Roll to roll sintering system for wide inorganic tape material and sintered articles

Patent metadata

Field	Value
Publication number	US-2026005295-A1
Application number	US-202519318088-A
Country	US
Kind code	A1
Filing date	Sep 3, 2025
Priority date	Dec 21, 2016
Publication date	Jan 1, 2026
Grant date	—

Abstract

A roll-to-roll sintering system for wide inorganic tape material may include a spool on which is wound a continuous tape material comprising a green tape material and a backing layer, a take-up reel, and a heating station including at least one furnace. The heating station is configured to receive an unwound length of the continuous tape. The heating station further includes a first curved section such that the continuous tape material is bent through a radius of curvature of 0.01 m to 13,000 m, and at least two rollers defining the first curved section over which the continuous tape material is bent. The heating station is controlled to provide at least a portion of the heating station with an air free atmosphere, that being at least one of vacuum, hydrogen, or helium.

First claim

What is claimed is:

1 . A multi-layered ribbon, comprising:
a first layer comprising ceramic grains sintered to one another; a second layer at least partially overlaying the first layer; a width of the ribbon of 1 cm or greater; a length of the ribbon of 10 m or greater; and a thickness of the ribbon of 1 mm or less.

2 . The ribbon of claim 1 , wherein the ribbon has a crystalline ceramic content of at least 10% by volume.

3 . The ribbon of claim 1 , wherein the second layer is sintered, and wherein material of the second layer at least partially infiltrates and fills pores of the first layer.

4 . The ribbon of claim 1 , wherein the first and second layers each have a thickness of 150 μm or less.

5 . The ribbon of claim 4 , wherein first layer has a thickness of at least 3 μm.

6 . The ribbon of claim 5 , wherein the width of the ribbon is no more than 2 m, and wherein the ribbon has a length of no more than 5 km

7 . The ribbon of claim 1 , wherein the ribbon, including the first and second layers, comprises at least 40 layers.

8 . The ribbon of claim 1 , further comprising a third layer coupled to and overlaying the first layer on a side thereof opposite the second layer.

9 . The ribbon of claim 8 , wherein the second layer applies a stress on the first layer, and wherein stress applied by the third layer to the first layer offsets the stress applied by the second layer, thereby facilitating a flatter ribbon, rather than curled.

10 . The ribbon of claim 1 , wherein the first layer comprises lithium.

11 . The ribbon of claim 10 , wherein the second layer comprises metal and is in direct contact with the first layer.

12 . The ribbon of claim 10 , wherein the first layer comprises a lithium-containing garnet polycrystalline ceramic.

13 . The ribbon of claim 12 , wherein the first layer has ionic conductivity greater than 5×10 −5 S/cm or higher.

14 . The ribbon of claim 13 , wherein the grains sintered to one another have an average grain size of 5 μm or less.

15 . The ribbon of claim 1 , wherein the length is at least 30 m, and wherein the ribbon is rolled on a spool.

16 . The ribbon of claim 1 , wherein the first layer has an unpolished granular profile such that the profile includes grains protruding outward from a respective surface thereof with a height of at least 25 nm and no more than 150 μm relative to recessed portions of the respective surface at boundaries between the respective grains.

17 . The ribbon of claim 1 , wherein the second layer has a surface facing away from the first layer that is smoother than the surface of the first layer with the unpolished granular profile.

18 . The ribbon of claim 1 , wherein fewer than 10 pin holes of a cross-sectional area of at least a square micrometer pass through the first layer per square millimeter of surface thereof on average.

19 . A multi-layered ribbon, comprising:
a first layer comprising ceramic grains sintered to one another, wherein the first layer comprises lithium; a second layer at least partially overlaying the first layer, wherein material of the second layer at least partially infiltrates and fills pores of the first layer; a width of the ribbon of 1 cm or greater; a length of the ribbon of 10 m or greater; and a thickness of the ribbon of 1 mm or less.

20 . A multi-layered ribbon, comprising:
a first layer comprising ceramic grains sintered to one another, wherein the first layer comprises lithium; a second layer at least partially overlaying the first layer, a width of the ribbon of 1 cm or greater; a length of the ribbon of 10 m or greater; and a thickness of the ribbon of 1 mm or less, wherein the ribbon is flattenable without fracturing as determined by pressing a 10 cm length of the ribbon between rigid parallel surfaces at 23° C. such that the length overlays or is within a distance of 0.05 mm of a flat plane.

Assignees

• Corning Inc

Inventors

• Badding Michael Edward
• Brown Jacqueline Leslie
• Heine Jennifer Anella
• Ketcham Thomas Dale
• Merz Gary Edward
• Miller Eric Lee
• Song Zhen
• Tanner Cameron Wayne
• Walsh Conor James

Classifications

• H10W90/724

  between a chip and a stacked insulating package substrate, interposer or RDL · CPC title

• H10W74/00

  Encapsulations, e.g. protective coatings · CPC title

• H10W72/07554

  changes in dispositions · CPC title

• H10W72/884

  Die-attach connectors and bond wires · CPC title

• H10W72/547

  Dispositions of multiple bond wires · CPC title