This work investigates the critical transition from solvent-based manufacturing of Solid Polymer Electrolytes (SPEs) to a sustainable, solvent-free hot-pressing dry-processing method. The team developed homogeneous, dense PEO-based electrolyte films that were successfully integrated into symmetric cells and Li|SPE|NCM811 pouch cells. Electrochemical testing confirmed stable cycling and reduced overpotential compared to coin cells.
In sum, dry processing of thermoplastic polymer electrolytes is a viable, safe, and environmentally friendly alternative for industrial-scale lithium metal battery manufacturing. By eliminating toxic and flammable solvents, this approach simplifies production lines and lowers energy consumption while maintaining strong electrochemical stability.