# US 12,183,881 B2 · Doped-zirconia ceramic ribbon

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 12,183,881 B2
- Document ID: US12183881B2
- Status: Granted
- Kind: B2
- Application number: 18/660,557
- Filed: 2024-05-10
- Published: 2024-11-21
- Granted: 2024-12-31
- Earliest claimed: 2016-12-21
- Assignees: Corning Incorporated
- Applicants: Corning Incorporated
- Inventors: Michael Edward Badding; Jacqueline Leslie Brown; Jennifer Anella Heine; Thomas Dale Ketcham; Gary Edward Merz; Eric Lee Miller; Zhen Song; Cameron Wayne Tanner; Conor James Walsh
- Web page: https://patentgrep.com/patent/US12183881B2

## CPC

- H01M 10/0562: Solid materials
- B28B 1/30: by applying the material on to a core or other moulding surface to form a layer thereon (to form a permanent layer B28B19/00)
- C04B 35/62218: {obtaining ceramic films, e.g. by using temporary supports}
- G02B 6/122: Basic optical elements, e.g. light-guiding paths
- H01M 4/0471: {involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis}
- H01M 4/131: Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
- H01M 4/1391: of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
- H01M 4/505: of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy
- H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
- H10W 40/259: {Ceramics or glasses (H10W40/254, H10W40/257, H10W40/255, H10W40/251, H10W40/253 take precedence)}
- H10W 70/692: Ceramics or glasses
- H10W 90/293: {characterised by non-galvanic coupling between the chips, e.g. capacitive coupling}
- H01M 4/136: Electrodes based on inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy
- H01M 4/1397: of electrodes based on inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy
- H01M 4/525: of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
- H01M 4/5825: {Oxygenated metallic salts or polyanionic structures, e.g. borates, phosphates, silicates, olivines}
- H01M 10/052: Li-accumulators
- H01M 2004/028: {Positive electrodes}
- H01M 2300/0071: Oxides
- H01M 2300/0077: based on zirconium oxide
- H10H 20/851: Wavelength conversion means
- H10H 20/855: Optical field-shaping means, e.g. lenses
- H10P 72/0442: {Apparatus for placing on an insulating substrate, e.g. tape}
- H10W 70/681: {comprising holes not having chips therein, e.g. for outgassing, underfilling or bond wire passage}
- H10W 70/682: {comprising holes having chips therein}
- H10W 72/01323: {in liquid form, e.g. by dispensing droplets or by screen printing}
- H10W 72/01335: {by plating, e.g. electroless plating or electroplating}
- H10W 72/01338: {in gaseous form, e.g. by CVD or PVD}
- H10W 72/072: {of bump connectors}
- H10W 72/073: {of die-attach connectors}
- H10W 72/07307: {the auxiliary member being a temporary substrate, e.g. a removable substrate}
- H10W 72/07334: {Using a reflow oven}
- H10W 72/07336: {Soldering or alloying}
- H10W 72/075: {of bond wires}
- H10W 72/07507: {the auxiliary member being a temporary substrate, e.g. a removable substrate}
- H10W 72/07554: {changes in dispositions}
- H10W 72/20: Bump connectors, e.g. solder bumps or copper pillars; Dummy bumps; Thermal bumps
- H10W 72/241: {Dispositions, e.g. layouts}
- H10W 72/30: Die-attach connectors
- H10W 72/547: {Dispositions of multiple bond wires}
- H10W 72/884: {Die-attach connectors and bond wires}
- H10W 72/944: {Dispositions of multiple bond pads}
- H10W 72/952: {comprising metals or metalloids, e.g. PbSn, Ag or Cu}
- H10W 74/00: Encapsulations, e.g. protective coatings
- H10W 90/724: {between a chip and a stacked insulating package substrate, interposer or RDL}
- H10W 90/734: {between a chip and a stacked insulating package substrate, interposer or RDL}
- H10W 90/754: {between a chip and a stacked insulating package substrate, interposer or RDL}
- Y02E 60/10: Energy storage using batteries
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- H10W: GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10
- H10H: INORGANIC LIGHT-EMITTING SEMICONDUCTOR DEVICES HAVING POTENTIAL BARRIERS
- H10P: GENERIC PROCESSES OR APPARATUS FOR THE MANUFACTURE OR TREATMENT OF DEVICES COVERED BY CLASS H10
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A cathode configured for a solid-state battery includes a body having grains of inorganic material sintered to one another, wherein the grains comprise lithium. A thickness of the body is from 3 μm to 100 μm. The first major surface and the second major surface have an unpolished granular profile such that the profile includes grains protruding outward from the respective major surface with a height of at least 25 nm and no more than 150 μm relative to recessed portions of the respective major surface at boundaries between the respective grains.

## Claims

### Claim 1

A sintered article, comprising:
a first major surface,
a second major surface opposing the first major surface,
a body extending between the first and second major surfaces, the body comprising a sintered ceramic comprising zirconia,
wherein the first and second major surfaces have a granular profile comprising grains of the sintered ceramic with a height in a range from 25 nm to 150 μm relative to recessed portions of the respective major surface at boundaries between the grains;
wherein the body has a thickness defined as a distance between the first and second major surfaces, wherein the thickness is in a range from 3 μm to 1 mm;
wherein the body has a width defined as a first dimension of the first major surface orthogonal to the thickness, wherein the width is greater than 40 mm; and
wherein the sintered article has a flatness in a range from about 100 nm to about 50 μm over a distance of a centimeter along a length thereof, the length defined as a second dimension of the first major surface orthogonal to both the thickness and the width.

### Claim 2 (depends on 1)

The sintered article of claim 1, wherein the width is greater than 125 mm.

### Claim 3 (depends on 2)

The sintered article of claim 2, wherein the sintered article is a ceramic ribbon, wherein length of the body is 10 m or greater.

### Claim 4 (depends on 1)

The sintered article of claim 1, wherein the ceramic comprises doped zirconia.

### Claim 5 (depends on 4)

The sintered article of claim 4, wherein the dopant comprises yttria (Y2O3), and wherein the Y2O3 is 3 mol % of the ceramic.

### Claim 6 (depends on 4)

The sintered article of claim 4, wherein the zirconia comprises tetragonal zirconia.

### Claim 7 (depends on 1)

The sintered article of claim 1, wherein the first major surface comprises at least ten square centimeters of area having fewer than one hundred surface defects from adhesion or abrasion with a dimension greater than 5 μm.

### Claim 8

A sintered article, comprising:
a first major surface,
a second major surface opposing the first major surface,
a body extending between the first and second major surfaces, the body comprising a sintered ceramic comprising zirconia,
wherein the first major and second major surfaces have a granular profile comprising grains of the sintered ceramic with a height in a range from 25 nm to 150 μm relative to recessed portions of the respective major surface at boundaries between the grains;
wherein the body has a thickness defined as a distance between the first and second major surfaces, wherein the thickness is in a range from 3 μm to 1 mm;
wherein the body has a width defined as a first dimension of the first major surface orthogonal to the thickness, wherein the width is greater than 40 mm; and
wherein the body is flattenable without fracturing as determined by pressing the body between rigid parallel surfaces at 23° C. such that the body overlays or is within a distance of 0.05 mm of a flat plane.

### Claim 9 (depends on 8)

The sintered article of claim 8, wherein the body has less than 10% porosity by volume.

### Claim 10 (depends on 8)

The sintered article of claim 8, wherein the width is greater than 125 mm.

### Claim 11 (depends on 8)

The sintered article of claim 8, wherein the sintered article is a ceramic ribbon, wherein the length of the body is 10 m or greater.

### Claim 12 (depends on 8)

The sintered article of claim 8, wherein the ceramic comprises doped zirconia.

### Claim 13 (depends on 8)

The sintered article of claim 8, wherein the sintered article has a roughness of from about 1 nm to about 10 μm over a distance of 1 cm along the length.

### Claim 14

A sintered article, comprising:
a first major surface,
a second major surface opposing the first major surface,
a body extending between the first and second major surfaces, the body comprising a sintered ceramic comprising zirconia,
wherein the first and second major surfaces have a granular profile comprising grains of the sintered ceramic with a height in a range from 25 nm to 150 μm relative to recessed portions of the respective major surface at boundaries between the grains;
wherein the body has a thickness defined as a distance between the first and second major surfaces, wherein the thickness is in a range from 3 μm to 1 mm;
wherein the body has a width defined as a first dimension of the first major surface orthogonal to the thickness, wherein the width is greater than 40 mm; and
wherein the sintered article is a ceramic ribbon, wherein length of the body is 10 m or greater.

### Claim 15 (depends on 14)

The sintered article of claim 14, wherein the width is greater than 125 mm.

### Claim 16 (depends on 14)

The sintered article of claim 14, wherein the sintered article is a ceramic ribbon, wherein the length of the body is 10 m or greater.

### Claim 17 (depends on 14)

The sintered article of claim 14, wherein the ceramic comprises doped zirconia.

### Claim 18 (depends on 14)

The sintered article of claim 14, wherein the zirconia comprises tetragonal zirconia.

### Claim 19 (depends on 14)

The sintered article of claim 14, wherein the body has less than 10% porosity by volume.

### Claim 20 (depends on 14)

The sintered article of claim 14, wherein the first and second major surfaces each have at least ten square centimeters of area having fewer than one hundred surface defects from adhesion or abrasion with a dimension greater than 5 μm.