Reactive sintering of ceramic lithium-ion solid electrolytes
AssigneeCorning Incorporated
InventorsBruce Gardiner Aitken, Michael Edward Badding, George Halsey Beall, Curtis Robert Fekety, Lanrik Wayne Kester, Robert Michael Morena, Zhen Song
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Abstract
A method of forming a solid, dense, hermetic lithium-ion electrolyte membrane comprises combing an amorphous, glassy, or low melting temperature solid reactant with a refractory oxide reactant to form a mixture, casting the mixture to form a green body, and sintering the green body to form a solid membrane. The resulting electrolyte membranes can be incorporated into lithium-ion batteries.
Claims20
A method of forming a solid lithium-ion electrolyte membrane, comprising:
- forming a powder mixture comprising an amorphous, glassy, or low melting temperature solid reactant and a refractory oxide reactant;
- tape-casting the mixture to form a green body;
- and
- reacting the amorphous, glassy, or low melting temperature solid reactant to form the solid lithium-ion electrolyte membrane,
- wherein:
- the green body comprises at least one of a binder and a plasticizer, and
- an average particle size of the amorphous, glassy, or low melting temperature solid reactant is less than 0.5 μm, and an average particle size of the refractory oxide reactant is less than 0.5 μm.
A solid lithium-ion ceramic electrolyte membrane, comprising:
- an average thickness of less than 200 pm;
- constituent electrolyte material having an average grain size of less than 10 μm, and
- wherein the membrane is free-standing.
A lithium-ion conductive ceramic electrolyte membrane, comprising:
- an average thickness of less than 200 μm;
- a thickness of the membrane is at least 30 μm;
- an average grain size of less than 10 pm;
- a conductivity of at least 10′ S/cm;
- a density of at least 95% theoretical density;
- wherein the membrane is free-standing, unsupported by a substrate.
Dependencies are inferred from the claim text.