Enabling Low-Stack-Pressure Silicon-Based All-Solid-State Batteries: Mechanisms, Materials and Manufacturing

Abstract

Silicon-based all-solid-state batteries (Si-ASSBs) are regarded as the most promising next-generation energy-storage technology, offering both high energy density with intrinsic safety. However, state-of-the-art Si-ASSBs typically rely on excessively huge stack pressures beyond 50 MPa to sustain solid-solid interfacial contact and electrode integrity, far exceeding the practical pressure limits (≤ 2.0 MPa) required for scalable cell manufacturing and operation. This review systematically summarizes recent progress toward enabling Si-ASSBs to operate under reduced stack pressures, with a discussion by four core dimensions: electrode design, interface engineering, structural optimization, and cell-assembly approaches. Low-pressure mechanisms enabling Si-ASSBs operation are analyzed across multiple scale insights, ranging from active material preparation and electrode microstructure regulation to cell-/module-level configurations. We further synthesize recently potential studies aimed at decoupling electrochemical performance with external stacking pressure, which can be realized by in-situ physicochemical characterization, artificial intelligence or machine learning-assisted optimization, conductive-elastic filler design, and the Si-anode matched roll-to-roll or cold-pressing manufacturing processes. By integrating mechanistic understanding with scalable engineering approaches, this review provides a comprehensive guidance for the rational design and practical implementation of high-performance Si-ASSBs under low-stack pressure (≤ 2.0 MPa).

Keywords

all-solid-state batteries / interfacial mechanics / ion-electron transport / low-stack pressure / silicon anode

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