Reactive sintering of ceramic lithium-ion solid electrolytes

Patent metadata

Field	Value
Publication number	US-12300779-B2
Application number	US-202217844471-A
Country	US
Kind code	B2
Filing date	Jun 20, 2022
Priority date	Nov 29, 2011
Publication date	May 13, 2025
Grant date	May 13, 2025

Abstract

Solid lithium-ion ceramic electrolyte membranes have an average thickness of less than 200 micrometers. A constituent electrolyte material has an average grain size of less than 10 micrometers. The solid lithium-ion ceramic electrolyte is free-standing. Alternatively, solid lithium-ion electrolyte membranes have a composition represented by Li1+x−yMxM′2−x−yM″y(PO4)3, where M is a 3+ ion, M′ is a 4+ ion, M″ is a 5+ ion, 0≤x≤2 and 0≤y≤2.

First claim

What is claimed is:

1. A solid lithium-ion ceramic electrolyte membrane, comprising:
an average thickness of less than 200 μm;
constituent electrolyte material comprising Li 1.4 Al 0.4 Sn 1.6 (PO 4 ) 3 and having an average grain size of less than 10 μm, and
wherein the solid lithium-ion ceramic electrolyte membrane is free-standing.

2. The solid lithium-ion ceramic electrolyte membrane of claim 1 , wherein the average thickness is less than 150 μm.

3. The solid lithium-ion ceramic electrolyte membrane of claim 1 , wherein the average thickness is at least 30 μm.

4. The solid lithium-ion ceramic electrolyte membrane of claim 1 , wherein the average grain size of the constituent electrolyte material is less than 1 μm.

5. The solid lithium-ion ceramic electrolyte membrane of claim 1 , wherein a conductivity of the solid lithium-ion ceramic electrolyte membrane is greater than 10 −6 S/cm.

6. The solid lithium-ion ceramic electrolyte membrane of claim 1 , wherein a conductivity of the solid lithium-ion ceramic electrolyte membrane is greater than 10 −4 S/cm.

7. The solid lithium-ion ceramic electrolyte membrane of claim 1 , wherein a density of the solid lithium-ion ceramic electrolyte membrane is at least 95% of its theoretical density.

8. The solid lithium-ion ceramic electrolyte membrane of claim 1 , wherein the solid lithium-ion ceramic electrolyte membrane is hermetic such that the solid lithium-ion ceramic electrolyte membrane is configured to provide a barrier between an anode and a cathode of a battery.

9. The solid lithium-ion ceramic electrolyte membrane of claim 1 , wherein a conductivity of the solid lithium-ion ceramic electrolyte membrane is greater than 10 −5 S/cm.

10. The solid lithium-ion ceramic electrolyte membrane of claim 1 , wherein a conductivity of the solid lithium-ion ceramic electrolyte membrane is greater than 2×10 −4 S/cm.

11. The solid lithium-ion ceramic electrolyte membrane of claim 1 , wherein the average thickness is from at least 30 μm to less than 150 μm.

12. The solid lithium-ion ceramic electrolyte membrane of claim 11 , wherein the average grain size of the constituent electrolyte material is less than 1 μm.

13. The solid lithium-ion ceramic electrolyte membrane of claim 12 , wherein the solid lithium-ion ceramic electrolyte membrane is hermetic such that the solid lithium-ion ceramic electrolyte membrane is configured to provide a barrier between an anode and a cathode of a battery.

14. The solid lithium-ion ceramic electrolyte membrane of claim 13 , wherein a conductivity of the solid lithium-ion ceramic electrolyte membrane is greater than 10 −5 S/cm.

15. The solid lithium-ion ceramic electrolyte membrane of claim 13 , wherein a conductivity of the solid lithium-ion ceramic electrolyte membrane is greater than 2×10 −4 S/cm.

16. The solid lithium-ion ceramic electrolyte membrane of claim 13 , wherein a conductivity of the solid lithium-ion ceramic electrolyte membrane is greater than 2×10 −4 S/cm.

17. The solid lithium-ion ceramic electrolyte membrane of claim 13 , wherein a density of the solid lithium-ion ceramic electrolyte membrane is at least 95% of its theoretical density.

18. The solid lithium-ion ceramic electrolyte membrane of claim 13 , wherein a density of the solid lithium-ion ceramic electrolyte membrane is at least 97% of its theoretical density.

19. The solid lithium-ion ceramic electrolyte membrane of claim 1 , wherein a density of the solid lithium-ion ceramic electrolyte membrane is at least 96% of its theoretical density.

20. The solid lithium-ion ceramic electrolyte membrane of claim 1 , wherein a density of the solid lithium-ion ceramic electrolyte membrane is at least 97% of its theoretical density.

Assignees

• Corning Inc

Inventors

• Aitken Bruce Gardiner
• Badding Michael Edward
• Beall George Halsey
• Fekety Curtis Robert
• Kester Lanrik Wayne
• Morena Robert Michael
• Song Zhen

Classifications

• H01M10/0562 Primary

  Solid materials · CPC title

• C04B2235/785

  Submicron sized grains, i.e. from 0,1 to 1 micron · CPC title

• C04B2235/77

  Density · CPC title

• C04B2235/5454

  nanometer sized, i.e. below 100 nm · CPC title

• C04B2235/5445

  submicron sized, i.e. from 0,1 to 1 micron · CPC title