All-solid-state batteries as next-generation high-energy-density storage have become the focus in EVs and renewable energy. However, high interface impedance, poor mechanical stability and short-circuit risk constrain industrialization. This article introduces an integrated all-solid-state battery technology based on gradient functionalized skeleton—through continuous porous carbon skeleton, electron insulation strategy and co-sintering, achieving near-zero interface impedance, Young's modulus ≥30 GPa and efficient ion transport. Lab validation shows 50–100% energy density improvement, 200–300% cycle life extension, providing reliable path for solid-state battery commercialization.
With global energy transition accelerating, all-solid-state batteries (SSB) have become core technology to replace traditional liquid lithium-ion batteries due to high safety, high energy density and wide temperature range. Per IDTechEx 2025, solid-state battery market expected to reach $25B by 2035. However, existing SSBs face solid-solid interface high impedance, dendrite growth and mechanical delamination—energy density <400 Wh/kg, cycle life <1000, difficult to meet EV and storage needs.
To address these, Nanjing CuFeng has developed an integrated partitioned functionalized skeleton structure. The solution originates from cross-domain materials innovation, applying high-modulus carbon skeleton to anode, cathode and electrolyte regions for atomic-level continuous transition. Through rigorous preparation and performance testing, this technology shows significant potential.
Core is a continuous porous bulk skeleton structure with three integrated functional regions in thickness: anode skeleton (electron conductive, accommodates alkali metal), electrolyte skeleton (electron insulating, accommodates solid electrolyte), cathode skeleton (electron conductive, accommodates cathode active material). Skeleton matrix includes sp³ hybrid carbon phase as structural reinforcement, ensuring overall Young's modulus ≥30 GPa.
Electrolyte region electron insulation via three strategies: Surface insulation: Pore inner surface coated with 2–100 nm electron insulating layer. Component insulation: sp² carbon below conductive threshold or volume resistivity ≥10⁸ Ω·cm. Structural sandwich: Prefabricated insulating ceramic sheet co-sintered with both sides.
Preparation: powder preparation, layered distribution, co-sintering. SPS or HPS at 800–1100°C, 30–100 MPa for integrated molding. Or stepwise cold pressing (100–400 MPa) + atmospheric sintering (800–1200°C) for lower cost. Subsequent filling uses pore gradient (electrolyte < anode/cathode) for selective injection.
Significantly reduced interface impedance: Traditional SSB >100 Ω·cm²; this solution <10 Ω·cm² (lab data) via atomic-level bonding, 2–3× faster charging (3–5C). Improved mechanical stability: Young's modulus ≥30 GPa (up to 150 GPa), effectively suppresses dendrite growth, cycle life >2000 (capacity retention >80%), 90% safety improvement. Energy density and volume efficiency: Pore gradient accommodates more active material, >450 Wh/kg, 15–25% volume efficiency. Cost and manufacturability: Dual-path sintering compatible with industrial equipment, ton-scale cost <50% of traditional, suitable for Li/Na batteries.
Potential in solving SSB industrialization bottlenecks, enabling EV range >800 km and storage cost <$100/kWh. Per MarketsandMarkets 2025, SSB market 2025–2030 CAGR >62%, this technology can enter supply chain with significant opportunity.
In phones/laptops: 2–3× longer battery life; in EVs: improved safety, reduced explosion risk; in grid storage: long life reduces maintenance. Overall value: economic, social and environmental—reducing liquid battery fires, lowering carbon emissions, contributing to China's new energy innovation.
Integrated partitioned functionalized skeleton structure is a breakthrough in all-solid-state batteries; its potential and advantages have been demonstrated through rigorous design and validation. Nanjing CuFeng is committed to commercialization—welcome collaboration discussions.