Centerless sintering setters

Patent metadata

Field	Value
Publication number	US-2025360653-A1
Application number	US-202519294094-A
Country	US
Kind code	A1
Filing date	Aug 7, 2025
Priority date	Feb 14, 2023
Publication date	Nov 27, 2025
Grant date	—

Abstract

Set forth herein are materials, systems, and methods for sintering bilayers that include a layer of a metal and a layer of a ceramic.

First claim

1 . A stack comprising:
a bottom setter comprising at least one or more refractory materials; a bilayer disposed on the bottom setter, wherein the bilayer comprises:
a layer comprising an oxide, and
a layer comprising a metal;
a top setter disposed on the bilayer, wherein the top setter has a perimeter but does not have a center.

2 . The stack of claim 1 , wherein the layer comprising an oxide does not comprise a metal in the layer comprising an oxide.

3 . The stack of claim 2 , wherein the layer comprising an oxide consists of an oxide.

4 . The stack of claim 2 or 3 , wherein the layer comprising an oxide consists essentially of an oxide.

5 . The stack of any one of claims 1-4 , wherein the layer comprising an oxide comprises a lithium-stuffed garnet oxide.

6 . The stack of any one of claim 1 or 4-5 , wherein the layer comprising an oxide further comprises metal in the layer comprising an oxide.

7 . The stack of claim 6 , wherein the metal in the layer comprising an oxide is selected from the group consisting of nickel (Ni), iron (Fe), copper (Cu), titanium (Ti), zirconium (Zr), and combinations thereof.

8 . The stack of claim 6 or 7 , wherein the metal in the layer comprising an oxide is Ni.

9 . The stack of claim 6 or 7 , wherein the metal in the layer comprising an oxide is Fe.

10 . The stack of any one of claim 6 or 7-9 , comprising more than one type of metal in the layer comprising an oxide.

11 . The stack of any one of claims 1-10 , wherein the layer comprising a metal comprises a metal selected from the group consisting of nickel (Ni), iron (Fe), copper (Cu), titanium (Ti), zirconium (Zr), and combinations thereof.

12 . The stack of claim 11 , wherein the layer comprising a metal comprises Ni.

13 . The stack of claim 11 , wherein the layer comprising a metal comprises Fe.

14 . The stack of claim 11 , wherein the layer comprising a metal comprises Cu.

15 . The stack of any one of claims 1-14 , wherein the top setter is a metallic foam.

16 . The stack of any one of claims 1-15 , wherein the top setter is a nickel (Ni) foam.

17 . The stack of any one of claims 1-16 , wherein, the refractory materials are, individually, selected from the group consisting of Al 2 O 3 , LiAlO 2 , Li 7 La 3 Zr 2 O 12 , Li 2 ZrO 3 , xLi 2 O-(1-x)SiO 2 (where x=0.01-0.99), aLi 2 O-bB 2 O 3 -cSiO 2 (where a+b+c=1), LiLaO 2 , Li 2 O, Li 3 PO 4 , ZrO 2 , ZnO 2 , and combinations thereof.

18 . The stack of any one of claims 1-17 , wherein, the top setter comprises a refractory materials selected from the group consisting of Al 2 O 3 , LiAlO 2 , Li 7 La 3 Zr 2 O 12 , Li 2 ZrO 3 , xLi 2 O-(1-x)SiO 2 (where x=0.01-0.99), aLi 2 O-bB 2 O 3 -cSiO 2 (where a+b+c=1), LiLaO 2 , LiAlO 2 , Li 2 O, Li 3 PO 4 , ZrO 2 , ZnO 2 , and combinations thereof.

19 . The stack of claim 17 or 18 , wherein the refractory materials comprise LiAlO 2 .

20 . The stack of any one of claims 1-19 , further comprising at least one or more shims disposed between the top setter and the bottom setter.

21 . The stack of any one of claims 1-20 , further comprising a third setter comprising at least one or more refractory materials disposed above the top setter.

22 . The stack of claim 21 , further comprising a layer comprising a shim disposed above the top setter and between the top setter and the third setter comprising at least one or more refractory materials disposed above the top setter.

23 . Two or more stacks of any one of claims 1-22 , wherein the two or more stacks are stacked on top of each other.

24 . A stack comprising:
a bottom setter; a bilayer disposed on the bottom setter, wherein the bilayer comprises:
a layer comprising an oxide, and
a layer comprising a metal;
a metallic mesh disposed on the electrolyte bilayer.

25 . The stack of claim 24 , wherein the metal mesh comprises Ni.

26 . The stack of claim 24 or 25 , wherein the metal mesh is a metallic foam.

27 . The stack of any one of claims 24-26 , wherein the layer comprising an oxide does not comprise a metal in the layer comprising an oxide.

28 . The stack of any one of claims 24-26 , wherein the layer comprising an oxide consists of an oxide.

29 . The stack of any one of claims 24-28 , wherein the layer comprising an oxide consists essentially of an oxide.

30 . The stack of any one of claims 24-29 , wherein the layer comprising an oxide comprises a lithium-stuffed garnet oxide.

31 . The stack of any one of claim 24-26 or 28-30 , wherein the layer comprising an oxide further comprises metal in the layer comprising an oxide.

32 . The stack of claim 31 , wherein the metal in the layer comprising an oxide is selected from the group consisting of nickel (Ni), iron (Fe), copper (Cu), titanium (Ti), zirconium (Zr), and combinations thereof.

33 . The stack of claim 31 or 32 , wherein the metal in the layer comprising an oxide is Ni.

34 . The stack of claim 31 or 32 , wherein the metal in the layer comprising an oxide is Fe.

35 . The stack of claim 31 or 32 , comprising more than one type of metal in the layer comprising an oxide.

36 . The stack of any one of claims 24-35 , wherein the layer comprising a metal comprises a metal selected from the group consisting of nickel (Ni), iron (Fe), copper (Cu), titanium (Ti), zirconium (Zr), and combinations thereof.

37 . The stack of claim 36 , wherein the layer comprising a metal comprises Ni.

38 . The stack of claim 36 , wherein the layer comprising a metal comprises Fe.

39 . The stack of claim 36 , wherein the layer comprising a metal comprises Cu.

40 . The stack of any one of claims 24-39 , wherein the bottom setter comprises one or more refractory materials, wherein the refractory materials are selected from the group consisting of Al 2 O 3 , LiAlO 2 , Li 7 La 3 Zr 2 O 12 , Li 2 ZrO 3 , xLi 2 O-(1-x)SiO 2 (where x=0.01-0.99), aLi 2 O-bB 2 O 3 -cSiO 2 (where a+b+c=1), LiLaO 2 , Li 2 O, Li 3 PO 4 , ZrO 2 , ZnO 2 , and combinations thereof.

41 . The stack of any one of claims 24-40 , wherein, the top setter comprises one or more refractory materials selected from Al 2 O 3 , LiAlO 2 , Li 7 La 3 Zr 2 O 12 , Li 2 ZrO 3 , xLi 2 O-(1-x)SiO 2 (where x=0.01-0.99), aLi 2 O-bB 2 O 3 -cSiO 2 (where a+b+c=1), LiLaO 2 , Li 2 O, Li 3 PO 4 , ZrO 2 , ZnO 2 , or combinations thereof.

42 . The stack of claim 40 or 41 , wherein the refractory material comprises LiAlO 2 .

43 . The stack of any one of claims 24-42 , further comprising at least one or more shims disposed between the metallic mesh and the bottom setter.

44 . The stack of any one of claims 24-42 , further wherein the metallic mesh contacts the bilayer.

45 . The stack of any one of claims 24-44 , further comprising a setter comprising at least one or more refractory materials disposed above the metallic mesh.

46 . The stack of claim 45 , further comprising a layer comprising a shim disposed above the metallic mesh and between the metallic mesh and the setter comprising at least one or more refractory materials di

Assignees

• Quantumscape Battery Inc

Inventors

• Donnelly Niall
• Venugopal Saranya
• Ramadas Lakshmi
• Goldsberry John

Classifications

• Y02E60/10

  Energy storage using batteries · CPC title

• C04B2237/405

  Iron metal group, e.g. Co or Ni · CPC title

• C04B2237/348

  Zirconia, hafnia, zirconates or hafnates · CPC title

• C04B2237/56

  Using constraining layers before or during sintering · CPC title

• B28B7/42 Primary

  for heating or cooling, e.g. steam jackets {, by means of treating agents acting directly on the moulding material} · CPC title