US12183881B2 · US · B2
| Field | Value |
|---|---|
| Publication number | US-12183881-B2 |
| Application number | US-202418660557-A |
| Country | US |
| Kind code | B2 |
| Filing date | May 10, 2024 |
| Priority date | Dec 21, 2016 |
| Publication date | Dec 31, 2024 |
| Grant date | Dec 31, 2024 |
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A cathode configured for a solid-state battery includes a body having grains of inorganic material sintered to one another, wherein the grains comprise lithium. A thickness of the body is from 3 μm to 100 μm. The first major surface and the second major surface have an unpolished granular profile such that the profile includes grains protruding outward from the respective major surface with a height of at least 25 nm and no more than 150 μm relative to recessed portions of the respective major surface at boundaries between the respective grains.
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What is claimed is: 1. A sintered article, comprising: a first major surface, a second major surface opposing the first major surface, a body extending between the first and second major surfaces, the body comprising a sintered ceramic comprising zirconia, wherein the first and second major surfaces have a granular profile comprising grains of the sintered ceramic with a height in a range from 25 nm to 150 μm relative to recessed portions of the respective major surface at boundaries between the grains; wherein the body has a thickness defined as a distance between the first and second major surfaces, wherein the thickness is in a range from 3 μm to 1 mm; wherein the body has a width defined as a first dimension of the first major surface orthogonal to the thickness, wherein the width is greater than 40 mm; and wherein the sintered article has a flatness in a range from about 100 nm to about 50 μm over a distance of a centimeter along a length thereof, the length defined as a second dimension of the first major surface orthogonal to both the thickness and the width. 2. The sintered article of claim 1 , wherein the width is greater than 125 mm. 3. The sintered article of claim 2 , wherein the sintered article is a ceramic ribbon, wherein length of the body is 10 m or greater. 4. The sintered article of claim 1 , wherein the ceramic comprises doped zirconia. 5. The sintered article of claim 4 , wherein the dopant comprises yttria (Y 2 O 3 ), and wherein the Y 2 O 3 is 3 mol % of the ceramic. 6. The sintered article of claim 4 , wherein the zirconia comprises tetragonal zirconia. 7. The sintered article of claim 1 , wherein the first major surface comprises at least ten square centimeters of area having fewer than one hundred surface defects from adhesion or abrasion with a dimension greater than 5 μm. 8. A sintered article, comprising: a first major surface, a second major surface opposing the first major surface, a body extending between the first and second major surfaces, the body comprising a sintered ceramic comprising zirconia, wherein the first major and second major surfaces have a granular profile comprising grains of the sintered ceramic with a height in a range from 25 nm to 150 μm relative to recessed portions of the respective major surface at boundaries between the grains; wherein the body has a thickness defined as a distance between the first and second major surfaces, wherein the thickness is in a range from 3 μm to 1 mm; wherein the body has a width defined as a first dimension of the first major surface orthogonal to the thickness, wherein the width is greater than 40 mm; and wherein the body is flattenable without fracturing as determined by pressing the body between rigid parallel surfaces at 23° C. such that the body overlays or is within a distance of 0.05 mm of a flat plane. 9. The sintered article of claim 8 , wherein the body has less than 10% porosity by volume. 10. The sintered article of claim 8 , wherein the width is greater than 125 mm. 11. The sintered article of claim 8 , wherein the sintered article is a ceramic ribbon, wherein the length of the body is 10 m or greater. 12. The sintered article of claim 8 , wherein the ceramic comprises doped zirconia. 13. The sintered article of claim 8 , wherein the sintered article has a roughness of from about 1 nm to about 10 μm over a distance of 1 cm along the length. 14. A sintered article, comprising: a first major surface, a second major surface opposing the first major surface, a body extending between the first and second major surfaces, the body comprising a sintered ceramic comprising zirconia, wherein the first and second major surfaces have a granular profile comprising grains of the sintered ceramic with a height in a range from 25 nm to 150 μm relative to recessed portions of the respective major surface at boundaries between the grains; wherein the body has a thickness defined as a distance between the first and second major surfaces, wherein the thickness is in a range from 3 μm to 1 mm; wherein the body has a width defined as a first dimension of the first major surface orthogonal to the thickness, wherein the width is greater than 40 mm; and wherein the sintered article is a ceramic ribbon, wherein length of the body is 10 m or greater. 15. The sintered article of claim 14 , wherein the width is greater than 125 mm. 16. The sintered article of claim 14 , wherein the sintered article is a ceramic ribbon, wherein the length of the body is 10 m or greater. 17. The sintered article of claim 14 , wherein the ceramic comprises doped zirconia. 18. The sintered article of claim 14 , wherein the zirconia comprises tetragonal zirconia. 19. The sintered article of claim 14 , wherein the body has less than 10% porosity by volume. 20. The sintered article of claim 14 , wherein the first and second major surfaces each have at least ten square centimeters of area having fewer than one hundred surface defects from adhesion or abrasion with a dimension greater than 5 μm.
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