Lithium-ion batteries (LIB) are established in the field of mobile devices and electromobility due to their high energy and power density. Commercial systems currently in use enable the ion transport and thus the function of LIBs through a liquid electrolyte. The use of solid electrolytes has shown great potential to increase the energy density and improve the safety of LIBs. Sulfide solid-state electrolytes (SSE) are of great technical interest due to their high ionic conductivity. A specific challenge with solid electrolyte batteries (All Solid-State Lithium Ion Battery, ASSLIB) is the sufficient compaction of the particulate materials in order to achieve sufficiently high ionic conductivity and mechanical stability.

In order to investigate the performance and stability of ASSLIB cells based on sulfide solid electrolytes as well as their dependence on temperature and pressure at the experimental cell level, a manufacturing process with a high reproducibility was developed and the impact of key processing parameters analyzed. First, various sulfide SSE-Coins were manufactured under different compaction conditions, the resulting porosity determined, and the mechanical stability and surface properties evaluated qualitatively. In addition, the reproducible and scalable mixing of active materials with conductive additives and solid electrolytes and the subsequent compaction into stable catholyte coins present significant challenges. In this context, the approach frequently used in the literature of preparing the mixture with the aid of a mortar is deliberately avoided in this work due to its low reproducibility. An in-house mixing routine was developed using a shaker mixer to achieve good homogenization of the individual components and ensure low mechanical stress to the particles as well as any existing coating.

Various cell configurations were built using the developed manufacturing routine and characterized using both commercial and in-house developed experimental cell housings. The voltage behavior of the cells was measured under defined conditions within an automated test bench and the performance and its relationship to the material configuration and manufacturing parameters were evaluated. In additional optical post-mortem analyses possible occurring degradation mechanisms were investigated and discussed in relation to the configurations examined and the literature.