Slurry formulation for the formation of layers for solid state batteries

Patent metadata

Field	Value
Publication number	US-10700378-B2
Application number	US-201615383286-A
Country	US
Kind code	B2
Filing date	Dec 19, 2016
Priority date	Dec 17, 2015
Publication date	Jun 30, 2020
Grant date	Jun 30, 2020

Abstract

Disclosed are electrochemical devices, such as lithium ion battery electrodes, lithium ion conducting solid-state electrolytes, and solid-state lithium ion batteries including these electrodes and solid-state electrolytes. Also disclosed are methods for making such electrochemical devices.

First claim

What is claimed is:

1. A method for forming a lithium ion conducting solid-state electrolyte, the method comprising:
(a) casting a slurry on a surface to form a layer; and
(b) sintering the layer to form the solid-state electrolyte,
wherein the slurry comprises a solid electrolyte material and a dispersant providing a source of lithium ions, and
wherein the dispersant comprises a lithium salt of a fatty acid.

2. The method of claim 1 wherein:
the solid electrolyte material is selected from the group consisting of any combination oxide or phosphate materials with the garnet, perovskite, NaSICON, or LiSICON phase.

3. The method of claim 1 wherein:
the solid electrolyte material is selected from the group consisting of oxide materials with the garnet phase.

4. The method of claim 1 wherein:
the solid electrolyte material has the formula Li u Re v M w A x O y , wherein
Re can be any combination of elements with a nominal valance of +3 including La, Nd, Pr, Pm, Sm, Sc, Eu, Gd, Tb, Dy, Y, Ho, Er, Tm, Yb, and Lu;
M can be any combination of metals with a nominal valance of +3, +4, +5 or +6 including Zr, Ta, Nb, Sb, W, Hf, Sn, Ti, V, Bi, Ge, and Si;
A can be any combination of dopant atoms with nominal valance of +1, +2, +3 or +4 including H, Na, K, Rb, Cs, Ba, Sr, Ca, Mg, Fe, Co, Ni, Cu, Zn, Ga, Al, B, and Mn;
u can vary from 3-7.5;
v can vary from 0-3;
w can vary from 0-2; and
y can vary from 11-12.5.

5. The method of claim 1 wherein:
the dispersant is lithium stearate.

6. The method of claim 1 wherein the slurry comprises:
35 wt. % to 65 wt. % of the solid electrolyte material, and
0.1 wt. % to 5 wt. % of the dispersant,
wherein all weight percentages are percent by weight of the total slurry.

7. The method of claim 1 wherein the slurry comprises:
40 wt. % to 60 wt. % of the solid electrolyte material wherein the solid electrolyte material comprises lithium lanthanum zirconium oxide having the formula Li 6.25 La 3 Zr 2 Al 0.25 O 12 ,
0.1 wt. % to 2 wt. % of the dispersant,
1 wt. % to 5 wt. % of a binder,
1 wt. % to 5 wt. % of a plasticizer,
20 wt. % to 45 wt. % of a solvent,
wherein all weight percentages are percent by weight of the total slurry.

8. The method of claim 1 wherein the slurry further comprises:
a sintering aid.

9. The method of claim 1 wherein:
step (b) comprises sintering the layer at a temperature in a range of 600° C. to 1100° C.

10. The method of claim 1 wherein:
the layer has a thickness in a range of 10 to 100 microns.

11. The method of claim 1 wherein:
the slurry further comprises 1 wt. % to 5 wt. % of a binder,
wherein all weight percentages are percent by weight of the total slurry.

12. The method of claim 11 wherein:
the binder is selected from the group consisting of non-fluorinated polymeric materials.

13. The method of claim 1 wherein:
the fatty acid is selected from lauric acid, myristic acid, palmitic acid, stearic acid, oleic acid, linoleic acid, linolenic acid, arachidic acid, and behenic acid.

14. The method of claim 8 wherein:
the sintering aid provides a source of borate, silicate, phosphate, or aluminate ions.

15. A method for forming a lithium ion conducting solid-state electrolyte, the method comprising:
(a) casting a slurry on a surface to form a layer; and
(b) sintering the layer to form the solid-state electrolyte,
wherein the slurry comprises a solid electrolyte material and a dispersant providing a source of lithium ions, and
wherein the slurry further comprises 1 wt. % to 30 wt. % of a plasticizer, wherein all weight percentages are percent by weight of the total slurry, and
the plasticizer is selected from the group consisting of plant oils.

16. The method of claim 15 wherein:
the plant oil is selected from the group consisting of coconut oil, castor oil, soybean oil, palm kernel oil, almond oil, corn oil, canola oil, rapeseed oil, and mixtures thereof.

Assignees

• Sakamoto Jeffrey
• Thompson Travis
• Boona Isabel N
• Univ Michigan Regents
• Univ Michigan State

Inventors

• Sakamoto Jeffrey
• Thompson Travis
• Boona Isabel N

Classifications

• C01G25/006

  Compounds containing zirconium, with or without oxygen or hydrogen, and containing two or more other elements · CPC title

• Y02P70/50

  Manufacturing or production processes characterised by the final manufactured product · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M4/0402

  Methods of deposition of the material · CPC title

• H01M4/139

  Processes of manufacture · CPC title