Rapid ceramic processing techniques and equipment

Patent metadata

Field	Value
Publication number	US-2023415376-A1
Application number	US-202217905822-A
Country	US
Kind code	A1
Filing date	Mar 9, 2022
Priority date	Mar 9, 2021
Publication date	Dec 28, 2023
Grant date	—

Abstract

Provided herein are rapid, high quality film sintering processes that include high-throughput continuous sintering of lithium-lanthanum zirconium oxide (lithium-stuffed garnet). The instant disclosure sets forth equipment and processes for making high quality, rapidly-processed ceramic electrolyte films. These processes include high-throughput continuous sintering of lithium-lanthanum zirconium oxide for use as electrolyte films. In certain processes, the film is not in contact with any surface as it sinters (i.e., during the sintering phase).

First claim

What is claimed is:

1 .- 2 . (canceled)

3 . A continuous manufacturing line (CML) comprising:
a front roller onto which is wound a bilayer, wherein the bilayer comprises a metal layer and a green body layer; an end roller; at least one furnace between the front roller and the end roller; and at least one atmospheric controller which controls at least one condition in the furnace selected from the group consisting of gas flow rate, flow direction, gas composition, pressure, and a combination thereof.

4 . The CML of claim 3 , wherein the at least one furnace comprises (a) a binder burn-out section; (b) a bisque section; and (c) a sintering section.

5 . The CML of claim 3 , wherein the at least one furnace is sealed such that the at least one atmospheric controller controls the flow of gas into and out of the at least one furnace.

6 . The CML of claim 3 , comprising a pressurized gas line between the bisque section and the sintering section which pumps gas into the bisque section and into the sintering section.

7 . The CML of claim 3 , wherein the at least one furnace is enclosed in a sealed container.

8 . The CML of any one of claim 7 , wherein the sealed container comprises an atmosphere of Ar, N 2 , H 2 O, H 2 , or a combination thereof.

9 . The CML of claim 3 , wherein the atmospheric controller maintains a reducing atmosphere in the sintering section.

10 . The CML of claim 3 , wherein the atmospheric controller maintains an atmosphere in the sintering section comprising argon (Ar) gas; nitrogen (N 2 ) gas; hydrogen (H 2 ) gas; or a mixture thereof.

11 . The CML of claim 3 , wherein the atmospheric controller maintains an atmosphere comprising less than 500 ppm O 2 in the bisque section, the sintering section, or both the bisque section and the sintering section.

12 . The CML of claim 10 , wherein the H 2 gas is present at about 1, 2, 3, 4, or 5% v/v.

13 .- 14 . (canceled)

15 . The CML of claim 3 , wherein the bilayer is oriented for curtain processing as it moves through the CML.

16 . The CML of claim 3 , wherein the bilayer is oriented for vertical processing as it moves through the CML.

17 . The CML of claim 3 , wherein the metal layer comprises a metal selected from the group consisting of nickel (Ni), iron (Fe), copper (Cu), platinum (Pt), gold (Au), silver), an alloy thereof, or a combination thereof.

18 . (canceled)

19 . The CML of claim 17 , wherein the metal layer is an alloy of Fe and Ni, and the amount of Fe is 1% to 25% (w/w) with the remainder being Ni.

20 . (canceled)

21 . The CML of claim 3 , wherein the bilayer is suspended as it moves through the CML.

22 . (canceled)

23 . The CML of claim 3 , wherein the sintered bilayer comprise sintered lithium-stuffed garnet.

24 . The CML of claim 3 , wherein the CML is configured to move the bilayer through the at least one furnace at a rate of at least 2 inches per minute.

25 . The CML of claim 3 , further comprising a curved ramp before the sintering section.

26 . The CML of claim 3 , further comprising a curved ramp inside the at least one furnace.

27 . A process of using a continuous manufacturing line, comprising the following operations:
(a) providing, or having provided, a CML as in claim 3 ; (b) sintering the green body while moving the green body through the at least one furnace to produce a sintered body, and (c) winding the sintered body onto an end roller.

28 .- 32 . (canceled)

Assignees

• Quantumscape Battery Inc

Inventors

• Holme Timothy
• Winterkorn Martin M
• Olenick John
• Berkstresser David
• Sheffield Matthew
• Mohan Yamini
• Zhou Yi
• Broganer Lucas

Classifications

• B28B11/243 Primary

  Setting, e.g. drying, dehydrating or firing ceramic articles (B28B11/242 takes precedence) · CPC title

• C04B35/486

  Fine ceramics · CPC title

• C04B35/64

  Burning or sintering processes (C04B33/32 takes precedence {; powder metallurgy B22F}) · CPC title

• C04B35/6264

  Mixing media, e.g. organic solvents · CPC title

• C04B35/6261

  Milling · CPC title