Effect of current density on the solid electrolyte interphase formation at the lithium∣Li(6)PS(5)Cl interface

Ruthenium clusters decorated on lattice expanded hematite Fe2O3 for efficient electrocatalytic alkaline water splitting

Electrocatalytic water splitting in alkaline media plays an important role in hydrogen production technology. Normally, the catalytic activity of commonly used transition metal oxides usually suffers from unsatisfactory electron conductivity and unfavorable binding strength for transition intermediates. To boost the intrinsic catalytic activity, we propose a rational strategy to construct lattice distorted transition metal oxides decorated with noble-metal nanoclusters. This strategy is verified by loading ruthenium clusters onto lithium ion intercalated hematite Fe2O3, which leads to significant distortion of the FeO6 unit cells. A remarkable overpotential of 21 mV with a Tafel slope of 39.8 mV dec-1 is achieved at 10 mA cm-2 for the hydrogen evolution reaction in 1.0 M KOH aqueous electrolyte. The assembled alkaline electrolyzer can catalyse overall water splitting for as long as 165 h at a current density of 250 mA cm-2 with negligible performance degradation, indicating great potential in the field of sustainable hydrogen production.

In Situ Characterization of Interface Evolution in Argyrodite-Based All-Solid-State Li Batteries

Interfacial stability is one of the critical challenges in all-solid-state Li metal batteries. Multiple processes such as solid electrolyte (SE) decomposition and lithium dendrite growth take place at the solid interfaces during cycling, leading to the overall cell failure. To deconvolute these complex processes, in situ characterization is of paramount importance to elucidate the interfacial evolution on the SE upon Li plating/stripping. Herein, an all-solid-state asymmetric in situ cell is developed that allows the direct visualization of the highly localized Li plating/stripping processes under the optical microscope. Moreover, this cell configuration enables reliable post-mortem chemical and morphological analysis of the intact SE/Li interface. Using combined scanning electron microscopy and energy-dispersive X-ray spectroscopy, the study reveals that the evolution of the Li argyrodite interface is strongly influenced by the current density, particularly in terms of chemical distribution and Li plating morphology. More specifically, the solid interface is LiCl-rich with the formation of Li cubes at low current densities, while high currents result in more uniform elemental distribution and filament morphology. These findings elucidate the dynamic evolution mechanism at solid interfaces and offer valuable guidance for developing stable solid interfaces in all-solid-state Li metal batteries.

Understanding Electrochemical Reaction Mechanisms of All-Electrochem-Active Mg2Si Electrode in All-Solid-State Batteries

To better understand the electrochemical reaction mechanism of the Mg2Si electrode in all-solid-state batteries (ASSBs), a rational all-electrochem-active Mg2Si electrode is first designed to minimize the inactive component-related interfacial degradation. This is due to its unique mixed conductivity properties, including a high electronic conductivity of up to 8.9 × 10-2 S cm-1 and an ionic conductivity of 9.7 × 10-5 S cm-1, which allow for fast charges transport. In ASSBs, the Mg2Si electrode exhibits a higher initial Coulombic efficiency of 83.5% at 300 mA g-1 compared with the Si electrode (72.3%). X-ray diffraction and X-ray photoelectron spectroscopy results demonstrate that intermediate products (LixMg2Si, Li-Si alloy, and Li-Mg alloy) can form when the Mg2Si electrode discharges to 0.01 V, and partial Mg2Si still does not react with lithium. This work provides valuable insights into the reaction mechanisms and guides optimization strategies for developing next-generation Si-based ASSBs.

Mechanical shutdown of battery separators: Silicon anode failure

The pulverization of silicon (Si) anode materials is recognized as a major cause of their poor cycling performance, yet a mechanistic understanding of this degradation from a full cell perspective remains elusive. Here, we identify an overlooked contributor to Si anode failure: mechanical shutdown of separators. Through mechano-structural characterization of Si full cells, combined with digital-twin simulation, we demonstrate that the volume expansion of Si exerts localized compressive stress on commercial polyethylene separators, leading to pore collapse. This structural disruption impairs ion transport across the separator, exacerbating redox nonuniformity and Si pulverization. Compression simulation reveals that a Young's modulus greater than 1 GPa is required for separators to withstand the volume expansion of Si. To fulfill this requirement, we design a high modulus separator, enabling a high-areal-capacity pouch-type Si full cell to retain 88% capacity after 400 cycles at a fast charge rate of 4.5 mA cm-2.

In situ XPS investigation of the SEI formed on LGPS and LAGP with metallic lithium

In situ X-ray photoelectron spectroscopy (XPS) techniques have proven to be powerful tools for the characterisation of the solid electrolyte interphase (SEI) formed between the anode and solid electrolyte (SE) in solid-state batteries. XPS offers access to time and operational condition-resolved information on the SEI's chemical composition in the absence of destructive sample preparation. Here we present a Virtual Electrode Plating XPS (VEP-XPS) investigation of the composition and stability of the SEI formed between lithium metal and two different solid electrolytes: Li10GeP2S12 (LGPS) and Li1.5Al0.5Ge1.5(PO4)3 (LAGP). LAGP shows slower SEI formation kinetics, as proven by the emergence of a metallic lithium signal, while LGPS exhibits rapid SEI growth that prevents metallic lithium from plating. We attribute these observations to the SEI composition, distribution and physical properties of secondary decomposition products and in particular to the mixed ion-electron conductive Li3P which can be observed in LGPS and not in LAGP.

In Situ Analysis of Interfacial Morphological and Chemical Evolution in All-Solid-State Lithium-Metal Batteries

In situ analysis of Li plating/stripping processes and evolution of solid electrolyte interphase (SEI) are critical for optimizing all-solid-state Li metal batteries (ASSLMB). However, the buried solid-solid interfaces present a challenge for detection which preclude the employment of multiple analysis techniques. Herein, by employing complementary in situ characterizations, morphological/chemical evolution, Li plating/stripping dynamics and SEI dynamics were directly detected. As a mixed ionic-electronic conducting interface, Li|Li10GeP2S12 (LGPS) performed distinct interfacial morphological/chemical evolution and dynamics from ionic-conducting/electronic-isolating interface like Li|Li3PS4 (LPS), which were revealed by combination of in situ atomic force microscopy and in situ X-ray photoelectron spectroscopy. Though Li plating speed in LGPS was higher than LPS, speed of SSE decomposition was similar and ~85 % interfacial SSE turned into SEI during plating and remained unchanged in stripping. To leverage strengths of different SSEs, an LPS-LGPS-LPS sandwich electrolyte was developed, demonstrating enhanced ionic conductivity and improved interfacial stability with less SSE decomposition (25 %). Using in situ Kelvin probe force microscopy, Li-ion behavior at interface between different SSEs was effectively visualized, uncovering distribution of Li ions at LGPS|LPS interface under different potentials.

A Cost-Effective Sulfide Solid Electrolyte Li7P3S7.5O3.5 with Low Density and Excellent Anode Compatibility

The commercialization of all-solid-state Li batteries (ASSLBs) demands solid electrolytes with strong cost-competitiveness, low density (for enabling satisfactory energy densities), and decent anode compatibility (the need for cathode compatibility can be circumvented by the cathode coating techniques that are widely applied in sulfide-based ASSLBs). However, none of the reported oxide, sulfide, or chloride solid electrolytes meets these requirements simultaneously. Here, we design a Li7P3S7.5O3.5 (LPSO) solid electrolyte, which shows a combination of all the aforementioned characteristics. The synthesis of this material does not need the expensive Li2S, so the raw materials cost is only $14.42/kg, which, unlike most solid electrolytes, lies below the $50/kg threshold for commercialization. The density of LPSO is 1.70 g cm-3, considerably lower than those of the oxide (typically above 5 g cm-3) and chloride (around 2.5 g cm-3) solid electrolytes. Besides, LPSO also shows excellent anode compatibility. The Li|LPSO|Li cell cycles stably with a potential of ~50 mV under 0.1 mA cm-2 for over 4200 h at 25 °C, and the all-solid-state pouch cell with the Si anode shows a capacity retention of 89.29 % after 200 cycles under 88.6 mA g-1 at 60 °C.

All-Solid-State Lithium-Sulfur Batteries of High Cycling Stability and Rate Capability Enabled by a Self-Lithiated Sn-C Interlayer

All-solid-state lithium-sulfur batteries (ASSLSBs) have attracted intense interest due to their high theoretical energy density and intrinsic safety. However, constructing durable lithium (Li) metal anodes with high cycling efficiency in ASSLSBs remains challenging due to poor interface stability. Here, a compositionally stable, self-lithiated tin (Sn)-carbon (C) composite interlayer (LSCI) between Li anode and solid-state electrolyte (SSE), capable of homogenizing Li-ion transport across the interlayer, mitigating decomposition of SSE, and enhancing electrochemical/structural stability of interface, is developed for ASSLSBs. The LSCI-mediated Li metal anode enables stable Li plating/stripping over 7000 h without Li dendrite penetration. The ASSLSBs equipped with LSCI thus exhibit excellent cycling stability of over 300 cycles (capacity retention of ≈80%) under low applied pressure (<8 MPa) and demonstrate improved rate capability even at 3C. The enhanced electrochemical performance and corresponding insights of the designed LSCI broaden the spectrum of advanced interlayers for interface manipulation, advancing the practical application of ASSLSBs.

Synergistic Evolution of Alloy Nanoparticles and Carbon in Solid-State Lithium Metal Anode Composites at Low Stack Pressure

Solid-state batteries with Li metal anodes can offer increased energy density compared to Li-ion batteries. However, the performance of pure Li anodes has been limited by morphological instabilities at the interface between Li and the solid-state electrolyte (SSE). Composites of Li metal with other materials such as carbon and Li alloys have exhibited improved cycling stability, but the mechanisms associated with this enhanced performance are not clear, especially at the low stack pressures needed for practical viability. Here, we investigate the structural evolution and correlated electrochemical behavior of Li metal composites containing reduced graphene oxide (rGO) and Li-Ag alloy particles. The nanoscale carbon scaffold maintains homogeneous contact with the SSE during stripping and facilitates Li transport to the interface; these effects largely prevent interfacial disconnection even at low stack pressure. The Li-Ag is needed to ensure cyclic refilling of the rGO scaffold with Li during plating, and the solid-solution character of Li-Ag improves cycling stability compared to other materials that form intermetallic compounds. Full cells with sulfur cathodes were tested at relatively low stack pressure, achieving 100 stable cycles with 79% capacity retention.

The impact of magnesium content on lithium-magnesium alloy electrode performance with argyrodite solid electrolyte

Solid-state lithium-based batteries offer higher energy density than their Li-ion counterparts. Yet they are limited in terms of negative electrode discharge performance and require high stack pressure during operation. To circumvent these issues, we propose the use of lithium-rich magnesium alloys as suitable negative electrodes in combination with Li6PS5Cl solid-state electrolyte. We synthesise and characterise lithium-rich magnesium alloys, quantifying the changes in mechanical properties, transport, and surface chemistry that impact electrochemical performance. Increases in hardness, stiffness, adhesion, and resistance to creep are quantified by nanoindentation as a function of magnesium content. A decrease in diffusivity is quantified with 6Li pulsed field gradient nuclear magnetic resonance, and only a small increase in interfacial impedance due to the presence of magnesium is identified by electrochemical impedance spectroscopy which is correlated with x-ray photoelectron spectroscopy. The addition of magnesium aids contact retention on discharge, but this must be balanced against a decrease in lithium diffusivity. We demonstrate via electrochemical testing of symmetric cells at 2.5 MPa and 30∘C that 1% magnesium content in the alloy increases the stripping capacity compared to both pure lithium and higher magnesium content alloys by balancing these effects.

PVDF-HFP via Localized Iodization as Interface Layer for All-Solid-State Lithium Batteries with Li6PS5Cl Films

All-solid lithium (Li) metal batteries (ASSLBs) with sulfide-based solid electrolyte (SEs) films exhibit excellent electrochemical performance, rendering them capable of satisfying the growing demand for energy storage systems. However, challenges persist in the application of SEs film owing to their reactivity with Li metal and uncontrolled formation of lithium dendrites. In this study, iodine-doped poly(vinylidenefluoride-hexafluoropropylene) (PVDF-HFP) as an interlayer (PHI) to establish a stable interphase between Li metal and Li6PS5Cl (LPSCl) films is investigated. The release of I ions and PVDF-HFP produces LiI and LiF, effectively suppressing lithium dendrite growth. Density functional theory calculations show that the synthesized interlayer layer exhibits high interfacial energy. Results show that the PHI@Li/LPSCl film/PHI@Li symmetrical cells can cycle for more than 650 h at 0.1 mA cm-2. The PHI@Li/LPSCl film/NCM622 cell exhibits a distinct enhancement in capacity retention of ≈26% when using LiNi0.6Mn0.2Co0.2O2 (NCM622) as the cathode, compared to pristine Li metal as the anode. This study presents a feasible method for producing next-generation dendrite-free SEs films, promoting their practical use in ASSLBs.

Heteroionic Interfaces in Hybrid Solid-State Batteries─Current Constriction at the Interface between Different Solid Electrolytes

The requirements for suitable electrolyte materials in solid-state batteries are diverse and vary greatly depending on their role as separator or as part of the composite cathode. Hybrid cell concepts that incorporate different types of solid electrolytes are considered a promising solution to overcome the limitations of single material classes. However, the kinetics at the heteroionic interface (i.e., charge transfer) substantially affects the cell performance. Moreover, non-ideal physical contacts hinder detailed electrochemical characterization of the interface properties. Thus, we use microstructure-resolved electric network computations to explore how the impedance response of a homogeneous bilayer system is influenced by the interface morphology and the material parameters of the single solid electrolyte layers. Porous interfaces and the resulting current constriction effects give rise to signatures in the impedance spectrum that resemble that of actual migration processes. This hinders unequivocal identification of the origin of the impedance contributions. The resistance and capacitance of this geometric interface signal depend strongly on the contact area and its spatial distribution, the pore capacitance, and the local conductivities around the interface. An experimental case study of an oxide-sulfide multilayer is considered to highlight the challenges in impedance analysis and the assessment of reliable material parameters. These findings are universal and apply to any heterojunction.

Nanoscale Visualization of Lithium Plating/Stripping Tuned by On-site Formed Solid Electrolyte Interphase in All-Solid-State Lithium-Metal Batteries

The interfacial processes, mainly the lithium (Li) plating/stripping and the evolution of the solid electrolyte interphase (SEI), are directly related to the performance of all-solid-state Li-metal batteries (ASSLBs). However, the complex processes at solid-solid interfaces are embedded under the solid-state electrolyte, making it challenging to analyze the dynamic processes in real time. Here, using in situ electrochemical atomic force microscopy and optical microscopy, we directly visualized the Li plating/stripping/replating behavior, and measured the morphological and mechanical properties of the on-site formed SEI at nanoscale. Li spheres plating/stripping/replating at the argyrodite solid electrolyte (Li6 PS5 Cl)/Li electrode interface is coupled with the formation/wrinkling/inflating of the SEI on its surface. Combined with in situ X-ray photoelectron spectroscopy, details of the stepwise formation and physicochemical properties of SEI on the Li spheres are obtained. It is shown that higher operation rates can decrease the uniformity of the Li+ -conducting networks in the SEI and worsen Li plating/stripping reversibility. By regulating the applied current rates, uniform nucleation and reversible plating/stripping processes can be achieved, leading to the extension of the cycling life. The in situ analysis of the on-site formed SEI at solid-solid interfaces provides the correlation between the interfacial evolution and the electrochemical performance in ASSLBs.

Li5AlO4-Assisted Low-Temperature Sintering of Dense Li7La3Zr2O12 Solid Electrolyte with High Critical Current Density

In recent years, solid electrolytes (SEs) have been developed a lot due to the superior safety of solid-state batteries (SSBs) upon liquid electrolyte-based commercial batteries. Among them, garnet-type Li7La3Zr2O12 (LLZO) is one of the few SEs that is stable to lithium anode with high Li+ conductivity and the feasibility of preparation under ambient air, which makes it a promising candidate for fabricating SSBs. However, high sintering temperature (>1200 °C) prevents its large-scale production, further hindering its application. In this work, the Li5AlO4 sintering aid is proposed to decrease the sintering temperature and modify the grain boundaries of LLZO ceramics. Li5AlO4 generates in situ Li2O atmosphere and molten Li-Al-O compounds at relatively low temperatures to facilitate the gas-liquid-solid material transportation among raw LLZO grains, which decreases the densification temperature over 150 °C and strengthens the grain boundaries against lithium dendrites. As an example, Ta-doped LLZO ceramics without excessive Li sintered with 2 wt % Li5AlO4 at 1050 °C delivered high relative density > 94%, an ionic conductivity of 6.7 × 10-4 S cm-1, and an excellent critical current density (CCD) of 1.5 mA cm-2 at room temperature. In comparison, Ta-doped LLZO with 15% excessive Li sintered at 1200 °C delivered low relative density < 89%, a low ionic conductivity of ∼2 × 10-4 S cm-1, and a poor CCD of 0.5 mA cm-2. Li symmetric cells and Li-LFP full cells fabricated with Li5AlO4-assised ceramics were stably cycled at 0.2 mA cm-2 over 2000 h and at 0.8C over 100 cycles, respectively.

Recent progress in SEI engineering for boosting Li metal anodes

Lithium metal anodes (LMAs) are ideal anode candidates for achieving next-generation high-energy-density battery systems due to their high theoretical capacity (3680 mA h g-1) and low working potential (-3.04 V versus the standard hydrogen electrode). However, the non-ideal solid electrolyte interface (SEI) derived from electrolyte/electrode interfacial reactions plays a vital role in the lithium deposition/stripping process and battery cycling performance. The composition and morphology of a SEI, which is sensitive to the outside environment, make it difficult to characterize and understand. With the development of characterization techniques, the mechanism, composition, and structure of a SEI can be better understood. In this review, the mechanism formation, the structure model evolution, and the composition of a SEI are briefly presented. Moreover, the development of in situ characterization techniques in recent years is introduced to better understand a SEI followed by the properties of the SEI, which are beneficial to the battery performance. Furthermore, recent optimization strategies of the SEI including the improvement of intrinsic SEIs and construction of artificial SEIs are summarized. Finally, the current challenges and future perspectives of SEI research are summarized.

Designing electrolytes and interphases for high-energy lithium batteries

High-energy and stable lithium-ion batteries are desired for next-generation electric devices and vehicles. To achieve their development, the formation of stable interfaces on high-capacity anodes and high-voltage cathodes is crucial. However, such interphases in certain commercialized Li-ion batteries are not stable. Due to internal stresses during operation, cracks are formed in the interphase and electrodes; the presence of such cracks allows for the formation of Li dendrites and new interphases, resulting in a decay of the energy capacity. In this Review, we highlight electrolyte design strategies to form LiF-rich interphases in different battery systems. In aqueous electrolytes, the hydrophobic LiF can extend the electrochemical stability window of aqueous electrolytes. In organic liquid electrolytes, the highly lithiophobic LiF can suppress Li dendrite formation and growth. Electrolyte design aimed at forming LiF-rich interphases has substantially advanced high-energy aqueous and non-aqueous Li-ion batteries. The electrolyte and interphase design principles discussed here are also applicable to solid-state batteries, as a strategy to achieve long cycle life under low stack pressure, as well as to construct other metal batteries.

Halogen chemistry of solid electrolytes in all-solid-state batteries

All-solid-state batteries (ASSBs) using solid-state electrolytes, replacing flammable liquid electrolytes, are considered one of the most promising next-generation electrochemical energy storage devices because of their improved, inherent safety and energy density. A family of solid electrolytes incorporating halogens has attracted attention because of their potentially high ionic conductivity, good deformability and wide electrochemical windows. Although progress has been made for halogen-containing solid electrolytes (HSEs) in ASSBs, challenges in the preparations, characterizations and low-cost industrial scalability remain. In this Review, we focus on the development of halide battery chemistry, the preparation, modification and properties of HSEs, and issues with HSEs in ASSBs. The chemical action of halogen and ion transport mechanisms are discussed. Moreover, the main challenges and future development directions of halide-based ASSBs are discussed to pave the way for practical applications of HSEs for next-generation rechargeable batteries.

Understanding Interfaces at the Positive and Negative Electrodes on Sulfide-Based Solid-State Batteries

Despite the high ionic conductivity and attractive mechanical properties of sulfide-based solid-state batteries, this chemistry still faces key challenges to encompass fast rate and long cycling performance, mainly arising from dynamic and complex solid-solid interfaces. This work provides a comprehensive assessment of the cell performance-determining factors ascribed to the multiple sources of impedance from the individual processes taking place at the composite cathode with high-voltage LiNi0.6Mn0.2Co0.2O2, the sulfide argyrodite Li6PS5Cl separator, and the Li metal anode. From a multiconfigurational approach and an advanced deconvolution of electrochemical impedance signals into distribution of relaxation times, we disentangle intricate underlying interfacial processes taking place at the battery components that play a major role on the overall performance. For the Li metal solid-state batteries, the cycling performance is highly sensitive to the chemomechanical properties of the cathode active material, formation of the SEI, and processes ascribed to Li diffusion in the cathode composite and in the space-charge layer. The outcomes of this work aim to facilitate the design of sulfide solid-state batteries and provide methodological inputs for battery aging assessment.

One Stone, Three Birds: An Air and Interface Stable Argyrodite Solid Electrolyte with Multifunctional Nanoshells

Li6 PS5 Cl (LPSC) solid electrolytes, based on Argyrodite, have shown potential for developing high energy density and safe all-solid-state lithium metal batteries. However, challenges such as interfacial reactions, uneven Li deposition, and air instability remain unresolved. To address these issues, a simple and effective approach is proposed to design and prepare a solid electrolyte with unique structural features: Li6 PS4 Cl0.75 -OF0.25 (LPSC-OF0.25 ) with protective LiF@Li2 O nanoshells and F and O-rich internal units. The LPSC-OF0.25 electrolyte exhibits high ionic conductivity and the capability of "killing three birds with one stone" by improving the moist air tolerance, as well as the interface compatibility between the anode or cathode and the solid electrolyte. The improved performance is attributed to the peculiar morphology and the self-generating and self-healing interface coupling capability. When coupled with bare LiCoO2 , the LPSC-OF0.25 electrolyte enables stable operation under high cutoff voltage (≈4.65 V vs Li/Li+ ), thick cathodes (25 mg cm-2 ), and large current density (800 cycles at 2 mA cm-2 ). This rationally designed solid electrolyte offers promising prospects for solid-state batteries with high energy and power density for future long-range electric vehicles and aircrafts.

SEI growth on Lithium metal anodes in solid-state batteries quantified with coulometric titration time analysis

Lithium-metal batteries with a solid electrolyte separator are promising for advanced battery applications, however, most electrolytes show parasitic side reactions at the low potential of lithium metal. Therefore, it is essential to understand how much (and how fast) charge is consumed in these parasitic reactions. In this study, a new electrochemical method is presented for the characterization of electrolyte side reactions occurring on active metal electrode surfaces. The viability of this new method is demonstrated in a so-called anode-free stainless steel ∣ Li6PS5Cl ∣ Li cell. The method also holds promise for investigating dendritic lithium growth (and dead lithium formation), as well as for analyzing various electrolytes and current collectors. The experimental setup allows easy electrode removal for post-mortem analysis, and the SEI's heterogeneous/layered microstructure is revealed through complementary analytical techniques. We expect this method to become a valuable tool in the future for solid-state lithium metal batteries and potentially other cell chemistries.

Operando Characterization and Theoretical Modeling of Metal|Electrolyte Interphase Growth Kinetics in Solid-State Batteries. Part I: Experiments

To harness all of the benefits of solid-state battery (SSB) architectures in terms of energy density, their negative electrode should be an alkali metal. However, the high chemical potential of alkali metals makes them prone to reduce most solid electrolytes (SE), resulting in a decomposition layer called an interphase at the metal|SE interface. Quantitative information about the interphase chemical composition and rate of formation is challenging to obtain because the reaction occurs at a buried interface. In this study, a thin layer of Na metal (Na⁰) is plated on the surface of an SE of the NaSICON family (Na_3.4Zr₂Si_2.4P_0.6O₁₂ or NZSP) inside a commercial X-ray photoelectron spectroscopy (XPS) system while continuously analyzing the composition of the interphase operando. We identify the existence of a solid electrolyte interphase at the Na⁰|NZSP interface, and more importantly, we demonstrate for the first time that this protocol can be used to study the kinetics of interphase formation. A second important outcome of this article is that the surface chemistry of NZSP samples can be tuned to improve their stability against Na⁰. It is demonstrated by XPS and time-resolved electrochemical impedance spectroscopy (EIS) that a native Na _x PO _y layer present on the surface of as-sintered NZSP samples protects their surface against decomposition.

Thin Solid Electrolyte Separators for Solid-State Lithium-Sulfur Batteries

The lithium-sulfur battery is one of the most promising "beyond Li-ion" battery chemistries owing to its superior gravimetric energy density and low cost. Nonetheless, its commercialization has been hindered by its low cycle life due to the polysulfide shuttle and nonuniform Li-metal plating and stripping. Thin and dense solid electrolyte separators could address these issues without compromising on energy density. Here, we introduce a novel argyrodite (Li₆PS₅Cl)-carboxylated nitrile butadiene rubber (XNBR) composite thin solid electrolyte separator (TSE) (<50 μm) processed by a scalable calendering technique and compatible with Li-metal. When integrated in a full cell with a commercial tape-cast sulfur cathode (3.54 mg_S cm^-2) in the presence of an in situ polymerized lithium bis(fluorosulfonyl)imide-polydioxolane catholyte and a 100 μm Li-metal foil anode, we demonstrate stable cycling for 50 cycles under realistic operating conditions (stack pressure of <1 MPa and 30 °C).