Ultra-high throughput manufacturing method for composite solid-state electrolytes

The transition from liquid organic electrolytes to solid-state electrolytes promises safer and more energy-dense lithium ion batteries. Although this technology has been demonstrated, the question of how to manufacture solid-state batteries at the cost and scales needed to be competitive remains. Here we propose and demonstrate curtain coating as a method for manufacturing composite solid-state electrolytes in roll-to-roll processes at web-speeds of over 80 m/min. The method is compatible with existing lithium-ion battery electrode manufacturing lines and is able to produce uniform electrolyte films with thicknesses below 15 micrometers.