Binder Effects on Processing, Mechanical Properties, and Performance of Thin Sulfide Solid-State Electrolytes

All-solid-state batteries (ASSBs) offer enhanced safety and energy density compared to conventional lithium-ion batteries by replacing flammable liquid electrolytes with solid-state electrolytes (SSEs). Among SSEs, sulfide-based electrolytes exhibit high ionic conductivity and mechanical deformability, making them promising candidates for next-generation energy storage. However, their practical implementation is hindered by interfacial instability, mechanical brittleness, and challenges in fabricating ultrathin electrolyte membranes (<30 μm) with robust mechanical integrity. This study systematically examines the influence of polymeric binders—polyisobutylene, hydrogenated nitrile butadiene rubber, and styrene–ethylene–butylene–styrene (SEBS)—on the structural, mechanical, and electrochemical performance of thin sulfide SSE membranes. Key findings reveal that SEBS enables the fabrication of ultrathin, uniform membranes, while binder elasticity significantly affects structural stability during cycling. Operando stack pressure measurements indicate that binder properties directly influence adhesion force for LPSCl particles, influencing their stabilizing cycling period. These results underscore the critical role of polymer binders beyond mechanical reinforcement, positioning them as essential design variables in sulfide SSE engineering. By linking binder chemistry to processability and electrochemical performance, this study provides insights into optimizing sulfide SSEs, advancing their commercial viability in ASSBs.