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Mechanofusion-derived cathode composite microstructures with scalable mixed conducting matrix coatings for solid state batteries
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  • Published: 03 April 2026

Mechanofusion-derived cathode composite microstructures with scalable mixed conducting matrix coatings for solid state batteries

  • Maximilian Kissel  ORCID: orcid.org/0000-0001-9201-07481 na1,
  • Finn Frankenberg  ORCID: orcid.org/0009-0005-0644-15652 na1,
  • Thomas Demuth  ORCID: orcid.org/0009-0002-9796-49593,
  • Anton Lai  ORCID: orcid.org/0009-0007-2524-31711,
  • Niklas Laser2,
  • Daniel Wagner  ORCID: orcid.org/0009-0006-9012-63451,
  • Ahmed Eisa2,
  • Peter Michalowski  ORCID: orcid.org/0000-0001-6738-81082,
  • Kerstin Volz3,
  • Arno Kwade  ORCID: orcid.org/0000-0002-6348-73092 &
  • …
  • Jürgen Janek  ORCID: orcid.org/0000-0002-9221-47561 

Nature Communications , Article number:  (2026) Cite this article

We are providing an unedited version of this manuscript to give early access to its findings. Before final publication, the manuscript will undergo further editing. Please note there may be errors present which affect the content, and all legal disclaimers apply.

Subjects

  • Batteries

Abstract

The successful implementation of solid state batteries not only requires the use of high-capacity anodes, but also high-performance composite cathodes. However, the production of solid state battery cathode composites with optimized microstructures remains a significant challenge, especially for large-scale fabrication. Here, we present a scalable high-intensity dry mixing process to create tailored functional coatings on single-crystalline LiNi0.82Mn0.07Co0.11O2 via mechanofusion. We investigate the coating of LiNi0.82Mn0.07Co0.11O2 with the malleable halide solid electrolyte Li3InCl6 under various process conditions, linking process parameters obtained from discrete element method simulations with experimentally accessible morphological properties to offer guidelines for further optimization. In this way nanometer-thin covering coatings as well as thick matrix coatings are successfully produced. Incorporating carbon black into the thick matrix coating results in well-performing mixed conducting matrices that can be used directly as composite cathodes without further treatment. The compositions investigated enable stable cycling with a specific capacity of up to qcomp = 100 mAh g−1 (based on the total mass of the composite cathode) at a C-rate of 1 C (60 min). While higher carbon black content is observed to improve CAM utilization, excessive amounts are detrimental for cell kinetics and chemo-mechanics, emphasizing the importance of the cathode mixing process and composition on overall cell performance.

Data availability

The source data used for all figures in this study are provided in the Source data File, which has been deposited, together with additional data, in Zenodo at https://doi.org/10.5281/zenodo.18493074.

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Acknowledgements

M.K., F.F., J.J., and A.K. acknowledge financial support by Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) through the priority program 2289 (project 462470125) and by BMFTR through the projects 03XP0430A, 03XP0430C (FestBatt Cluster of Competence, FB2-Thio) and 03XP0590D (FoFeBat). Language and grammar of the manuscript have partially been improved with the help of DeepL Write and ChatGPT4.0 (by OpenAI).

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  1. These authors contributed equally: Maximilian Kissel, Finn Frankenberg.

Authors and Affiliations

  1. Institute of Physical Chemistry & Center for Materials Research, Justus-Liebig-Universität Gießen, Gießen, Germany

    Maximilian Kissel, Anton Lai, Daniel Wagner & Jürgen Janek

  2. Institute for Particle Technology, Technische Universität Braunschweig, Braunschweig, Germany

    Finn Frankenberg, Niklas Laser, Ahmed Eisa, Peter Michalowski & Arno Kwade

  3. Materials Science Center (WZMW) and Department of Physics, Philipps-University Marburg, Marburg, Germany

    Thomas Demuth & Kerstin Volz

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Contributions

M.K. and F.F. contributed equally to this work. M.K., F.F., A.K., and J.J. conceived the project. M.K. and F.F. designed and coordinated the experiments. F.F. prepared the mixtures with the help of N.L., measured the porosities, carried out DEM simulations of the mixing process and analyzed the data. M.K. carried out the electrochemical investigations with help of A.L., measured and analyzed the EDX-SEM and XPS data. T.D. carried out the STEM-EDX and TEM investigations. D.W. analyzed the XRD data. M.K. and F.F. wrote the first version of the manuscript which was edited by all authors.

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Correspondence to Arno Kwade or Jürgen Janek.

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Kissel, M., Frankenberg, F., Demuth, T. et al. Mechanofusion-derived cathode composite microstructures with scalable mixed conducting matrix coatings for solid state batteries. Nat Commun (2026). https://doi.org/10.1038/s41467-026-71305-2

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  • Received: 04 June 2025

  • Accepted: 04 March 2026

  • Published: 03 April 2026

  • DOI: https://doi.org/10.1038/s41467-026-71305-2

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