Lithium stuffed garnet setter plates for solid electrolyte fabrication
AssigneeQuantumScape Corporation
InventorsSriram Iyer, Tim Holme, Niall Donnelly
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Abstract
Setter plates are fabricated from Li-stuffed garnet materials having the same, or substantially similar, compositions as a garnet Li-stuffed solid electrolyte. The Li-stuffed garnet setter plates, set forth herein, reduce the evaporation of Li during a sintering treatment step and/or reduce the loss of Li caused by diffusion out of the sintering electrolyte. Li-stuffed garnet setter plates, set forth herein, maintain compositional control over the solid electrolyte during sintering when, upon heating, lithium is prone to diffuse out of the solid electrolyte.
Claims60
A method of using a setter plate to fabricate a Li-stuffed garnet solid electrolyte film for a rechargeable battery, the method comprising:
- placing a green film comprising unsintered Li-stuffed garnet between two setter plates;
- and
- sintering the green film between and in contact with the two setter plates;
- wherein each of the two setter plates comprises at least two members selected from the group consisting of Li2ZrO3, Li2SiO3, LiLaO2, LiAlO2, Li2O, Li3PO4, and a Li-stuffed garnet compound characterized by the formula LiALaBM′CM″DZrEOF, wherein 4<A<8.5, 1.5<B<4, 0≤C≤2, 0≤D≤2;
- 0≤E<2, 10<F<13, and M′ and M″ are each, independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, and Ta;
- wherein at least one setter plate comprises a Li-stuffed garnet;
- wherein the thickness of each of the two setter plates is about 0.1 mm to about 100 mm.
A method of using a Li-stuffed garnet setter plate to fabricate a Li-stuffed garnet solid electrolyte film for a rechargeable battery, the method comprising:
- placing a green film of unsintered Li-stuffed garnet precursor materials on top of a Li-stuffed garnet setter plate,
- wherein the Li-stuffed garnet setter plate comprises a lithium-stuffed garnet characterized by the formula LiALaBM′CM″DZrEOF, wherein 4<A<8.5, 1.5<B<4, 0≤C≤2, 0≤D≤2;
- 0≤E<2, 10<F<13, and M′ and M″ are each, independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, and Ta and at least one member selected from the group consisting of Li2ZrO3, Li2SiO3, LiLaO2, LiAlO2, Li2O, Li3PO4, and a Li-stuffed garnet compound characterized by the formula LiALaBM′CM″DZrEOF, wherein 4<A<8.5, 1.5<B<4, 0≤C≤2, 0≤D≤2;
- 0≤E<2, 10<F<13, and M′ and M″ are each, independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, and Ta;
- and
- sintering the green film on top of the Li-stuffed garnet setter plate to form a sintered garnet film.
A method of sintering a green film comprising a Li-stuffed garnet or the chemical precursors to a Li-stuffed garnet, comprising:
- providing a green film comprising a Li-stuffed garnet or the chemical precursors to a Li-stuffed garnet;
- and
- sintering the green film in proximity to a Li-stuffed garnet setter such that the setter prevents the loss of Li from the sintering green film,
- wherein the Li-stuffed garnet setter comprises a lithium-stuffed garnet characterized by the formula LiALaBM′CM″DZrEOF, wherein 4<A<8.5, 1.5<B<4, 0≤C≤2, 0≤D≤2;
- 0≤E<2, 10<F<13, and M′ and M″ are each, independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, and Ta and at least one member selected from the group consisting of Li2ZrO3, Li2SiO3, LiLaO2, LiAlO2, Li2O, Li3PO4, and a Li-stuffed garnet compound characterized by the formula LiALaBM′CM″DZrEOF, wherein 4<A<8.5, 1.5<B<4, 0≤C≤2, 0≤D≤2;
- 0≤E<2, 10<F<13, and M′ and M″ are each, independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, and Ta.
A method of sintering a green film comprising a Li-stuffed garnet or the chemical precursors to a Li-stuffed garnet, comprising:
- providing a green film comprising a Li-stuffed garnet or the chemical precursors to a Li-stuffed garnet;
- and
- sintering the green film in proximity to a Li-stuffed garnet setter such that the setter maintains the amount of Li in the sintering green film,
- wherein the Li-stuffed garnet setter comprises a lithium-stuffed garnet characterized by the formula LiALaBM′CM″DZrEOF, wherein 4<A<8.5, 1.5<B<4, 0≤C≤2, 0≤D≤2;
- 0≤E<2, 10<F<13, and M′ and M″ are each, independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, and Ta and at least one member selected from the group consisting of Li2ZrO3, Li2SiO3, LiLaO2, LiAlO2, Li2O, Li3PO4, and a Li-stuffed garnet compound characterized by the formula LiALaBM′CM″DZrEOF, wherein 4<A<8.5, 1.5<B<4, 0≤C≤2, 0≤D≤2;
- 0≤E<2, 10<F<13, and M′ and M″ are each, independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, and Ta.
A method of sintering a green film comprising a Li-stuffed garnet or the chemical precursors to a Li-stuffed garnet, comprising:
- providing a green film comprising a Li-stuffed garnet or the chemical precursors to a Li-stuffed garnet;
- and
- sintering the green film in proximity to a Li-stuffed garnet setter such that the setter maintains the amount of Li in the sintering green film,
- wherein the Li-stuffed garnet setter comprises a lithium-stuffed garnet characterized by the formula LiALaBM′CM″DZrEOF, wherein 4<A<8.5, 1.5<B<4, 0≤C≤2, 0≤D≤2;
- 0≤E<2, 10<F<13, and M′ and M″ are each, independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, and Ta and at least one member selected from the group consisting of Li2ZrO3, Li2SiO3, LiLaO2, LiAlO2, Li2O, Li3PO4, and a Li-stuffed garnet compound characterized by the formula LiALaBM′CM″DZrEOF, wherein 4<A<8.5, 1.5<B<4, 0≤C≤2, 0≤D≤2;
- 0≤E<2, 10<F<13, and M′ and M″ are each, independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, and Ta;
- wherein the sintering is in an oven or furnace wherein the partial pressure of Li(g) LiO(g), and/or Li2O(g) is between 10 and 10−5 Pascals (Pa).
Dependencies are inferred from the claim text.