Challenges and Innovations for Manufacturing and Operating Solid-state Batteries

Driven by the tremendous global energy demands, lithium-ion batteries are reaching their performance limits, underscoring the need for next-generation energy storage systems. Solid-state batteries (SSBs) have emerged as a promising candidate due to their enhanced safety and potential higher energy density. Major battery manufacturers have announced plans to scale up production of SSB. However, academic researchers remain focused on small-scale cells (~1 cm^2), leaving a giant gap between lab-scale demonstrations and industrial-scale implementation—particularly in developing larger pouch cells (>25 cm^2), the preferred format for commercial applications. This thesis addresses the key challenges and innovations involved in the manufacturing and operation of SSBs. This thesis presents a method for producing fiber-reinforced, high-strength solid electrolyte membranes using pulsed laser processing. Second, the process science of assembling pouch cells incorporating lithium metal anodes and silver-carbon interlayer layers has been investigated. Third, the origins of high stack pressure requirements are carefully examined for halide-based SSBs. Finally, the future directions and opportunities are presented. This thesis provides a comprehensive understanding of the material, mechanical, and manufacturing barriers that must be addressed to bridge the gap between laboratory-scale cells and industry-relevant solid-state battery prototypes.

Name thesis:degree_name

Doctor of Philosophy

Discipline thesis:degree_discipline

Materials Engineering

Grantor

University of Houston

Year dc:date.issued

2025

Author dc:creator

• Guo, Liqun

Advisor dc:contributor.advisor

• Yao, Yan

Committee members dc:contributor.committeemember

• Zhao, Lihong
• Bao, jiming
• Li, Jianlin
• Sacci, Robert

• Materials

Language dc:language.iso

English

Handle dc:identifier.uri

https://hdl.handle.net/10657/20638

OAI identifier oai:identifier

oai:uh-ir.tdl.org:10657/20638