Direct Precursor Route for the Fabrication of LLZO Composite Cathodes for Solid-State Batteries

Solid-state batteries based on Li7La3Zr2O12 (LLZO) garnet electrolyte are a robust and safe alternative to conventional lithium-ion batteries. However, the large-scale implementation of ceramic composite cathodes is still challenging due to a complex multistep manufacturing process. A new one-step route for the direct synthesis of LLZO during the manufacturing of LLZO/LiCoO2 (LCO) composite cathodes based on cheap precursors and utilizing the industrially established tape casting process is presented. It is shown that Al, Ta:LLZO can be formed directly in the presence of LCO from metal oxide precursors (LiOH, La2O3, ZrO2, Al2O3, and Ta2O5) by heating to 1050 degrees C, eliminating the time- and energy-consuming synthesis of preformed LLZO powders. In addition, performance-optimized gradient microstructures can be produced by sequential casting of slurries with different compositions, resulting in dense and flat phase-pure cathodes without unwanted ion interdiffusion or secondary phase formation. Freestanding cathodes with a thickness of 85 mu m, a relative density of 95%, and an industrial relevant LCO loading of 15 mg show an initial capacity of 82 mAh g-1 (63% of the theoretical capacity of LCO) in a solid-state cell with Li metal anodes, which is comparable to conventional LCO/LLZO cathodes and can be further improved in the future. Free-standing solid-state cathodes of Li7La3Zr2O12 (LLZO) solid electrolyte and LiCoO2 (LCO) are formed in a one-step process based on cheap precursors and utilizing the industrially established tape casting process. LLZO can be formed directly in the presence of LCO from metal oxide precursors by heating to 1050 degrees C, eliminating the time- and energy-consuming synthesis of preformed LLZO powders. image