Porous garnet ribbon by reaction sintering method

Patent metadata

Field	Value
Publication number	US-12202737-B2
Application number	US-202217974646-A
Country	US
Kind code	B2
Filing date	Oct 27, 2022
Priority date	Oct 29, 2021
Publication date	Jan 21, 2025
Grant date	Jan 21, 2025

Abstract

The disclosure relates to porous garnet ribbons and methods of making such porous garnet ribbons.

First claim

What is claimed is:

1. A method of making a sintered LLZO ribbon, the method comprising:
sintering a tape cast slip composition at a temperature of greater than or equal to 600° C. to produce the sintered LLZO ribbon, the tape cast slip composition comprising:
Li 2 CO 3 ,
a lanthanum compound,
ZrO 2 , and
at least one of the group consisting of: a dispersant, solvent, plasticizer, binder, and defoamer,
wherein the tape cast slip composition comprises substantially no pore forming agent,

wherein the sintered LLZO ribbon comprises an open-pore lithium-ion conducting ceramic layer comprising:
a porosity of from greater than or equal to 50% to less than or equal to 90%,
a d 90 pore size of less than or equal to 10 μm, and
the thickness of the open-pore lithium-ion conducting ceramic layer is from greater than or equal to half the d 90 pore size and less than or equal to 70 μm.

2. The method of claim 1 , wherein the lanthanum compound is La 2 O 3 or La(OH) 3 .

3. The method of claim 1 , further comprising preparing the tape cast slip composition.

4. The method of claim 3 , wherein the Li 2 CO 3 , lanthanum compound, and ZrO 2 are first batched and milled to a D 50 particle size of less than or equal to 0.6 μm prior to preparing the tape cast slip composition.

5. The method of claim 3 , wherein the Li 2 CO 3 , lanthanum compound, and the ZrO 2 are first batched and water is added to form a mixed composition, and the mixed composition is utilized to prepare the tape cast slip composition.

6. The method of claim 3 , wherein the tape cast slip composition is an organic tape cast slip composition or an aqueous tape cast slip composition.

7. The method of claim 3 , further comprising casting a tape casting slip composition on a substrate to form the tape cast slip composition.

8. The method of claim 7 , wherein the substrate is a silicone-coated carrier film.

9. The method of claim 1 , wherein the tape cast slip composition further comprises a dopant.

10. The method of claim 1 , wherein the sintered LLZO ribbon comprises greater than or equal to 65 wt. % of a cubic garnet phase.

11. The method of claim 1 , wherein the sintered LLZO ribbon comprises greater than or equal to 75 wt % of a cubic garnet phase.

12. The method of claim 1 , wherein the sintered LLZO ribbon has a lithium-ion conductivity of greater than or equal to 10 −5 S/cm.

13. The method of claim 1 , wherein the total amount of Li present in the sintered LLZO ribbon is equal to a stoichiometric amount of Li in the sintered LLZO.

Assignees

• Corning Inc

Inventors

• Degeorge Aaron David
• Oyer Barbara Anna
• Samai Soumyadyuti
• Song Zhen
• Tanner Cameron Wayne
• Tepesch Patrick David

Classifications

• C01P2006/16

  Pore diameter · CPC title

• C01P2004/03

  obtained by SEM · CPC title

• C01P2002/76

  by a space-group or by other symmetry indications · CPC title

• C01P2002/30

  Three-dimensional structures · CPC title

• H01M2300/0077

  based on zirconium oxide · CPC title