Micromachined electrolyte sheet

Patent metadata

Field	Value
Publication number	US-12283660-B2
Application number	US-202217862036-A
Country	US
Kind code	B2
Filing date	Jul 11, 2022
Priority date	Sep 30, 2011
Publication date	Apr 22, 2025
Grant date	Apr 22, 2025

Abstract

Lithium-containing polycrystalline ceramic sheets include grains having an average grain size of less than 5 μm, a relative density greater than 90%, and a thickness of up to 200 μm. In aspects, the lithium-containing polycrystalline ceramic sheets include an outer edge of the sheet that has no height variations greater than 1 mm from baseline in a perimeter trace. In aspects, the lithium-containing polycrystalline ceramic sheets include microstructural features of an outer edge of the sheet are no greater than about ⅓ the thickness of the sheet. In aspects, the lithium-containing polycrystalline ceramic sheets include an outer edge of the sheet that is enriched in lithium relative to a bulk of the sheet.

First claim

What is claimed:

1. A sheet comprising:
grains having an average grain size of less than 5 μm;
a relative density greater than 90%; and
a thickness of up to 200 μm,
wherein the sheet is a lithium-containing polycrystalline ceramic sheet, and an outer edge of the sheet has no height variations greater than 1 mm from baseline in a perimeter trace.

2. The sheet of claim 1 , wherein the thickness is less than about 100 μm.

3. The sheet of claim 2 , wherein the thickness is at least about 40 μm.

4. The sheet of claim 1 , wherein within the sheet there is substantially no interconnected porosity such that the sheet is hermetic.

5. The sheet of claim 1 , wherein the sheet is unsupported mechanically, not integrated into a multi-layer structure.

6. The sheet of claim 1 , wherein the relative density is greater than 95%.

7. The sheet of claim 1 , wherein the average grain size is less than 3 μm.

8. A sheet comprising:
grains having an average grain size of less than 5 μm;
a relative density greater than 90%; and
a thickness of up to 200 μm,
wherein the sheet is a lithium-containing polycrystalline ceramic sheet, and microstructural features of an outer edge of the sheet are no greater than about ⅓ the thickness of the sheet.

9. The sheet of claim 8 , wherein the thickness is less than about 100 μm.

10. The sheet of claim 9 , wherein the thickness is at least about 40 μm.

11. The sheet of claim 8 , wherein within the sheet there is substantially no interconnected porosity such that the sheet is hermetic.

12. The sheet of claim 8 , wherein the sheet is unsupported mechanically, not integrated into a multi-layer structure.

13. The sheet of claim 8 , wherein the relative density is greater than 95%.

14. The sheet of claim 8 , wherein the average grain size is less than 3 μm.

15. A sheet comprising:
grains having an average grain size of less than about 5 μm;
a relative density greater than about 90%; and
a thickness of up to about 200 μm;
wherein the sheet is a lithium-containing polycrystalline ceramic sheet, and an outer edge of the sheet is enriched in lithium relative to a bulk of the sheet.

16. The sheet of claim 15 , wherein the thickness is less than about 100 μm.

17. The sheet of claim 16 , wherein the thickness is at least about 40 μm.

18. The sheet of claim 17 , wherein within the sheet there is substantially no interconnected porosity such that the sheet is hermetic.

19. The sheet of claim 18 , wherein the sheet is unsupported mechanically, not integrated into a multi-layer structure.

20. The sheet of claim 19 , wherein the relative density is greater than 95%.

Assignees

• Corning Inc

Inventors

• Badding Michael Edward
• Dutta Indrajit
• Kester Lanrik Wayne
• Li Xinghua

Classifications

• H01M50/406

  Moulding; Embossing; Cutting · CPC title

• H01M2300/0068

  inorganic · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M10/0562 Primary

  Solid materials · CPC title