US20170022112A1 - Processes and materials for casting and sintering green garnet thin films - Google Patents

Processes and materials for casting and sintering green garnet thin films Download PDF

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Publication number
US20170022112A1
US20170022112A1 US15/216,636 US201615216636A US2017022112A1 US 20170022112 A1 US20170022112 A1 US 20170022112A1 US 201615216636 A US201615216636 A US 201615216636A US 2017022112 A1 US2017022112 A1 US 2017022112A1
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Prior art keywords
slurry
source powder
green tape
examples
lithium
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US15/216,636
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Inventor
Oleh Karpenko
Gengfu Xu
Niall Donnelly
Sriram Iyer
Tim Holme
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Quantumscape Battery Inc
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Quantumscape Corp
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Priority to US15/216,636 priority Critical patent/US20170022112A1/en
Assigned to QUANTUMSCAPE CORPORATION reassignment QUANTUMSCAPE CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DONNELLY, Niall, IYER, SRIRAM, KARPENKO, OLEH, HOLME, TIM, XU, GENGFU
Publication of US20170022112A1 publication Critical patent/US20170022112A1/en
Priority to US16/734,196 priority patent/US12084387B2/en
Priority to US17/588,108 priority patent/US20220250988A1/en
Assigned to QUANTUMSCAPE SUBSIDIARY, INC. reassignment QUANTUMSCAPE SUBSIDIARY, INC. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: QUANTUMSCAPE CORPORATION
Priority to US18/643,795 priority patent/US20240343652A1/en
Priority to US19/022,525 priority patent/US20250178968A1/en
Abandoned legal-status Critical Current

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    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/658—Atmosphere during thermal treatment
    • C04B2235/6588—Water vapor containing atmospheres
    • C—CHEMISTRY; METALLURGY
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/66—Specific sintering techniques, e.g. centrifugal sintering
    • C—CHEMISTRY; METALLURGY
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/74—Physical characteristics
    • C04B2235/76—Crystal structural characteristics, e.g. symmetry
    • C04B2235/762—Cubic symmetry, e.g. beta-SiC
    • C04B2235/764—Garnet structure A3B2(CO4)3
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    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/34—Oxidic
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    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/34—Oxidic
    • C04B2237/343—Alumina or aluminates
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    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32—Ceramic
    • C04B2237/34—Oxidic
    • C04B2237/345—Refractory metal oxides
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    • C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/56—Using constraining layers before or during sintering
    • C04B2237/562—Using constraining layers before or during sintering made of alumina or aluminates
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2300/00—Electrolytes
    • H01M2300/0017—Non-aqueous electrolytes
    • H01M2300/0065—Solid electrolytes
    • H01M2300/0068—Solid electrolytes inorganic
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2300/00—Electrolytes
    • H01M2300/0017—Non-aqueous electrolytes
    • H01M2300/0065—Solid electrolytes
    • H01M2300/0068—Solid electrolytes inorganic
    • H01M2300/0071—Oxides
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the present disclosure concerns precursors to inorganic thin films (e.g., green tapes or sintered films made from green tapes), processes for using these precursors to make sintered thin films, and sintered thin films made by the processes set forth herein.
  • the sintered thin films made by the processes set forth herein are useful as solid electrolytes in rechargeable batteries.
  • the green tapes which are set forth herein and used to make sintered thin films have a higher solid loading than known green tapes.
  • the sintered thin films prepared by the processes herein have a lower porosity, a higher density, less defects, and, or, are prepared in higher yield than known sintered thin films.
  • Solid state ceramics such as lithium-stuffed garnet materials and lithium borohydrides, oxides, sulfides, oxyhalides, and halides have several advantages as materials for ion-conducting electrolyte membranes and separators in a variety of electrochemical devices including fuel cells and rechargeable batteries.
  • the aforementioned solid ceramics possess safety and economic advantages as well as advantages related to the material's solid state and density which allows for correspondingly high volumetric and gravimetric energy densities when these materials are incorporated into electrochemical devices as electrolyte separators.
  • Solid state ion conducting ceramics are well suited for solid state electrochemical devices because of their high ion conductivity properties in the solid state, their electric insulating properties, as well as their chemical compatibility with a variety of species such as lithium metal and their stability to a wide window of voltages.
  • solid state ion conducting ceramics have a series of advantageous and beneficial properties, these materials suffer from a range of issues related to forming green films (i.e., green tapes) and to subsequently sintering these green films.
  • green films i.e., green tapes
  • these films When solid state ion conducting ceramics are typically formulated as thin films and sintered, these films have a tendency to stick to the substrate on which they are prepared, to crack or warp on account of the processing conditions, or are too brittle post-sintering to handle and manipulate. In particular, during sintering of thin films, these films have a tendency to crack, warp, or otherwise have surface deteriorations.
  • the instant disclosure sets forth methods for casting a thin film tape, in which the methods include, generally, providing at least one source power, modifying the at least one source powder to prepare a modified source powder, providing a slurry of the modified source powder, casting the slurry to form a green tape, drying the green tape; and sintering the green tape to form a sintered thin film.
  • the instant disclosure sets forth a slurry for casting a green tape, in which the slurry includes a source powder, optionally precursors to the source powder, and at least one member selected from binders, dispersants, and solvents.
  • the instant disclosure sets forth a method for sintering a green tape, the method including: (a) providing at least one source powder; (b) modifying the at least one source powder to prepare a modified source powder; (c) providing a slurry of the modified source powder; (d) casting the slurry to form a green tape; (e) drying the green tape; and (f) sintering the green tape; thereby sintering a green tape.
  • the instant disclosure sets forth a slurry for preparing a cast green film, the slurry including:
  • the instant disclosure sets forth a green tape, including:
  • the instant disclosure sets forth a method of making a green tape, including the following steps: (a) providing a slurry; (b) providing a binder mixture; (c) mixing the slurry with the binder mixture to form a mixed slurry; and (d) casting the mixed slurry to provide a green tape, wherein the green tape has a total organic content of about 10-25% w/w.
  • FIG. 1 shows an example flow chart in accordance with an embodiment of the methods set forth herein.
  • FIG. 2 shows a scanning electron microscopy (SEM) image of a green tape made by the casting methods set forth in Example 1.
  • the tape include 15% binder, the garnet had a d 50 of about 180 nm, and a density of 2.3 g/cm 3 .
  • the organic portion is labeled 201
  • the inorganic portion is labeled 202 .
  • FIG. 3 shows an optical image of a 100-200 ⁇ m sintered green tape, prepared by Example 3.
  • FIG. 4 shows a scanning electron microscopy (SEM) image of a sintered tape made by Example 2 with slurry composition 1 and binder composition 1.
  • the disclose herein sets forth green tapes, processes for making these tapes, and processes for sintering these tapes.
  • the processes herein produce sintered thin films having improved surface qualities when compared with films prepared by conventionally known methods.
  • Some of the films prepared by the methods described herein are prepared with uniformly rough (i.e., smooth) surfaces. These films have a surface, as sintered, which is suitable for incorporation into an electrochemical device without further processing, such as polishing or lapping.
  • polishing or lapping it may be necessary to process the sintered films prepared herein by polishing or lapping, but for other applications the films, as sintered by the methods set forth herein, are suitable for electrochemical device applications.
  • the films prepared herein have a surface roughness less than 5 ⁇ m post-sintering.
  • providing refers to the provision of, generation or, presentation of, or delivery of that which is provided. Providing includes making something available. For example, providing a power refers to the process of making the powder available, or delivering the powder, such that the powder can be used as set forth in a method described herein. As used herein, providing also means measuring, weighing, transferring combining, or formulating.
  • casting means to provide, deposit, or deliver a cast solution or slurry onto a substrate. Casting includes, but is not limited to, slot casting, dip coating, and doctor blading.
  • slot casting refers to a deposition process whereby a substrate is coated, or deposited, with a solution, liquid, slurry, or the like by flowing the solution, liquid, slurry, or the like, through a slot or mold of fixed dimensions that is placed adjacent to, in contact with, or onto the substrate onto which the deposition or coating occurs.
  • slot casting includes a slot opening of about 1 to 100 ⁇ m.
  • the phrase “dip casting” or “dip coating” refers to a deposition process whereby substrate is coated, or deposited, with a solution, liquid, slurry, or the like, by moving the substrate into and out of the solution, liquid, slurry, or the like, often in a vertical fashion.
  • “casting a slurry” refers to a process wherein a slurry is deposited onto, or adhered to, a substrate. Casting can include, but is not limited to, slot casting and dip casting.
  • slot casting refers to a deposition process whereby a substrate is coated, or deposited, with a solution, liquid, slurry, or the like by flowing the solution, liquid, slurry, or the like, through a slot or mold of fixed dimensions that is placed adjacent to, in contact with, or onto the substrate onto which the deposition or coating occurs.
  • slot casting includes a slot opening of about 1 to 100 ⁇ m.
  • dip casting or “dip coating” refers to a deposition process whereby substrate is coated, or deposited, with a solution, liquid, slurry, or the like, by moving the substrate into and out of the solution, liquid, slurry, or the like, often in a vertical fashion.
  • casting also includes depositing, coating, or spreading a cast solution or cast slurry onto a substrate.
  • the phrase “casting a film,” refers to the process of delivering or transferring a liquid or a slurry into a mold, or onto a substrate, such that the liquid or the slurry forms, or is formed into, a film. Casting may be done via doctor blade, meyer rod, comma coater, gravure coater, microgravure, reverse comma coater, slot dye, slip and/or tape casting, and other methods known to those skilled in the art.
  • the phrase “casting a film,” refers to the process of delivering or transferring a liquid or a slurry into a mold, or onto a substrate, such that the liquid or the slurry forms, or is formed into, a film. Casting may be done via doctor blade, Meyer rod, comma coater, gravure coater, microgravure, reverse comma coater, slot dye, slip and/or tape casting, and other methods known to those skilled in the art.
  • slot casting refers to a deposition process whereby a substrate is coated, or deposited, with a solution, liquid, slurry, or the like by flowing the solution, liquid, slurry, or the like, through a slot or mold of fixed dimensions that is placed adjacent to, in contact with, or onto the substrate onto which the deposition or coating occurs.
  • slot casting includes a slot opening of about 1 to 100 ⁇ m.
  • dip casting or “dip coating” refers to a deposition process whereby substrate is coated, or deposited, with a solution, liquid, slurry, or the like, by moving the substrate into and out of the solution, liquid, slurry, or the like, often in a vertical fashion.
  • the term “laminating” refers to the process of sequentially depositing a layer of one precursor specie, e.g., a lithium precursor specie, onto a deposition substrate and then subsequently depositing an additional layer onto an already deposited layer using a second precursor specie, e.g., a transition metal precursor specie. This laminating process can be repeated to build up several layers of deposited vapor phases.
  • the term “laminating” also refers to the process whereby a layer comprising an electrode, e.g., positive electrode or cathode active material comprising layer, is contacted to a layer comprising another material, e.g., garnet electrolyte.
  • the laminating process may include a reaction or use of a binder which adheres or physically maintains the contact between the layers which are laminated.
  • Laminating also refers to the process of bringing together unsintered, i.e. “green” ceramic films.
  • green tape or “green film” refers to an unsintered film including at least one member selected from garnet materials, precursors to garnet materials, binder, solvent, carbon, dispersant, or combinations thereof
  • film thickness refers to the distance, or median measured distance, between the top and bottom faces of a film.
  • top and bottom faces refer to the sides of the film having the largest surface area.
  • garnet precursor chemicals refers to chemicals which react to form a lithium stuffed garnet material described herein.
  • These chemical precursors include, but are not limited to, lithium hydroxide (e.g., LiOH), lithium oxide (e.g., Li 2 O), lithium carbonate (e.g., LiCO 3 ), zirconium oxide (e.g., ZrO 2 ), lanthanum oxide (e.g., La 2 O 3 ), aluminum oxide (e.g., Al 2 O 3 ), aluminum (e.g., Al), aluminum nitrate (e.g., AlNO 3 ), aluminum nitrate nonahydrate, aluminum (oxy) hydroxide (gibbsite and boehmite), gallium oxide, niobium oxide (e.g., Nb 2 O 5 ), and tantalum oxide (e.g., Ta 2 O 5 ).
  • lithium hydroxide e.g., LiOH
  • lithium oxide e.g., Li 2 O
  • lithium carbonate e.
  • the phrase “subscripts and molar coefficients in the empirical formulas are based on the quantities of raw materials initially batched to make the described examples” means the subscripts, (e.g., 7, 3, 2, 12 in Li 7 La 3 Zr 2 O 12 and the coefficient 0.35 in 0.35Al 2 O 3 ) refer to the respective elemental ratios in the chemical precursors (e.g., LiOH, La 2 O 3 , ZrO 2 , Al 2 O 3 ) used to prepare a given material, (e.g., Li 7 La 3 Zr 2 O 12 .0.35Al 2 O 3 ).
  • the phrase “characterized by the formula,” refers to a molar ratio of constituent atoms either as batched during the process for making that characterized material or as empirically determined.
  • solvent refers to a liquid that is suitable for dissolving or solvating a component or material described herein.
  • a solvent includes a liquid, e.g., toluene, which is suitable for dissolving a component, e.g., the binder, used in the garnet sintering process.
  • removing a solvent refers to the process whereby a solvent is extracted or separated from the components or materials set forth herein.
  • Removing a solvent includes, but is not limited to, evaporating a solvent.
  • Removing a solvent includes, but is not limited to, using a vacuum or a reduced pressure to drive off a solvent from a mixture, e.g., an unsintered thin film.
  • a thin film that includes a binder and a solvent is heated or also optionally placed in a vacuum or reduced atmosphere environment in order to evaporate the solvent to leave the binder, which was solvated, in the thin film after the solvent is removed.
  • thin means, when qualifying a film, membrane, or the like, a dimension less than 200 ⁇ m, more preferably less than 100 ⁇ m and in some cases between 0.1 and 60 ⁇ m.
  • film tape refers to a roll or continuous layer of casted tape, either dry or not dry, which is sintered or can be sintered.
  • a “binder” refers to a material that assists in the adhesion of another material.
  • polyvinyl butyral is a binder because it is useful for adhering garnet materials.
  • Other binders include polycarbonates.
  • Other binders may include polymethylmethacrylates. These examples of binders are not limiting as to the entire scope of binders contemplated here but merely serve as examples.
  • Binders useful in the present disclosure include, but are not limited to, polypropylene (PP), atactic polypropylene (aPP), isotactive polypropylene (iPP), ethylene propylene rubber (EPR), ethylene pentene copolymer (EPC), polyisobutylene (PIB), styrene butadiene rubber (SBR), polyolefins, polyethylene-co-poly-1-octene (PE-co-PO), PE-co-poly(methylene cyclopentane) (PE-co-PMCP), poly methyl-methacrylate (and other acrylics), acrylic, polyvinylacetacetal resin, polyvinylbutylal resin, PVB, polyvinyl acetal resin, stereoblock polypropylenes, polypropylene polymethylpentene copolymer, polyethylene oxide (PEO), PEO block copolymers, silicone, and the like.
  • PP polypropylene
  • aPP atactic polypropylene
  • lithium-stuffed garnet electrolyte refers to oxides that are characterized by a crystal structure related to a garnet crystal structure.
  • Lithium-stuffed garnets include compounds having the formula Li A La B M′ c M′′ D Zr E O F , Li A La B M′ C M′′ D Ta E O F , or Li A La B M′ C M′′ D Nb E O F , wherein 4 ⁇ A ⁇ 8.5, 1.5 ⁇ B ⁇ 4, 0 ⁇ C ⁇ 2, 0 ⁇ D ⁇ 2; 0 ⁇ E ⁇ 2, 10 ⁇ F ⁇ 13, and M′′ and M′′ are each, independently in each instance selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, or Ta, or Li a La b Zr C Al d Me′′ e O f , wherein 5 ⁇ a ⁇ 7.7; 2 ⁇ b ⁇ 4; 0 ⁇ c ⁇ 2.5; 0 ⁇ d ⁇ 2; 0 ⁇ e ⁇ 2, 10 ⁇ f ⁇ 13 and Me′′
  • Garnets as used herein, also include those garnets described above that are doped with Al 2 O 3 . Garnets, as used herein, also include those garnets described above that are doped so that Al 3+ substitutes for Li + .
  • garnet used herein includes, but is not limited to, Li x La 3 Zr 2 O 12 +yAl 2 O 3 , wherein x ranges from 5.5 to 9; and y ranges from 0 to 1.
  • x is 6-7 and y is 1.0.
  • x is 7 and y is 0.35.
  • x is 6-7 and y is 0.7.
  • x is 6-7 and y is 0.4.
  • garnets as used herein include, but are not limited to, Li x La 3 Zr 2 O 12 +yAl 2 O 3 .
  • Non-limiting example lithium-stuffed garnet electrolytes are found, for example, in US Patent Application Publication No. 2015-0200420 A1, which published Jul. 16, 2015.
  • garnet does not include YAG-garnets (i.e., yttrium aluminum garnets, or, e.g., Y 3 Al 5 O 12 ).
  • garnet does not include silicate-based garnets such as pyrope, almandine, spessartine, grossular, hessonite, or cinnamon-stone, tsavorite, uvarovite and andradite and the solid solutions pyrope-almandine-spessarite and uvarovite-grossular-andradite.
  • Garnets herein do not include nesosilicates having the general formula X 3 Y 2 (SiO 4 ) 3 wherein X is Ca, Mg, Fe, and, or, Mn; and Y is Al, Fe, and, or, Cr.
  • garnet-type electrolyte refers to an electrolyte that includes a lithium stuffed garnet material described herein as the ionic conductor.
  • Li-stuffed, garnet solid state electrolytes are many, including as a substitution for liquid, flammable electrolytes commonly used in lithium rechargeable batteries.
  • d 50 diameter refers to the median size, in a distribution of sizes, measured by microscopy techniques or other particle size analysis techniques, such as, but not limited to, scanning electron microscopy or dynamic light scattering. D 50 includes the characteristic dimension at which 50% of the particles are smaller than the recited size.
  • d 90 diameter refers to the median size, in a distribution of sizes, measured by microscopy techniques or other particle size analysis techniques, such as, but not limited to, scanning electron microscopy or dynamic light scattering. D 90 includes the characteristic dimension at which 90% of the particles are smaller than the recited size.
  • a “thickness” by which is film is characterized refers to the distance, or median measured distance, between the top and bottom faces of a film.
  • the top and bottom faces refer to the sides of the film having the largest surface area.
  • the phrase “subscripts and molar coefficients in the empirical formulas are based on the quantities of raw materials initially batched to make the described examples” means the subscripts, (e.g., 7, 3, 2, 12 in Li 7 La 3 Zr 2 O 12 and the coefficient 0.35 in 0.35Al 2 O 3 ) refer to the respective elemental ratios in the chemical precursors (e.g., LiOH, La 2 O 3 , ZrO 2 , Al 2 O 3 ) used to prepare a given material, (e.g., Li 7 La 3 Zr 2 O 12 .0.35Al 2 O 3 ).
  • the chemical precursors e.g., LiOH, La 2 O 3 , ZrO 2 , Al 2 O 3
  • the phrase “sintering the film,” refers to a process whereby a thin film, as described herein, is densified (made denser, or made with a reduced porosity) through the use of heat sintering or field assisted sintering. Sintering includes the process of forming a solid mass of material by heat and/or pressure without melting it to the point of complete liquification.
  • plasticizer refers to an additive that imparts either flexibility or plasticity to the green tape. It may be a substance or material used to increase the binder's flexibility, workability, or distensibility. Flexibility is the ability to bend without breaking. Plasticity is the ability to permanently deform.
  • stress relieving refers to a process which eliminates residual stress in a casted green tape during drying and associated shrinkage.
  • One method of stress relieving includes heating the green tape at a temperature above the glass transition temperature of the organic components in the green tape to allow structural and stress rearrangement in the casted green tape to eliminate residual stress.
  • Another method of stress relieving includes heating a casted green tape to 70° C. and holding at that temperature for a minute to allow casted green tape to relieve stress.
  • pH modifier refers to an acid or a base that can be added to a slurry to adjust the acidity or basicity of the slurry in order to achieve better dispersion stability of cast slurry.
  • pH modifiers include, but are not limited to, citric acid and ammonia hydroxide, as well as other equivalent pH modifiers.
  • the phrase “as batched,” refers to the respective molar amounts of components as initially mixed or provided at the beginning of a synthesis.
  • the formula Li 7 La 3 Zr 2 O 12 as batched, means that the ratio of Li to La to Zr to O in the reagents used to make Li 7 La 3 Zr 2 O 12 was 7 to 3 to 2 to 12.
  • a picnometry density is measured using a Micromeritics AccuPycII 1340 Calibrate instrument. Using this instrument, a controlled amount of a powder sample is placed in a cup and its mass measured. The instrument is used to measure volume and calculate density by mass/volume.
  • the phrase “sintering aid,” refers to an additive that is used to either form lower the melting point of a liquid phase or that allows for faster sintering than otherwise would be possible without the sintering add. Sintering aids assist in the diffusion/kinetics of atoms being sintered.
  • LiAlO 2 may be used as an additive in a slurry having garnet since the LiAlO 2 can form a liquid with the garnet at between about 1050 and 1100° C., which provides for faster densification of garnet during sintering.
  • a particle size distribution is measured by light scattering, for example, using on a Horiba LA-950 V2 particle size analyzer in which the solvents used for the analysis include toluene, IPA, or acetonitrile and the analysis includes a one-minute sonication before measurement.
  • the solvents used for the analysis include toluene, IPA, or acetonitrile and the analysis includes a one-minute sonication before measurement.
  • the phrase “source powder” refers to an inorganic material used in a slurry set forth herein.
  • the source powder is a lithium-stuffed garnet.
  • the source powder may include a powder of Li 7 La 3 Zr 2 O 12 .0.5Al 2 O 3 .
  • phosphate ester refers to, for example, phosphate esters known as Hypermer KD-23TM, Hypermer KD24TM, Phoschem PDTM, Phoschem R-6TM, Phospholan PS-131TM, and Rhodoline 4188TM.
  • DBP refers to the chemical having the formula C 16 H 22 O 4 , Dibutyl phthalate, having a Molecular weight of 278.35 g/mol.
  • BBP benzyl butyl phthalate
  • PEG polyethylene glycol
  • the green tapes casted by the methods set forth herein contain refractory and, or, ceramic materials that are formulated as ceramic particles intimately mixed with a binder.
  • the purpose of this binder is, in part, to assist the sintering of the ceramic particles to result in a uniform and thin film, or layer, of refractory or ceramic post-sintering.
  • the binder burns (e.g., calcination) out of the sintering thin film.
  • this binder burns out of the sintering film at a temperature less than 700° C., less than 450° C., less than 400° C., less than 350° C., less than 300° C., less than 250° C., or in some examples less than 200° C., or in some examples less than 150° C., or in some examples less than 100° C.
  • the oxygen and water partial pressures may be controlled.
  • the composites set forth herein can be made by a variety of methods.
  • a slurry containing a source powder is prepared, this slurry is cast onto a substrate or a setter plate, and then this slurry is dried and sintered to prepare a dried and sintered solid ion conducting ceramic.
  • the substrate may include, for example, Mylar, silicone coated Mylar, surfaces coated with polymers, surface modified polymers, or surface assembled monolayers adhered, attached, or bonded to a surface.
  • the methods set forth herein are substantially as set forth in FIG. 1 .
  • Method 100 is described.
  • the first step includes slip preparation 101 . This entails combining a solvent, dispersant, and a source powder such as garnet into a reaction container (e.g., a 50 ml Nalgene bottle). Milling media is also added.
  • step 102 the combined contents are milled for 1 hour to 3 days.
  • step 103 the binder, plasticizer, and or, homogenizers are added to the reaction container to form a slurry.
  • the fourth step 104 the slurry is rolled by rolling the reaction container to blend the binder.
  • the slurry is de-aired by a de-airing process to remove gas.
  • the slurry is cast by a doctor blade cast method onto a substrate (e.g., silicone coated Mylar).
  • the cast film is dried. In this step 107 , the drying is accomplished in a controlled fashion to avoid cracking or defect formation in the film.
  • the slurry included 70 g of garnet powder that had a d 50 of approximately 3 ⁇ m, 16 g of MEK solvent, 1.4 g of phosphate ester, 8.4 g of poly methyl methacrylate binder in 50% by weight (w/w) MEK, 3.5 g of a plasticizer (e.g., S-160), and 1.6 g of cyclohexanone.
  • a plasticizer e.g., S-160
  • the binders suitable for use with the slurries described herein include binders, used to facilitate the adhesion between the Li-stuffed garnet particles, include, but are not limited to, polypropylene (PP), polyvinyl butyral (PVB), poly ethyl methacrylate (PEMA), polyvinyl pyrrolidone (PVP), atactic polypropylene (aPP), isotactive polypropylene ethylene propylene rubber (EPR), ethylene pentene copolymer (EPC), polyisobutylene (PIB), styrene butadiene rubber (SBR), polyolefins, polyethylene-copoly-1-octene (PE-co-PO); PE-co-poly(methylene cyclopentane) (PE-co-PMCP); stereo block polypropylenes, polypropylene polymethylpentene copolymer, poly propylene carbonate, methyl methacrylate (or PMMA), ethacrylate (
  • binders include binder is selected polypropylene (PP), atactic polypropylene (aPP), isotactic polypropylene (iPP), ethylene propylene rubber (EPR), ethylene pentene copolymer (EPC), polyisobutylene (PIB), styrene butadiene (SBR), polyolefins, polyethylene-co-poly-1-octene (PE-co-PO), PE-co-poly(methylene cyclopentene) (PE-co-PMCP), stereoblock polypropylenes, polypropylene polymethyl pentene, polyethylene oxide (PEO), PEO block copolymers, silicone, and combinations thereof.
  • dispersants include, but are not limited to, phosphate esters, esters such as fish oil, surfactants, fluorosurfactants, polyvinylpyridine (PVP), polyvinyl butadiene (PVB), polyalkylene amine, acrylic polymers.
  • PVP polyvinylpyridine
  • PVB polyvinyl butadiene
  • acrylic polymers acrylic polymers.
  • the slurry may also include a surfactant.
  • a surfactant includes cetylpyridinium chloride, cetylpyridium bromide, and sodium dodecylbenzenesulfonate.
  • the slurry may also include a pH modifier.
  • Example pH modifiers include, but are not limited to, glacial acetic acid, NH 4 OH, monoethanol amine, NaOH, Na 2 CO 3 , and KOH.
  • the slurry may also include a plasticizer.
  • plasticizers include, but are not limited to, dibutyl phthalate, dioctyl phthalate, and benzyl butyl phthalate.
  • the slurry includes Li garnet powders or precursors that strongly interact with solvents or organic binders and which increase slurry viscosity via re-flocculation.
  • the re-flocculation is at a high level that does not result in high quality slurries and casted tapes.
  • the process can be controlled by the addition of an agent which changes the pH of the slurry so that it has a stable dispersion in the slurry.
  • the process can also controlled by the addition of less reactive solvents and, or, binders.
  • the slurries have good dispersion, low viscosity and minimal organic content.
  • the methods include casting a tape of ceramic source powder onto a substrate (e.g., porous or nonporous alumina, zirconia, garnet, alumina-zirconia, lanthanum alumina-zirconia).
  • a substrate e.g., porous or nonporous alumina, zirconia, garnet, alumina-zirconia, lanthanum alumina-zirconia.
  • the tape is prepared on a substrate such as a silicone coated substrate (e.g., silicone coated Mylar, or silicone coated Mylar on alumina).
  • the sintering films release volatile components. These components can often result in cracking or surface deterioration in the sintering film unless setter plates are used which allow for these volatile components to evaporate or volatilize away from the sintering film. In some particular examples, it is advantageous to use a porous setter plate to assist with the evaporation of these volatile components.
  • the methods set forth herein include drying a casted tape (e.g., a green film).
  • drying includes controlling the temperature of the casted tape by, for example, using a heated bed on which to place or deposit the casted film, infrared (IR) heating, or convection heating of the casted tape.
  • IR infrared
  • drying may include using environmental controls such as, but not limited to, stagnant and, or, flowing environment (e.g., atmospheric air, dry air, inert gas, nitrogen gas, argon gas) to manage or to control the amount of solvent in the drying ambient. In these methods, the drying is used to control the rate of solvent removal and to ensure that the cast film dries from the substrate to the surface as opposed to from the surface to the substrate.
  • the cast green tape prior to drying the cast green tape, includes a solvent which is an azeotrope.
  • this azeotrope is a solvent comprises cyclohexanone at 10-25 weight % of the green tape.
  • the weight percent of cyclohexanone in the azeotrope is 10 weight %.
  • the weight percent of cyclohexanone in the azeotrope is 11 weight %.
  • the weight percent of cyclohexanone in the azeotrope is 12 weight %.
  • the weight percent of cyclohexanone in the azeotrope is 13 weight %.
  • the weight percent of cyclohexanone in the azeotrope is 14 weight %. In some examples, the weight percent of cyclohexanone in the azeotrope is 15 weight %. In some examples, the weight percent of cyclohexanone in the azeotrope is 16 weight %. In some examples, the weight percent of cyclohexanone in the azeotrope is 17 weight %. In some examples, the weight percent of cyclohexanone in the azeotrope is 18 weight %. In some examples, the weight percent of cyclohexanone in the azeotrope is 19 weight %.
  • the weight percent of cyclohexanone in the azeotrope is 20 weight %. In some examples, the weight percent of cyclohexanone in the azeotrope is 21 weight %. In some examples, the weight percent of cyclohexanone in the azeotrope is 22 weight %. In some examples, the weight percent of cyclohexanone in the azeotrope is 23 weight %. In some examples, the weight percent of cyclohexanone in the azeotrope is 24 weight %. In some examples, the weight percent of cyclohexanone in the azeotrope is 25 weight %. In some examples, the solvent is a combination of MEK:IPA.
  • the ratio of MEK:IPA is 1:1. In certain examples, the ratio of MEK:IPA is 2:1. In certain examples, the ratio of MEK:IPA is 3:1. In certain examples, the ratio of MEK:IPA is 4:1. In certain examples, the ratio of MEK:IPA is 5:1. In certain examples, the ratio of MEK:IPA is 5:1. n certain examples, the ratio of MEK:IPA is 7:1. In certain examples, the ratio of MEK:IPA is 8:1. In certain examples, the ratio of MEK:IPA is 5:1. In certain examples, the ratio of MEK:IPA is 5:2. In certain examples, the ratio of MEK:IPA is 6:2. In certain examples, the ratio of MEK:IPA is 7:2. In certain examples, the ratio of MEK:IPA is 8:2.
  • the ratio of MEK:IPA is 9:2. In certain examples, the ratio of MEK:IPA is 10:3. In certain examples, the ratio of MEK:IPA is 11:3. In certain examples, the ratio of MEK:IPA is 5:3. In certain examples, the ratio of MEK:IPA is 6:3. In certain examples, the ratio of MEK:IPA is 7:3. In certain examples, the ratio of MEK:IPA is 8:3. In certain examples, the ratio of MEK:IPA is 9:3. In certain examples, the ratio of MEK:IPA is 10:3. In certain examples, the ratio of MEK:IPA is 11:3.
  • the total amount of material other than the source powder is about 10-25% by weight of the green tape. In some examples the total amount of material other than the source powder is 10% by weight of the green tape. In some examples the total amount of material other than the source powder is 11% by weight of the green tape. In some examples the total amount of material other than the source powder is 12% by weight of the green tape. In some examples the total amount of material other than the source powder is 13% by weight of the green tape. In some examples the total amount of material other than the source powder is 14% by weight of the green tape. In some examples the total amount of material other than the source powder is 15% by weight of the green tape. In some examples the total amount of material other than the source powder is 16% by weight of the green tape.
  • the total amount of material other than the source powder is 17% by weight of the green tape. In some examples the total amount of material other than the source powder is 18% by weight of the green tape. In some examples the total amount of material other than the source powder is 19% by weight of the green tape. In some examples the total amount of material other than the source powder is 20% by weight of the green tape. In some examples the total amount of material other than the source powder is 21% by weight of the green tape. In some examples the total amount of material other than the source powder is 22% by weight of the green tape. In some examples the total amount of material other than the source powder is 23% by weight of the green tape. In some examples the total amount of material other than the source powder is 24% by weight of the green tape. In some examples the total amount of material other than the source powder is 25% by weight of the green tape. In some of these examples, the amount of source powder is 60, 65, 70, 75, or 80% be weight for the green tape.
  • the green films prepared by the methods herein, and those incorporated by reference are sintered between setter plates.
  • these setter plates are composed of a metal, an oxide, a nitride, a metal, oxide or nitride with an organic or silicone laminate layer thereupon.
  • the setter plates are selected from the group consisting of platinum (Pt) setter plates, palladium (Pd) setter plates, gold (Au) setter plates, copper (Cu) setter plates, aluminum (Al) setter plates, alumina setter plates, porous alumina setter plates, steel setter plates, zirconium (Zr) setter plates, zirconia setter plates, porous zirconia setter plates, lithium oxide setter plates, porous lithium oxide setter plates, lanthanum oxide setter plates, porous lanthanum oxide setter plates, garnet setter plates, porous garnet setter plates, lithium-stuffed garnet setter plates, porous lithium-stuffed garnet setter plates, and combinations thereof.
  • the setter plates are garnet setter plates or porous garnet setter plates.
  • the green films prepared by the methods herein, and those incorporated by reference are sintered on at least one setter plate.
  • these setter plates are composed of a metal, an oxide, a nitride, a metal, oxide or nitride with an organic or silicone laminate layer thereupon.
  • the setter plates are selected from the group consisting of platinum (Pt) setter plates, palladium (Pd) setter plates, gold (Au) setter plates, copper (Cu) setter plates, aluminum (Al) setter plates, alumina setter plates, porous alumina setter plates, steel setter plates, zirconium (Zr) setter plates, zirconia setter plates, porous zirconia setter plates, lithium oxide setter plates, porous lithium oxide setter plates, lanthanum oxide setter plates, Lithium zirconium oxide (Li 2 ZrO 3 ) setter plates, Lithium aluminum oxide (LiAlO 2 ) setter plates, porous lanthanum oxide setter plates, garnet setter plates, porous garnet setter plates, lithium-stuffed garnet setter plates, porous lithium-stuffed garnet setter plates, and combinations of the aforementioned.
  • the green films prepared by the methods herein, and those incorporated by reference are sintered between setter plates in which a metal powder is positioned between the setter plate and the green film.
  • these setter plates are composed of a metal, an oxide, a nitride, a metal, oxide or nitride with an organic or silicone laminate layer thereupon.
  • the setter plates are selected from the group consisting of platinum (Pt) setter plates, palladium (Pd) setter plates, gold (Au) setter plates, copper (Cu) setter plates, aluminum (Al) setter plates, alumina setter plates, porous alumina setter plates, steel setter plates, zirconium (Zr) setter, zirconia setter plates, porous zirconia setter plates, lithium oxide setter plates, porous lithium oxide setter plates, lanthanum oxide setter plates, Lithium zirconium oxide (Li 2 ZrO 3 ) setter plates, Lithium aluminum oxide (LiAlO 2 ) setter plates, porous lanthanum oxide setter plates, Lithium zirconium oxide (Li 2 ZrO 3 ) setter plates, Lithium aluminum oxide (LiAlO 2 ) setter plates, porous lanthanum oxide setter plates, Lithium zirconium oxide (Li 2 ZrO 3 ) setter plates
  • the green films prepared by the methods herein, and those incorporated by reference are sintered between setter plates in which a metal layer or film is positioned between the setter plate and the green film.
  • these setter plates are composed of a metal, an oxide, a nitride, a metal, oxide or nitride with an organic or silicone laminate layer thereupon.
  • the setter plates are selected from the group consisting of platinum (Pt) setter plates, palladium (Pd) setter plates, gold (Au) setter plates, copper (Cu) setter plates, aluminum (Al) setter plates, alumina setter plates, porous alumina setter plates, steel setter plates, zirconium (Zr), zirconia setter plates, porous zirconia setter plates, lithium oxide setter plates, porous lithium oxide setter plates, lanthanum oxide setter plates, porous lanthanum oxide setter plates, garnet setter plates, porous garnet setter plates, lithium-stuffed garnet setter plates, porous lithium-stuffed garnet setter plates, magnesia setter plates, porous magnesia setter plates.
  • the metal powder is selected from Ni power, Cu powder, Mg powder, Mn power, Au powder, Fe powder, or combinations thereof.
  • a layer of particles e.g., a setter sheet
  • powder may be placed between the green film and the setter plates to assist with the sintering of the green film.
  • the layer of particles comprises a uniform layer of particles.
  • the layer of particles comprises a uniform layer of inert, or non-reactive with the green film, particles.
  • the layer of particles is provided as a sheet of particles. In some examples, the thickness of the sheet or layer or particles is about equal to the size of the particles in the sheet or layer.
  • the inert particles positions between the green film and the setter plate(s) is positioned between the contact surfaces of the green film and the parts of the green film which are being sintered.
  • the setter plates and, or, the particles, layers, or sheets which are placed between the setter plates and the green film may be moved or repositioned during the sintering process so that a continuous roll of sintered film is prepared in a continuous process.
  • the setter plates and the particles, layers, or sheets move in conjunction with the movement of the green film so that the portion of the green film being sintering is in contact with the particles, layers, or sheets which are also in contact with the setter plates.
  • the layers or sheets are prepared with a particular weight to prevent tape warping and surface deterioration.
  • the layer or sheet of inert and, or, uniform particles (or powders) assists the sintering process by providing a minimal amount of friction between the film and the setter plates so that the film is not strained as it sinters and reduces in volume and increases in density.
  • the green film can shrink with minimal stress during the sintering process. This provides for improved sintered films that do not stick to the setter plates, which do not distort during the sintering process, and which do not crack during the sintering process or thereafter.
  • other setter plates may be used, for example in combination with the lithium stuffed garnet setter plates described herein, so long as that other setter plate has a high melting point, a high lithium activity, and a stability in reducing environment.
  • these other setter plates should not induce a chemical potential in the sintering film which results in Li diffusion out of the sintering film and into the setter plate.
  • Additional materials include lanthanum aluminum oxide, pyrochlore and materials having a lithium concentration of greater than 0.01 mol/cm 3 .
  • the setter material may be provided as a powder or in a non-planar shape.
  • the slurry includes a solvent selected from isopropanol, water, butanol, tetrahydrofuran (THF), optionally with a binder (e.g., PVB), and optionally with a plasticizer.
  • the solvent includes about 10-30% w/w isopropanol, 1-10% w/w water, 1-10% w/w butanol, and 10-30% w/w tetrahydrofuran (THF) [e.g. 100 grams garnet, 12 grams binder, 12 grams DBP, 20-30 grams solvent].
  • the solvent includes about 20-30% w/w isopropanol, 3-6% w/w water, 3-6% w/w butanol, and 20-30% w/w tetrahydrofuran (THF).
  • the binder is 5% w/w.
  • the plasticizer is 5% w/w.
  • the garnet or calcined precursor materials represents the remaining % w/w (e.g., 40, 50, 60%, 70%, or 75% w/w).
  • a dispersant is used during the milling process.
  • the dispersant is a phosphate ester.
  • the plasticizer is dibutyl thalate or benzyl butyl phthalate.
  • the solvent is butanol and THF. In some examples, the solvent is butanol, water and THF. In some examples, the solvent is butanol, water, toluene, and THF. In some examples, the solvent is butanol and toluene. In some examples, the solvent is butanol, water and THF.
  • solvents examples include toluene, ethanol, diacetone alcohol, and combinations thereof.
  • Other examples of solvents include combinations of isopropanol (IPA, anhydrous), butanol, and toluene.
  • Other examples of solvents include methanol, ethanol, isopropanol, butanol, pentanol, hexanol, toluene, xylene, xylenes:butyl alcohol, cyclohexanone, tetrahydrofuran, toluene:ethanol, acetone, N-methyl-2-pyrrolidone (NMP) diacetone alcohol, ethyl acetate, acetonitrile, hexane, nonane, dodecane, methyl ethyl ketone (MEK), and combinations thereof.
  • NMP N-methyl-2-pyrrolidone
  • the solvent is a combination of MEK:IPA.
  • the ratio of MEK:IPA is 1:1. In certain examples, the ratio of MEK:IPA is 2:1. In certain examples, the ratio of MEK:IPA is 3:1. In certain examples, the ratio of MEK:IPA is 4:1. In certain examples, the ratio of MEK:IPA is 5:1. In certain examples, the ratio of MEK:IPA is 5:1. n certain examples, the ratio of MEK:IPA is 7:1. In certain examples, the ratio of MEK:IPA is 8:1. In certain examples, the ratio of MEK:IPA is 5:1. In certain examples, the ratio of MEK:IPA is 5:2. In certain examples, the ratio of MEK:IPA is 6:2.
  • the ratio of MEK:IPA is 7:2. In certain examples, the ratio of MEK:IPA is 8:2. In certain examples, the ratio of MEK:IPA is 9:2. In certain examples, the ratio of MEK:IPA is 10:3. In certain examples, the ratio of MEK:IPA is 11:3. In certain examples, the ratio of MEK:IPA is 5:3. In certain examples, the ratio of MEK:IPA is 6:3. In certain examples, the ratio of MEK:IPA is 7:3. In certain examples, the ratio of MEK:IPA is 8:3. In certain examples, the ratio of MEK:IPA is 9:3. In certain examples, the ratio of MEK:IPA is 10:3. In certain examples, the ratio of MEK:IPA is 11:3.
  • the solvent further comprises cyclohexanone at 10-25 weight %.
  • the weight percent of cyclohexanone in the slurry is 10 weight %.
  • the weight percent of cyclohexanone in the slurry is 11 weight %.
  • the weight percent of cyclohexanone in the slurry is 12 weight %.
  • the weight percent of cyclohexanone in the slurry is 13 weight %.
  • the weight percent of cyclohexanone in the slurry is 14 weight %.
  • the weight percent of cyclohexanone in the slurry is 15 weight %.
  • the weight percent of cyclohexanone in the slurry is 16 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 17 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 18 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 19 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 20 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 21 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 22 weight %.
  • the weight percent of cyclohexanone in the slurry is 23 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 24 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 25 weight %.
  • the solvent is a combination of MEK:IPA. In certain examples, the ratio of MEK:IPA is 1:1. In certain examples, the ratio of MEK:IPA is 2:1. In certain examples, the ratio of MEK:IPA is 3:1. In certain examples, the ratio of MEK:IPA is 4:1. In certain examples, the ratio of MEK:IPA is 5:1. In certain examples, the ratio of MEK:IPA is 5:1.
  • the ratio of MEK:IPA is 7:1. In certain examples, the ratio of MEK:IPA is 8:1. In certain examples, the ratio of MEK:IPA is 5:1. In certain examples, the ratio of MEK:IPA is 5:2. In certain examples, the ratio of MEK:IPA is 6:2. In certain examples, the ratio of MEK:IPA is 7:2. In certain examples, the ratio of MEK:IPA is 8:2. In certain examples, the ratio of MEK:IPA is 9:2. In certain examples, the ratio of MEK:IPA is 10:3. In certain examples, the ratio of MEK:IPA is 11:3. In certain examples, the ratio of MEK:IPA is 5:3. In certain examples, the ratio of MEK:IPA is 6:3.
  • the ratio of MEK:IPA is 7:3. In certain examples, the ratio of MEK:IPA is 8:3. In certain examples, the ratio of MEK:IPA is 9:3. In certain examples, the ratio of MEK:IPA is 10:3. In certain examples, the ratio of MEK:IPA is 11:3.
  • the solvent in the slurry includes MEK:IPA and cyclohexanone.
  • the weight percent of cyclohexanone in the slurry is 10 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 11 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 12 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 13 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 14 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 15 weight %.
  • the weight percent of cyclohexanone in the slurry is 16 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 17 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 18 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 19 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 20 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 21 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 22 weight %.
  • the weight percent of cyclohexanone in the slurry is 23 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 24 weight %. In some examples, the weight percent of cyclohexanone in the slurry is 25 weight %.
  • the solvent is a combination of MEK:IPA. In certain examples, the ratio of MEK:IPA is 1:1. In certain examples, the ratio of MEK:IPA is 2:1. In certain examples, the ratio of MEK:IPA is 3:1. In certain examples, the ratio of MEK:IPA is 4:1. In certain examples, the ratio of MEK:IPA is 5:1. In certain examples, the ratio of MEK:IPA is 5:1.
  • the ratio of MEK:IPA is 7:1. In certain examples, the ratio of MEK:IPA is 8:1. In certain examples, the ratio of MEK:IPA is 5:1. In certain examples, the ratio of MEK:IPA is 5:2. In certain examples, the ratio of MEK:IPA is 6:2. In certain examples, the ratio of MEK:IPA is 7:2. In certain examples, the ratio of MEK:IPA is 8:2. In certain examples, the ratio of MEK:IPA is 9:2. In certain examples, the ratio of MEK:IPA is 10:3. In certain examples, the ratio of MEK:IPA is 11:3. In certain examples, the ratio of MEK:IPA is 5:3. In certain examples, the ratio of MEK:IPA is 6:3.
  • the ratio of MEK:IPA is 7:3. In certain examples, the ratio of MEK:IPA is 8:3. In certain examples, the ratio of MEK:IPA is 9:3. In certain examples, the ratio of MEK:IPA is 10:3. In certain examples, the ratio of MEK:IPA is 11:3.
  • the ratio of MEK:IPA is 7:3
  • the solvent is a combination of MEK, IPA, and cyclohexanone.
  • the solvent herein further includes water.
  • the green films set forth herein can be sintered by sintering methods known in the relevant field.
  • the sintering conditions set forth in PCT/US2014/059578, Garnet Materials for Li Secondary Batteries and Methods of Making and Using Garnet Materials, filed Oct. 7, 2014, are herein incorporated by reference in their entirety for all purposes.
  • the green films set forth herein can be sintered in ovens open to the atmosphere.
  • the films are sintered in an O 2 rich atmosphere.
  • the films are sintered in an Argon rich atmosphere.
  • the films are sintered in an Argon/H 2 atmosphere.
  • the films are sintered in an Argon/H 2 O atmosphere.
  • the atmosphere used to sinter the films is not the same as the atmosphere used to cool the films after they have been sintered.
  • the method includes sintering the film, wherein sintering comprises heat sintering.
  • heat sintering includes heating the film in the range from about 700° C. to about 1200° C. for about 1 to about 600 minutes and in atmosphere having an oxygen partial pressure in the range of 1 e-1 atm to 1 e-15 atm.
  • heat sintering may include heating the film in the range from about 700° C. to about 1250° C.; or about 800° C. to about 1200° C.; or about 900° C. to about 1200° C.; or about 1000° C. to about 1200° C.; or about 1100° C. to about 1200° C.
  • heat sintering can include heating the film in the range from about 700° C. to about 1100° C.; or about 700° C. to about 1000° C.; or about 700° C. to about 900° C.; or about 700° C. to about 800° C.
  • heat sintering can include heating the film to about 700° C., about 750° C., about 850° C., about 800° C., about 900° C., about 950° C., about 1000° C., about 1050° C., about 1100° C., about 1150° C., or about 1200° C.
  • heat sintering can include heating the film to 700° C., 750° C., 850° C., 800° C., 900° C., 950° C., 1000° C., 1050° C., 1100° C., 1150° C., or 1200° C.
  • heat sintering can include heating the film to 700° C. In any of the methods set forth herein, heat sintering can include heating the film to 750° C. In any of the methods set forth herein, heat sintering can include heating the film to 850° C. In any of the methods set forth herein, heat sintering can include heating the film to 900° C. In any of the methods set forth herein, heat sintering can include heating the film to 950° C. In any of the methods set forth herein, heat sintering can include heating the film to 1000° C. In any of the methods set forth herein, heat sintering can include heating the film to 1050° C.
  • heat sintering can include heating the film to 1100° C. In any of the methods set forth herein, heat sintering can include heating the film to 1125° C. In any of the methods set forth herein, heat sintering can include heating the film to 1150° C. In any of the methods set forth herein, heat sintering can include heating the film to 1200° C.
  • the methods may include heating the film for about 1 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 20 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 30 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 40 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 50 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 60 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 70 to about 600 minutes.
  • the methods may include heating the film for about 80 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 90 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 100 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 120 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 140 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 160 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 180 to about 600 minutes.
  • the methods may include heating the film for about 200 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 300 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 350 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 400 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 450 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 500 to about 600 minutes. In any of the methods set forth herein, the methods may include heating the film for about 1 to about 500 minutes.
  • the methods may include heating the film for about 1 to about 400 minutes. In any of the methods set forth herein, the methods may include heating the film for about 1 to about 300 minutes. In any of the methods set forth herein, the methods may include heating the film for about 1 to about 200 minutes. In any of the methods set forth herein, the methods may include heating the film for about 1 to about 100 minutes. In any of the methods set forth herein, the methods may include heating the film for about 1 to about 50 minutes.
  • the sintering process may further include a filtration step.
  • the sintering process may further include a de-aeration step.
  • the sintering process may include sintering within a closed, but not sealed, furnace (i.e., oven, heating chamber).
  • the sintering film is placed between setter plates, optionally with setter sheets or layers therebetween as well, and the sintering film is placed next to, or in close proximity to, a sacrificial source of Li.
  • This sacrificial source of Li helps to prevent Li loss by way of evaporation from the sintering garnet.
  • the closed system includes Argon gas, a mixture of Argon gas and either Hydrogen gas or water, Air, purified Air, or Nitrogen.
  • the sacrificial source of Li has a higher surface area than the surface area of the green tape which is sintered.
  • the Li source and the sintering green film have the same type of lithium-stuffed garnets.
  • the green films are sintered while in contact with other components with which the post-sintered films would be combined if used in an electrochemical device.
  • the green films are layered or laminated to a positive electrode composition so that after sintering the green film, the sintered film is adhered to the positive electrode.
  • the green film is sintered while in contact with a metallic powder (e.g., nickel (Ni) powder).
  • a metallic powder e.g., nickel (Ni) powder.
  • Milling includes ball milling. Milling also includes milling methods that use inert solvents such as, but not limited to, ethanol, isopropanol, toluene, ethyl acetate, methyl acetate, acetone, acetonitrile, or combinations thereof. Depending on the material milled, the solvents may not be inert. In some of these examples, milling includes milling with solvents such as, but not limited to, ethanol, isopropanol, toluene, ethyl acetate, methyl acetate, acetone, acetonitrile, MEK, or combinations thereof.
  • solvents such as, but not limited to, ethanol, isopropanol, toluene, ethyl acetate, methyl acetate, acetone, acetonitrile, MEK, or combinations thereof.
  • the milling is ball milling. In some examples, the milling is horizontal milling. In some examples, the milling is attritor milling. In some examples, the milling is immersion milling. In some examples, the milling is jet milling. In some examples, the milling is steam jet milling. In some examples, the milling is high energy milling. In some examples, the high energy milling process results in a milled particle size distribution with d 50 of approximately 100 nm. In some examples, the milling is immersion milling.
  • high energy milling process is used to achieve a particle size distribution with d50 of about 100 nm.
  • the solvent is toluene.
  • the solvent is isopropyl alcohol (IPA).
  • the solvent is ethanol.
  • the solvent is diacetone alcohol.
  • the solvent is a polar solvents suitable for achieving the recited d50 size.
  • the milling includes high energy wet milling process with 0.3 mm yttria stabilized zirconium oxide grinding media beads.
  • ball milling, horizontal milling, attritor milling, or immersion milling can be used.
  • using a high energy milling process produces a particle size distribution of about d50-100 nm to 5000 nm.
  • the milling may include a classifying step such as sieving, centrifugation, or other known laboratory of separating particles of different size and/or mass.
  • a classifying step such as sieving, centrifugation, or other known laboratory of separating particles of different size and/or mass.
  • Sintering instruments used included 3′′ laboratory tube furnace with controlled atmosphere in the partial pressure oxygen range of 1 e-1 to 1 e-20 atm with a custom temperature and gas flow control system
  • a first slurry was prepared which included 18.75 g of a lithium-stuffed garnet (as batched, Li 7.1 Zr 2 La 3 O 12 +0.5Al 2 O 3 ) source powder mixed with 12.25 g of isopropanol, 1.875 g of polyvinylbutyral, 1.875 g of dibutyl phthalate, 2.81 g of phosphate ester, and 9 g of tetrahydrofuran.
  • a second slurry was prepared which included 18.75 g of a lithium-stuffed garnet source powder, mixed with 12.25 g of isopropanol, 1.875 g of polyvinylbutyral, 1.875 g of dibutyl phthalate, 2.81 g of phosphate ester, and 9 g of toluene.
  • a third slurry was prepared which included 18.75 g of a lithium-stuffed garnet source powder mixed with 12.25 g of a mixed solvent which included isopropanol and 20% by weight butanol, and 1.875 g of polyvinylbutyral, 1.875 g of dibutyl phthalate, and 2.81 g of phosphate ester, and 9 g of tetrahydrofuran.
  • a fourth slurry was prepared which included 18.75 g of a lithium-stuffed garnet source powder mixed with 12.25 g of a mixed solvent which included isopropanol and 20% by weight butanol, 1.875 g of polyvinylbutyral, 1.875 g of dibutyl phthalate, 2.81 g of phosphate ester, and 9 g of toluene.
  • the particle morphology of the lithium-stuffed garnet source powder, before and after attrition milling, for each slurry is illustrated in FIGS. 5 and 6 , respectively.
  • a green tape was prepared by casting a slurry of lithium-stuffed garnet onto a substrate by doctor blading, subsequently sintering the cast slurry by placing it between two porous garnet setter plates, and then removed from the setter plates.
  • the tape cast from the slurry was sintered at 1100° C. for 1-5 hours.
  • the tape was sintered at 1125° C. for 1-5 hours.
  • the tape was sintered at 1150° C. for 1-5 hours.
  • the binder Prior to the sintering, the binder was burned out in high pressure O 2 (PO 2 ) and H 2 O. During sintering the atmosphere around the sintering film had a PO 2 in the range 0.5-10 ⁇ 20 atm.
  • Green tape made in this example using slurry composition 1 was analyzed by SEM microscopy as set forth in FIG. 2 .
  • the following slurries (Slurry 1, Slurry 2 and Slurry 3) were prepared having the following components at the recites weight percent (%).
  • the source powder was Li 7.1 Zr 2 La 3 O 12 +0.5Al 2 O 3 , as batched. “Solids” below refers to the solid content of the Rhodoline 4160.
  • binder mixtures were prepared having the following components at the recites weight percent (%):
  • Binder mixture 3 (g/cm3) by weight % MEK 0.805 31.55% Ethanol 0.7781 31.55% B76 1.083 22.29% SANTICIZER 160 1.12 14.62%
  • Slurry 1 was combined with binder mixture 1 in a 2.4 weight ratio to form a mixed slurry.
  • Slurry 2 was combined with binder mixture 2 in a 2.1 weight ratio to form a mixed slurry.
  • Slurry 3 was combined with binder mixture 3 in a 2. weight ratio to form a mixed slurry.
  • a green tape was prepared by casting each mixed slurry onto a substrate by doctor blading, subsequently sintering the cast slurry by placing it between two porous garnet setter plates, and then removed from the setter plates.
  • the tape cast from the slurry was sintered at 1100° C. for 1-5 hours.
  • the tape was sintered at 1125° C. for 1-5 hours.
  • the tape was sintered at 1150° C. for 1-5 hours.
  • the binder Prior to the sintering, the binder was burned out in high pressure O 2 (PO 2 ) and H 2 O. During sintering the atmosphere around the sintering film had a PO 2 in the range 0.5-10 ⁇ 20 atm.
  • Sintered films made in this example using slurry composition 1 and binder mixture 1 were analyzed by SEM microscopy as set forth in FIG. 4 .
  • the slurries and binder mixtures were prepared and combined as in Example 2.
  • a green tape was prepared by casting each mixed slurry onto a substrate by doctor blading. The cast mixed slurry was allowed to dry in air to form a green tape.
  • a second layer of a green tape was deposited onto the dried green tape. This process was repeated until there were five layers of green tape stacked on top of each other. Then the stacked green tapes were sintered by placing them between two porous garnet setter plates, and then removed from the setter plates. The stacked green tapes were sintered, in one example, at 1100° C. for 1-5 hours. In another example, the tape was sintered at 1125° C. for 1-5 hours.
  • the tape was sintered at 1150° C. for 1-5 hours. Prior to the sintering, the binder was burned out in high pressure O 2 (PO 2 ) and H 2 O. During sintering the atmosphere around the sintering film had a PO 2 in the range
  • Sintered films made using the aforementioned green tapes in this example were analyzed by optical imaging as set forth in FIG. 3 .

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US20220250988A1 (en) 2022-08-11
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US12084387B2 (en) 2024-09-10
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CN107851774A (zh) 2018-03-27
EP3326223A1 (en) 2018-05-30
US20200216361A1 (en) 2020-07-09
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