Lithium metal anodes paired with solid-state electrolytes (SSEs) represent a paradigm shift in battery technology, offering theoretical capacities of 3860 mAh/g and enhanced safety due to non-flammable electrolytes. Recent breakthroughs in garnet-type Li7La3Zr2O12 (LLZO) electrolytes have achieved ionic conductivities exceeding 1 mS/cm at room temperature, rivaling liquid electrolytes. However, interfacial resistance between lithium and SSEs remains a bottleneck, often exceeding 100 Ω cm² without optimization.
Surface modification techniques such as atomic layer deposition (ALD) and polymer interlayers have significantly reduced interfacial resistance. ALD-coated Li3PO4 layers on LLZO have lowered resistance to <10 Ω cm² while enhancing mechanical adhesion. Polymer interlayers like polyethylene oxide (PEO) infused with LiTFSI salts have further improved interface stability, enabling stable cycling at current densities up to 1 mA/cm² for over 1000 hours without dendrite formation.
Dendrite suppression is another critical area of innovation. Nanostructured lithium hosts such as graphene foams and copper nanowire arrays have demonstrated uniform lithium plating/stripping behavior at current densities up to 3 mA/cm². These structures also reduce volume changes during cycling by confining lithium within porous frameworks, achieving Coulombic efficiencies >99% over extended cycles. Additionally, in-situ X-ray tomography has revealed that these hosts mitigate dendrite growth by redistributing current density across the electrode surface.
Scalability challenges are being addressed through roll-to-roll manufacturing techniques for SSEs and lithium anodes. Thin-film LLZO electrolytes produced via sputtering have achieved thicknesses <10 µm while maintaining high ionic conductivity (>0.5 mS/cm). Similarly, roll-pressed lithium foils with integrated polymer coatings have demonstrated consistent performance across large-area cells (>100 cm²), paving the way for EV-scale applications.
Future research is exploring hybrid SSE systems combining inorganic ceramics with flexible polymers to balance mechanical strength and ionic conductivity. Machine learning models are also being employed to predict optimal electrolyte compositions and interface designs.
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