatment process in water vapor for the low-temperature crystallization of ultrafine SE amorphous particles and the size control of crystalline nanoparticles. An ultrafine (approximately 5 nm) amorphous powder of Li_1.3Al_0.3Ti_1.7(PO₄)₃ (LATP), as a typical oxide-type SE, is produced via wet planetary ball milling in ethanol. The water vapor induces a rearrangement of the crystal framework in LATP and accelerates crystallization at a lower temperature than that in air. Further, since particle growth is also promoted by water vapor, depending on the heating temperature and time, this heat treatment process can be also applied to the size control of crystalline LATP nanoparticles. A combination of the wet planetary ball milling and heat treatment in water vapor will accelerate the practical application of bulk-type ASSBs.

The preparation of ultrafine particles through combined wet planetary ball milling and heat treatment in water vapor contributes to the fabrication of extensive composite electrodes with solid electrolytes for bulk-type all-solid-state batteries.

Reduced Sintering Temperatures of Li+ Conductive Li1.3Al0.3Ti1.7(PO4)3 Ceramics

All-solid-state batteries (ASSB) are considered promising candidates for future energy storage and advanced electric mobility. When compared to conventional Li-ion batteries, the substitution of Li-ion conductive, flammable liquids by a solid electrolyte and the application of Li-metal anodes substantially increase safety and energy density. The solid electrolyte Li1.3Al0.3Ti1.7(PO4)3 (LATP) provides high Li-ion conductivity of about 10−3 S/cm and is considered a highly promising candidate for both the solid electrolyte-separator and the ionically conductive part of the all-solid state composite cathode, consisting of the cathode material, the solid electrolyte, and an electron conductor. Co-sintering of the composite cathode is a sophisticated challenge, because temperatures above 1000 °C are typically required to achieve the maximum ionic conductivity of LATP but provoke reactions with the cathode material, inhibiting proper electrochemical functioning in the ASSB. In the present study, the application of sintering aids with different melting points and their impact on the sinterability and the conductivity of LATP were investigated by means of optical dilatometry and impedance spectroscopy. The microstructure of the samples was analyzed by SEM. The results indicate that the sintering temperature can be reduced below 800 °C while maintaining high ionic conductivity of up to 3.6 × 10−4 S/cm. These insights can be considered a crucial step forward towards enable LATP-based composite cathodes for future ASSB.

New Na1+xGe2(SiO4)x(PO4)3-x NASICON Series with Improved Grain and Grain Boundary Conductivities

In this study, we synthesize glass-ceramics of the new Na_1+xGe₂(SiO₄)_x(PO₄)_3-x NASICON (Na super-ionic conductor) series to evaluate the effect of Si⁴⁺/P⁵⁺ substitution on the structural, microstructural, and electrical properties of the NaGe₂(PO₄)₃ system. From X-ray diffraction, the presence of the NASICON phase is confirmed in all glass-ceramics. An expansion of the unit cell volume suggesting an increase in the bottleneck of the NASICON structure is also observed. Impedance spectroscopy allowed the separation of grain and grain boundary contributions. We observe that the grain conductivity is higher than the specific grain boundary conductivity in all of the investigated compositions (0 ≤ x ≤ 0.8). The Si⁴⁺/P⁵⁺ substitution causes an enhancement of about 2 and 3 orders of magnitude in the grain and specific grain boundary conductivities, respectively. This behavior is attributable to the introduction of new charge carriers (Na⁺) in the NASICON structure and a decrease in the activation energy. Finally, the lowest activation energy for grain (0.586 eV) is observed in the x = 0.6 sample, which indicates the easiest displacement of ions in the investigated series, suggesting that this composition presents the most suitable bottleneck size for (Na⁺) sodium ion conduction.

Thermal Gradients with Sintered Solid State Electrolytes in Lithium-Ion Batteries

The electrolyte is one of the three essential constituents of a Lithium-Ion battery (LiB) in addition to the anode and cathode. During increasingly high power and high current charging and discharging, the requirement for the electrolyte becomes more strict. Solid State Electrolyte (SSE) sees its niche for high power applications due to its ability to suppress concentration polarization and otherwise stable properties also related to safety. During high power and high current cycling, heat management becomes more important and thermal conductivity measurements are needed. In this work, thermal conductivity was measured for three types of solid state electrolytes: Li 7 La 3 Zr 2 O 12 (LLZO), Li 1.5 Al 0.5 Ge 1.5 (PO 4 ) 3 (LAGP), and Li 1.3 Al 0.3 Ti 1.7 (PO 4 ) 3 (LATP) at different compaction pressures. LAGP and LATP were measured after sintering, and LLZO was measured before and after sintering the sample material. Thermal conductivity for the sintered electrolytes was measured to 0.470 ± 0.009 WK − 1 m − 1 , 0.5 ± 0.2 WK − 1 m − 1 and 0.49 ± 0.02 WK − 1 m − 1 for LLZO, LAGP, and LATP respectively. Before sintering, LLZO showed a thermal conductivity of 0.22 ± 0.02 WK − 1 m − 1 . An analytical temperature distribution model for a battery stack of 24 cells shows temperature differences between battery center and edge of 1–2 K for standard liquid electrolytes and 7–9 K for solid state electrolytes, both at the same C-rate of four.