Scalable fabrication of Solvent‐Free composite solid electrolyte by a continuous Thermal-Extrusion process

Zhen Li, Ammar M. Aboalsaud, Xiaowei Liu, Roshni L. Thankamony, I. Chun Chen, Yangxing Li, Zhiping Lai*

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

3 Scopus citations


Composite solid-state electrolytes (CSEs) are regarded as a promising alternative for the next‐generation lithium-ion batteries because they integrate the advantages of inorganic electrolytes and organic electrolytes. However, there are two issues faced by current CSEs: 1) a green and feasible approach to prepare CSEs in large scales is desired; and 2) the trace solvents, remaining from the preparation processes, lead to some serious concerns, such as safety hazard issues, electrolyte–electrode interfacial issues, and reduced durability of batteries. Here, a continuous thermal-extrusion process is presented to realize the large-scale fabrication of solvent‐free CSE. A 38.7-meter CSE membrane was prepared as a demonstration in this study. Thanks to the elimination of residual solvents, the electrolyte membrane exhibited a high tensile strength of 3.85 MPa, satisfactory lithium transference number (0.495), and excellent electrochemical stability (5.15 V). Excellent long-term stability was demonstrated by operating the symmetric lithium cell at a stable current density of 0.1 mA cm−2 for over 3700 h. Solvent-free CSE lithium metal batteries showed a discharge capacity of 155.7 – 25.17 mAh g−1 at 0.1 – 2.0C, and the discharge capacity remained 78.1% after testing for 380cycles.

Original languageEnglish (US)
Pages (from-to)64-71
Number of pages8
JournalJournal of colloid and interface science
StatePublished - Dec 15 2022

Bibliographical note

Funding Information:
This work was financially supported by the KAUST baseline fund BAS/1/1375-01 and competitive Research Fund under Award No. URF/1/4713-01 from KAUST. S.D.W. acknowledges the KAUST Office of Sponsored Research (OSR) under Award Nos. OSR-CARF/CCF-3079, IED OSR-2019-4208 and CRG2019-4093..

Publisher Copyright:
© 2022 Elsevier Inc.


  • Composite electrolyte
  • Micro-compounder
  • Polymer in ceramic
  • Solid-state lithium-ion battery
  • Solvent-free

ASJC Scopus subject areas

  • Electronic, Optical and Magnetic Materials
  • Biomaterials
  • Surfaces, Coatings and Films
  • Colloid and Surface Chemistry


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