The solid‐state electrolyte in a solid‐state battery acts as an electrons' barrier and an ions' bridge between the two electrodes. As solid‐state electrolyte does not store the mobile ions, it is necessary to achieve a thin solid‐state electrolyte to reduce the internal resistance and enhance the energy density. In this work, a thin NASICON solid‐state electrolyte, with a stoichiometry of Na3Zr2Si2PO12, is fabricated by the tape‐casting method and its thickness can be easily controlled by the gap between substrate and scraper. The areal‐specific resistance and the flexural strength increase with the electrolyte thickness. A solid‐state sodium metal battery with 86 μm thick Na3Zr2Si2PO12 exhibits a reversible specific capacity of 73–78 mAh g−1 with a redox potential of 3.4 V at 0.2 C. This work presents the importance of electrolyte thickness to reduce internal resistance and achieve a high energy density for sodium batteries.
In recent years, sodium ion batteries have shown its potential to compliment lithium ion batteries, especially in stationary energy storage system. Additionally, all-solid-state battery is perceived as the holy-grail battery. While numerous research efforts have been devoted to the search of solid-state materials with high ionic conductivity, it is paramount to reduce the thickness of the electrolyte to achieve a high energy density. In this study, the NASICON electrolyte is prepared by tape casting method and its thickness is controlled by the scrapper height during casting. It is realised that the areal specific resistance of the electrolyte is proportional to the thickness of the electrolyte and the 60 μm thick electrolyte shows an extremely low resistance of 42.7 Ω cm2. More importantly, such process is highly repeatable for large-scale production of thin freestanding solid-state electrolyte, which can be used in conventional bulk battery, redox-flow batteries, or metal-air batteries.
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