Separation apparatus and methods for separating a green tape from a carrier

Abstract

A method of separating a green ceramic tape (123) from a carrier (113) includes: i) conveying an assembly (125) of the green tape disposed on the carrier in a conveyance direction (143) with a first applied tension; ii) conveying the assembly (125) along a peeler plate (161) with the carrier facing a first surface (163) of the peeler plate; and iii) separating the green tape (123) and the carrier (113) at an edge (167) of the peeler plate (161) to form a separated green tape (127) and a separated carrier (126). The separated green tape (127) then travels in substantially the conveyance direction (147) while the separated carrier (126) is conveyed away from the edge (167) in a carrier direction (145) with a second applied tension that is greater than the first applied tension. A separation apparatus is also claimed, comprising a peeler plate (161) with an edge (167) between a first side (163) and a second side (165), configured to separate the carrier (113) from the green tape (123).

Description

SEPARATION APPARATUS AND METHODS FOR SEPARATING A GREEN TAPE FROM A CARRIER

[0001] This application claims the benefit of priority under 35 U.S. C. § 119 of U.S. Provisional Application Serial No. 63 / 600,802 filed on November 20, 2023, the content of which is relied upon and incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure relates to separation apparatus and methods for separating a green tape from a carrier, and methods of making the same, and more particularly, to separation apparatus comprising a peeler plate and methods for separating a green tape from a carrier using the same.BACKGROUND

[0003] Ceramic tapes can be used in a wide range of applications, including batteries, electrolyzer cells, and as substrates for semiconductors or other electronics. With the growth of renewable energy sources, the demand for battery technology has increased. In particular, there is a desire to provide thinner ceramic tapes that can be used as part of thinner and / or lighter weight battery for both electric vehicles and other energy storage solutions. However, existing technology and methods for manufacturing encounter problems as the thickness of ceramic tapes is decreased. Consequently, there is a need to develop apparatus and methods than can be used to manufacture ceramic tapes from green tapes, especially with reduced thickness.SUMMARY

[0004] The present disclosure provides a separation apparatus for separating a green tape from a carrier and methods for doing the same. While the peeler plate can be used with a green tape of any thickness, the peeler plate and / or associated aspects have the advantageous effect of being able to separate thin green tapes (e.g., with a green tape thickness from 5 micrometers (pm) to 50 pm or from 5 pm to 20 pm) from carriers, which cannot be reliably performed by known methods, especially in a continuous operation. Without wishing to be bound by theory, thin green tapes have reduced stiffness and / or reduced ability to tolerate pulling forces (relative to thicker green tapes), which makes it difficult to separate the green tape from the carrier. To separate the carrier from the green tape, the green tape and the carrier need to travel in different directions, but a low stiffness green tape is prone to follow the direction that the carrier travels. At the same, the reduced abilityto tolerate pulling forces of thin green tapes means that green tape can be easily damaged, for example by applied forces and / or tensions.

[0005] The peeler plate is configured to separate a green tape from a carrier, for example, due to one or more of the radius of curvature of the edge, the peeler angle, an angle between a conveyance direction of the green tape and a carrier direction that the carrier is conveyed along after the separation, and / or the applied tensions. If the edge of the peeler plate is too sharp (e.g., a radius of curvature of about 25 pm or less), the edge can cut the carrier, which interferes with separation of the green tape from the carrier (e.g., by releasing the second applied tension - discussed below), can increase costs (e.g., to replace the carrier), and / or interrupt processing of the green tape. On the other hand, if the edge of the peeler plate does not have a small enough radius of curvature (e.g., 800 pm or more corresponding to 1 / 32 inch), the peeler plate does not reliably (or entirely fails to) separate the carrier from the green tape. The peeler angle serves as a lower bound for an angle between the conveyance direction and a carrier direction that the carrier is conveyed along after the separation (discussed below). Also, it is believed that if the peeler angle is too small (e.g., 20° or less), an incidence of the carrier being cut by the peeler may increase, whereas peeler angles within the ranges discussed above in this paragraph have minimal (or no) incidence of cutting the carrier. Without wishing to be bound by theory, it is believed that this difference between the first applied tension and the second applied tension (e.g., a factor of 2 or more or 3 or more, or a second applied tension of about 1400 Newtons per linear meter or more) facilitates separation of the green tape and the carrier.

[0006] Some example aspects of the disclosure are described below with the understanding that any of the features of the various aspects may be used alone or in combination with one another.

[0007] Aspect 1. A method of separating a green tape from a carrier comprising: conveying an assembly comprising the green tape disposed on the carrier in a conveyance direction with a first applied tension; conveying the assembly along a first side of a peeler plate, the carrier facing the first side of the peeler plate; separating the green tape and the carrier at an edge of the peeler plate to form a separated green tape and a separated carrier, the edge positioned between the first side and a second side; conveying the separated green tape in substantially the conveyance direction; andconveying the separated carrier away from the edge in a carrier direction with a second applied tension, the second applied tension is greater than the first applied tension.

[0008] Aspect 2. The method of aspect 1, wherein the edge of peeler plate comprises a radius of curvature from about 25 micrometers to about 800 micrometers.

[0009] Aspect 3. The method of aspect 2, wherein the radius of curvature is from about 30 micrometers to about 400 micrometers.

[0010] Aspect 4. The method of any one of aspects 2-3, wherein the radius of curvature is from about 40 micrometers to about 200 micrometers.

[0011] Aspect 5. The method of any one of aspects 1-4, wherein a peeler angle defined at the edge between the first side and the second side is in a range from about 25° to about 45°.

[0012] Aspect 6. The method of aspect 5, wherein the peeler angle is in a range from about 30° to about 40°.

[0013] Aspect 7. The method of any one of aspects 1 -6, wherein an angle between the conveyance direction and the carrier direction is in a range from about 25° to about 75°.

[0014] Aspect 8. The method of aspect 7, wherein the angle between the conveyance direction and the carrier direction is in a range from about 30° to about 60°.

[0015] Aspect 9. The method of any one of aspects 1-8, wherein the second applied tension is two times or more the first applied tension.

[0016] Aspect 10. The method of aspect 9, wherein the second applied tension is three times or more the first applied tension.

[0017] Aspect 11. The method of any one of aspects 1-10, wherein the first applied tension is about 800 Newtons per linear meter N / m (4.6 pounds per linear inch Ib / in) or less.

[0018] Aspect 12. The method of aspects 11, wherein the first applied tension is in a range from about 350 N / m (2 Ib / in) to about 610 N / m (3.5 Ib / in).

[0019] Aspect 13. The method of any one of aspects 1-12, wherein the second applied tension is about 1400 Newtons per linear meter N / m (8 pounds per linear inch Ib / in) or more.

[0020] Aspect 14. The method of aspect 13, wherein the second applied tension is in a range from about 1400 N / m (8 Ib / in) to about 2100 N / m (12 Ib / in).

[0021] Aspect 15. The method of any one of aspects 1-14, wherein a thickness of the green tape is from about 5 micrometers to about 50 micrometers.

[0022] Aspect 16. The method of aspect 15, wherein the thickness from about 5 micrometers to about 20 micrometers.

[0023] Aspect 17. The method of any one of aspects 1-16, wherein the green tape comprises at least one of a zirconia with or without dopants, an alumina, a cordierite, a spinel, fused silica, lead lanthanum zirconate titanate, barium titanate, a lithium garnet, a sodium beta alumina, a lithium cobaltite (LCO), a lithium manganite spinel (LMO), a lithium nickel cobalt aluminate (NCA), a lithium nickel manganese cobalt oxide (NMC), a lithium iron phosphate (LFP), a lithium cobalt phosphate (LCP), a lithium titanate, a lithium niobium tungstate, a lithium titanium sulfide, , or combinations thereof.

[0024] Aspect 18. A method of making a sintered tape comprising: casting a green tape on a carrier; separating the green tape from the carrier using the method of any one of claims 1-17; and sintering the green tape to form a sintered tape.

[0025] Aspect 19. A separation apparatus comprising: a first conveyance apparatus configured to convey an assembly of a green tape and a carrier towards a peeler plate in a conveyance direction with a first applied tension; the peeler plate comprising an edge between a first side and a second side, the peeler plate configured to separate the carrier from the green tape in the assembly to form a separated green tape and a separated carrier; and a second conveyance apparatus configured to convey the separated carrier away from the edge of the peeler plate in a carrier direction with a second applied tension while the separated green tape is configured to travel in substantially the conveyance direction away from the edge of the peeler plate.

[0026] Aspect 20. The separation apparatus of aspect 19, wherein the edge of peeler plate comprises a radius of curvature from about 25 micrometers to about 800 micrometers.

[0027] Aspect 21. The separation apparatus of aspect 20, wherein the radius of curvature is from about 30 micrometers to about 400 micrometers.

[0028] Aspect 22. The separation apparatus of aspects 20-21, wherein the radius of curvature is from about 40 micrometers to about 200 micrometers.

[0029] Aspect 23. The separation apparatus of any one of aspects 19-22, wherein a peeler angle defined at the edge between the first side and the second side is in a range from about 25° to about 45°

[0030] Aspect 24. The separation apparatus of aspect 23, wherein the peeler angle is in a range from about 30° to about 40°.

[0031] Aspect 25. The separation apparatus of any one of aspects 19-24, wherein an angle between the conveyance direction and the carrier direction is in a range from about 25° to about 75°.

[0032] Aspect 26. The separation apparatus of aspect 25, wherein the angle between the conveyance direction and the carrier direction is in a range from about 30° to about 60°.

[0033] Aspect 27. The separation apparatus of any one of aspects 19-26, wherein the second conveyance apparatus is configured to apply the second applied tension that is two times or more the first applied tension that the first conveyance apparatus is configured to apply to the carrier.

[0034] Aspect 28. The separation apparatus of aspect 27, wherein the second applied tension is three times or more the first applied tension.

[0035] Aspect 29. The separation apparatus of any one of aspects 19-28, wherein the separation apparatus is configured to separate the green tape with a thickness is from about 5 micrometers to about 50 micrometers from the carrier.

[0036] Aspect 30. The separation apparatus of aspect 29, wherein the separation apparatus is configured to separate the green tape with the thickness is from about 5 micrometers to about 20 micrometers from the carrier.

[0037] Aspect 31. A method of making a sintered tape comprising: separating a green tape from a carrier using the method of any one of claims 1-17; and sintering the green tape to form a sintered tape.

[0038] Aspect 32. A method of forming a sintered tape comprising: separating a green tape from a carrier using the method of any one of aspects 1-17; and then sintering the green tape in a continuous sintering process.

[0039] Aspect 33. The method of any one of aspects 1-18 or 31-32 inclusive, wherein a carrier thickness of the carrier is from about 30 micrometers to about 200 micrometers.

[0040] Aspect 34. The method of aspect 33, wherein the carrier thickness is from about 40 micrometers to about 100 micrometers.BRIEF DESCRIPTION OF THE DRAWINGS

[0041] The above and other features and advantages of aspects of the present disclosure are better understood when the following detailed description is read with reference to the accompanying drawings, in which:

[0042] FIG. 1 is a schematic side view of an apparatus and method for making a green tape including separating the green tape from a carrier in accordance with aspects of the present disclosure;

[0043] FIG. 2 is an enlarged view 2 of FIG. 1 or FIG. 5 showing the peeler plate and the separation of the carrier from the green tape;

[0044] FIG. 3 is an enlarged view 3 of FIG. 2 showing an edge of the peeler plate;

[0045] FIG. 4 is a perspective view of a separation apparatus of methods of separating a green tape from a carrier in accordance with aspects of the present disclosure; and

[0046] FIG. 5 is a schematic side view of an apparatus and method for making a green tape including separating the green tape from a carrier in accordance with aspects of the present disclosure.DETAILED DESCRIPTION

[0047] As shown in FIGS. 1 and 4-5, casting apparatus 101, sintering apparatus 501, and / or peeling apparatus 401 comprises a peeler plate 161 comprising an edge 167 for separating a carrier 113 from a green tape 121. Unless otherwise noted, a discussion of features of aspects of the peeling apparatus, peeler plate, or methods of separating can apply equally to corresponding features of any aspects of the disclosure. For example, identical part numbers throughout the disclosure can indicate that, in some aspects, the identified features are identical to one another and that the discussion of the identified feature of one aspect, unless otherwise noted, can apply equally to the identified feature of any of the other aspects of the disclosure. It is to be understood that the drawings are not necessarily to scale in order to better illustrate the aspects of the disclosure and the interaction between different components illustrated therein.

[0048] As shown in FIGS. 1-2 and 4-5, aspects of the present disclosure produce a separated green tape 127 (e.g., green tape 121). As shown in FIG. 2, the green tape 121 comprises a first major surface 223 and a second major surface 225 opposite the first major surface 223. As shown,a green tape thickness 229 is defined for the green tape 121 after it has been separated from the carrier 113 (i.e., as a separated green tape 127) as an average distance between the first major surface 223 and the second major surface 225. In aspects, the green tape thickness 229 can be about 5 micrometers (pm) or more, about 8 pm or more, about 10 pm or more, about 12 pm or more, about 15 pm or more, about 18 pm or more, or about 20 pm or less, about 100 pm or less, about 80 pm or less, about 50 pm or less, about 40 pm or less, about 35 pm or less, about 30 pm or less, about 25 pm or less, about 22 pm or less, or about 20 pm or less. In aspects, the green tape thickness 229 can be in a range from about 5 pm to about 100 pm, from about 5 pm to about 80 pm, from about 5 pm to about 50 pm, from about 5 pm to about 40 pm, from about 5 pm to about 35 pm, from about 5 pm to about 30 pm, from about 5 pm to about 25 pm, from about 5 pm to about 20 pm, from about 8 pm to about 20 pm, from about 10 pm to about 18 pm, from about 12 pm to about 15 pm, or any range or subrange therebetween. In preferred aspects, the green tape thickness 229 can be in a range from about 5 pm to about 50 pm or from about 5 pm to about 20. While the peeler plate 161 of the casting apparatus 101 and / or peeling apparatus 401 can be used with a green tape of any thickness, the peeler plate 161 and / or associated aspects have the advantageous effect of being able to separate thin green tapes (e.g., with a green tape thickness from 5 pm to 50 pm or from 5 pm to 20 pm) from carriers, which cannot be reliably performed by known methods, especially in a continuous operation. Without wishing to be bound by theory, thin green tapes have reduced stiffness and / or reduced ability to tolerate pulling forces (relative to thicker green tapes), which makes it difficult to separate the green tape from the carrier. To separate the carrier from the green tape, the green tape and the carrier need to travel in different directions, but a low stiffness green tape is prone to follow the direction that the carrier travels. At the same, the reduced ability to tolerate pulling forces of thin green tapes means that green tape can be easily damaged, for example by applied forces and / or tensions.

[0049] As shown in FIG. 4, the green tape 121 can comprise a width W (e.g., measured perpendicular to a conveyance direction 143). The width W is not particularly limited by the present disclosure; however, the width of the green tape should be less than or equal to a corresponding dimension of the peeler plate 161. In aspects, the width W can be about 1 millimeter or more, about 10 mm or more, about 30 mm or more, about 50 mm or more, about 100 mm or more, about 200 mm or more, about 500 mm or more, about 10 meters or less, about 1 meter or less, about 800 mm or less, about 500 mm or less, about 300 mm or less, about 150 mm or less,about 100 mm or less, about 80 mm or less, about 50 mm or less, or about 20 mm or less. In aspects the width W can be in a range from about 1 mm to about 10 meters, from about 10 mm to about 1 meter, from about 30 mm to about 800 mm, from about 50 mm to about 500 mm, from about 100 mm to about 300 mm, or any range or subrange therebetween.

[0050] In aspects, although not labeled, the green tape 121 can comprise a length (e.g., measured in the conveyance direction 143). In further aspects, as shown in FIGS. 1 and 4, the green tape 121 can be made in a continuous process, where the length can be arbitrarily large, for example, equal to an amount that can reasonably fit in a spool (see spool 151 wrapped around core 152). In further aspects, the length of the green tape can be 1 meter or more, 10 meters or more, 20 meters or more, 50 meters or more, 100 meters or more, 200 meters or more, 500 meters or more, 1 kilometer (km) or more, 10 km or less, 1 km or less, 500 meters or less, 300 meters or less, 100 meters or less, 50 meters or less, or 30 meters or less. In further aspects, the length of the green tape can be in a range from about 1 meter to about 10 km, from about 10 meters to about 1 km, from about 20 meters to about 500 meters, from about 50 meters to about 300 meters, from about 100 meters to about 200 meters, or any range or subrange therebetween. Alternatively, although not shown, the green tape can be produced in predetermined lengths (e.g., prior to separation from the carrier, for example, by a caster in the casting chamber 109 dispensing a predetermined volume of material on the carrier 113 to form finite segments of green tape. The apparatus and methods in accordance with aspects of the disclosure can work equally well to separate continuous tapes from the carrier as it can to separate green tapes of finite length (e.g., 1 meter or less, 500 mm or less, or 100 mm or less).

[0051] In aspects, as shown in FIG. 1, the green tape (e.g., solvent-containing green tape 123 and / or solvent-free green tape - green tape 121) can comprise ceramic particles 107 in a binder system 105. In further aspects, the binder system 105 can initially comprise one or more of a solvent, a polymer, a dispersant, a viscosity modified, and / or other additives. The solvent can be initially present in an initial mixture cast to form a solvent-containing green tape 123, but is removed in a drying process (e.g., discussed below with reference to oven 131) to produce a solvent-free green tape. Unless otherwise indicated, “green tape” refers to a solvent-free green tape. Also, the phrase “solvent-free” green tape is not limited to green tapes with absolutely no solvent; rather, “solvent-free” is to indicate that a majority (e.g., 50% or more) of the solvent present in the initially cast solvent-containing green tape has been removed (e.g., in a dryingprocess). Throughout the disclosure, “as a wt% of a solvent-free green tape” refers to a weight percentage (wt%) of the green tape ignoring any contributions from solvent.

[0052] In aspects, the binder system initially includes a solvent that can be removed in a drying process (e.g., prior to separation of the green tape from the carrier). In further aspects, the solvent can comprise an aprotic solvent, for example, a polar aprotic solvent. Exemplary aspects of solvent include dimethyl carbonate, a ketone (e.g., methyl ethyl ketone, acetone) toluene, anisole, dioxolane, methoxy propyl acetate, N,N-dimethylformamide, dimethyl sulfoxide, dimethyl sulfoxide, and combinations thereof. In further aspects, a ratio of a weight of the solvent-free green tape to a weight of a solvent-containing green tape can be about 0.5 or more, about 0.55 or more, about 0.58 or more, about 0.7 or less, about 0.65 or less, or about 0.63 or less. In further aspects, a ratio of a weight of the solvent-free green tape to a weight of a solvent-containing green tape can range from about 0.5 to about 0.7, from about 0.55 to about 0.65, from about 0.58 to about 0.63, or any range or subrange therebetween.

[0053] In aspects, the binder system can include polymer. The polymer can provide strength to the green tape. The polymer can be any polymer compatible with the solvent (if present). In further aspects, the polymer can comprise a vinyl butyral resin (e.g., poly(vinyl butyral) (PVB)), a polycarbonate-based resin (e.g., polycarbonate (PC)), an acrylic resin (including methacrylates), a vinyl alcohol resin (e.g., poly(vinyl alcohol) (PVOH)), a vinyl acetate resin (e.g., poly (vinyl acetate) (PVA)), maleic acid polymer, a vinyl formal resin, a cellulose-based resin, or copolymers or combinations thereof. In further aspects, a wt% of the polymer in the solvent-free green tape can be about 1 wt% or more, about 2 wt% or more, about 5 wt% or more, about 7 wt% or more, about 10 wt% or more, about 20 wt% or less, about 15 wt% or less, about 12 wt% or less, about 10 wt% or less, about 8 wt% or less, or about 6 wt% or less. In further aspects, a wt% of the polymer in the solvent-free green tape can be in a range from about 1 wt% to about 20 wt%, from about 2 wt% to about 15 wt%, from about 5 wt% to about 12 wt%, from about 7 wt% to about 10 wt%, or any range or subrange therebetween.

[0054] In aspects, the binder system can comprise a dispersant. As used herein, a “dispersant” refers to a material that improves a separation of particles, improves a uniformity of a distribution of particles, decreases particle aggregation, and / or reduces settling of particles. In further aspects, the dispersant can comprise a fish oil or commercial dispersants, for example, the Hypermer line of dispersants (available from Croda Energy Technologies). In further aspects, the green tape, as awt% of the solvent-free green tape, can comprise the dispersant in an amount of 0 wt% or more, greater than 0 wt% or more, about 0.5 wt% or more, about 1 wt% or more, about 1.1 wt% or more, about 1.2 wt% or more, about 5 wt% or less, about 3 wt% or less, about 2 wt% or less, or about 1.5 wt% or less, or about 1.3 wt% or less. In further aspects, the green tape, as a wt% of the solvent- free green tape, can comprise the dispersant in a range from 0 wt% to about 5 wt%, from greater than 0 wt% to about 5 wt%, from about 0.5 wt% to about 3 wt%, from about 1 wt% to about 2 wt%, from about 1.1 wt% to about 1.5 wt%, from about 1.2 wt% to about 1.3 wt%, or any range or subrange therebetween. Alternatively, in aspects, the binder system can be free from a dispersant.

[0055] In aspects, the binder system can comprise a viscosity modifier. In further aspects, a viscosity modifier can increase a viscosity of the resulting mixture. In further aspects, the viscosity modifier can comprise a dibutyl carboxylic acid ester. Exemplary aspects of viscosity modifiers include dibutyl phthalate, dibutyl adipate, dibutyl maleate, poly(ethylene glycol), and combinations thereof. In further aspects, the green tape, as a wt% of the solvent-free green tape, can comprise the viscosity modifier in an amount of 0 wt% or more, greater than 0 wt% or more, about 0.5 wt% or more, about 1 wt% or more, about 1.5 wt% or more, about 5 wt% or less, about 4 wt% or less, or about 3 wt% or less, about 2.5 wt% or less, or about 2 wt% or less. In further aspects, the green tape, as a wt% of the solvent-free green tape, can comprise the viscosity modifier in a range from 0 wt% to about 5 wt%, from greater than 0 wt% to about 4 wt%, from about 0.5 wt% to about 3 wt%, from about 1 wt% to about 2.5 wt%, from about 1.5 wt% to about 2 wt%, or any range or subrange therebetween. Alternatively, in aspects, the binder system can be free from a viscosity modifier.

[0056] As noted above, the binder system can comprise one or more other additives, for example, a defoamer and / or a plasticizer. Exemplary aspects of plasticizers include dibutyl phthalate, dibutyl adipate, dibutyl maleate, poly(ethylene glycol), and combinations thereof. Alternatively, in aspects, the binder system can be free from a defoamer, a plasticizer, and / or other additional components.

[0057] In aspects, the ceramic particles of the green tape can be one or more of a zirconia with or without dopants, an alumina, a cordierite, a spinel, fused silica, a piezoelectric (e.g., lead lanthanum zirconate titanate (PLZT)), a ferroelectric (e.g., barium titanate), a lithium garnet, a sodium beta alumina, a lithium cobaltite (LCO), a lithium manganite spinel (LMO), a lithiumnickel cobalt aluminate (NCA), a lithium nickel manganese cobalt oxide (NMC), a lithium iron phosphate (LFP), a lithium cobalt phosphate (LCP), a lithium titanate, a lithium niobium tungstate, a lithium titanium sulfide, or combinations thereof. In aspects, the green tape, as a wt% of the solvent-free ceramic green tape, can comprise the ceramic particles in an amount of about 70 wt% or more, about 73 wt% or more, about 75 wt% or more, about 76 wt% or more, about 77 wt% or more, about 78 wt% or more, about 95 wt% or less, 93 wt% or less, about 90 wt% or less, about 85 wt% or less, about 84 wt% or less, about 83 wt% or less, or about 82 wt% or less. In aspects, the green tape, as a wt% of the solvent-free green tape, can comprise the ceramic particles in a range from about 70 wt% to about 95 wt%, from about 73 wt% to about 93 wt%, from about 75 wt% to about 90 wt%, from about 76 wt% to about 85 wt%, from about 77 wt% to about 84 wt%, from about 78 wt% to about 83 wt%, from about 78 wt% to about 82 wt%, or any range or subrange therebetween.

[0058] As shown in FIG. 1, the solvent-containing green tape 123 (e.g., green tape 121) can be cast onto a carrier 113 from a precursor solution comprising the ceramic particles 107 and the binder system 105 that can be within any of the corresponding ranges discussed above. Further, as shown, a casting chamber 109 can take in the precursor solution (e.g., a mixture of the ceramic particles 107 and the binder system 105), for example through funnel 103, and form (e.g., by extrusion, by calendaring, or by using a doctor blade) the solvent-containing green tape 123. In aspects, although not shown, an initial thickness of the solvent-containing green tape (as-cast) can be greater than the resulting green tape thickness (e.g., due to solvent loss), and the initial thickness can be adjusted to achieve a predetermined green tape thickness. For example, the initial thickness can be greater than the green tape thickness 229 by from about 1% to about 50%, from about 2% to about 40%, from about 5% to about 30%, from about 7% to about 20%, from about 10% to about 15%, or any range or subrange therebetween.

[0059] In aspects, the carrier 113 that the solvent-containing green tape 123 (e.g., green tape 121) is cast onto can be provided by from a spool 111 wrapped around a core 112 (e.g., for continuous operation), although other sources of the carrier can be provided in other aspects. In aspects, the carrier 113 can comprise one or more of a fluoropolymer (e.g., poly(tetrafluoroethylene) (PTFE)), a polyester (e.g., poly(ethylene terephthalate) (PET) with or without a silicone release layer coated thereof), parchment paper, or combinations thereof, although other materials can be used in other aspects. While it can be advantageous to provide a carrier that has minimal adhesion to the greentape to facilitate subsequent separation of the green tape from the carrier, the separation apparatus (e.g., peeler plate) and methods of using the same can achieve separation of green tapes from carriers with higher adhesion than may be possible otherwise (e.g., with other apparatus and / or methods). As shown, the carrier 113 comprises a third major surface 213 and a fourth major surface 215 opposite the third major surface 213. In aspects, a thickness of the carrier 113 can be in a range from about 30 pm to about 200 pm, from about 40 pm to about 100 pm, from about 50 pm to about 80 pm, or any range or subrange therebetween, which can minimize material costs for the carrier while providing the carrier with sufficient ability to withstand the applied tensions (discussed below) (e.g., without pronounced plastic deformation).

[0060] As shown in FIG. 1, an assembly of the solvent-containing green tape 123 (e.g., green tape 121) and the carrier 113 is conveyed for a predetermined period of time (and / or length) to allow the solvent (if present) to evaporation to form a solvent-free green tape (e.g., green tape 121). In aspects, as shown, the assembly of the solvent-containing green tape 123 and the carrier 113 can be conveyed through an oven 131 (e.g., furnace, lehr) with one or more heaters 133a and / or 133b to facilitate evaporation of the solvent in the solvent-containing green tape 123. In aspects, drying the solvent-containing green tape to form the solvent-free green tape may occur at ambient temperature or at a slightly elevated temperature of 60°C to 80°C (or begin at an ambient temperature and transition to an elevated temperature). Additionally, in aspects, air can be circulated (e.g., opposite a direction that the solvent-containing green tape is conveyed) to enhance drying. Additionally or alternatively, although not shown, the assembly of the solvent-containing green tape and the carrier tape can be conveyed through a solvent annealing chamber comprising a predetermined vapor pressure (e.g., gradient profile of vapor pressure that decreases as the assembly is conveyed therethrough) to enable the solvent in the solvent-containing green tape to evaporate at a controlled rate that minimizes the formation of defects in the resulting green tape (or sintered article).

[0061] After the solvent is removed, as shown in FIGS. 1-2 and 4, the assembly 125 of the green tape 123 and the carrier 113 is conveyed in a conveyance direction 143. As used herein, the conveyance direction refers to the direction that the assembly 125 is conveyed immediately prior (e.g., previous 100 mm or less, previous 50 mm, or from the previous 10 mm to the previous 50 mm) to the carrier 113 coming into contact with the peeler plate 161 (discussed below). Also, unless otherwise indicated, “upstream” and “downstream” are used with reference to theconveyance direction 143 At this point, the assembly 125 can be subject to a first applied tension from a first conveyance apparatus, for example, established by a first set of rollers 141 (e.g., acting on the carrier 113 prior to - upstream of - the solvent-containing green tape 123 being cast thereof) and one or more of the peeler plate 161 (static) and / or a second set of rollers 135 (e.g., acting on the green tape 121 after - downstream of - the peeler plate 161 and separation of the green tape 121 from the carrier 113). As used herein, applied tensions are described in terms of the force applied per width W of the article subjected to the force (with force reported in Newtons (SI) or pounds (imperial). In aspects, the first applied tension can be 800 Newtons per linear meter (N / m) or less (4.6 pounds per linear inch (ph) or less), about 700 N / m or less (4.0 Ib / in or less), about 650 N / m or less (3.7 Ib / in or less), about 610 N / m or less (3.5 Ib / in or less), about 560 N / m or less (3.2 Ib / in or less), about 530 N / m or less (3.0 Ib / in or less), about 490 N / m or less (2.8 Ib / in or less), about 440 N / m or less (2.5 Ib / in or less), about 400 N / m or less (2.3 Ib / in or less), about 260 N / m or more (1.5 Ib / in or more), about 300 N / m or more (1.7 Ib / in or more), about 320 N / m or more (1.8 Ib / in or more), about 350 N / m or more (2.0 Ib / in or more), about 370 N / m or more (2.1 Ib / in or more), about 400 N / m or more (2.3 Ib / in or more), about 440 N / m or more (2.5 Ib / in or more), about 490 N / m or more (2.9 Ib / in or more), about 530 N / m or more (3.0 Ib / in or more), or about 560 N / m or more (3.2 Ib / in or more). In aspects, the first applied tension can be in a range from about 260 N / m to about 800 N / m, from about 300 N / m to about 700 N / m, from about 320 N / m to about 650 N / m, from about 350 N / m to about 610 N / m, from about 370 N / m to about 560 N / m, from about 400 N / m to about 530 N / m, from about 440 N / m to about 490 N / m, or any range or subrange therebetween.

[0062] Alternatively, as shown in FIG. 5, the sintering apparatus 501 can provide the assembly 125 of the green tape 121 and the carrier 113 from a spool 511 wrapped around a core 512. Further, as shown, the assembly 125 (e.g., from the spool 511) can be conveyed through the first pair of rollers 141. As discussed above, at least the first pair of rollers 141 can subject the assembly 125 to the first applied tension (e.g., within one or more of the ranges discussed in the previous paragraph), for example, as the assembly 125 is conveyed in the conveyance direction 143. Otherwise, downstream aspects of the sintering apparatus 501 can be the same as for the casting apparatus 101 discussed herein.

[0063] As shown in FIGS. 2 and 4-5, as the assembly 125 is conveyed in the conveyance direction 143, the assembly 125 is conveyed along a first side 163 of the peeler plate 161. Specifically, asshown, the assembly 125 is configured with the carrier 113 (e.g., third major surface 213) facing the first side 163 of the peeler plate 161. In aspects, as shown, the third major surface 213 of the carrier 113 can contact the first side 163 of the peeler plate 161. For example, as shown, the third major surface 213 of the carrier 113 can contact the first side 163 of the peeler plate 161 for substantially the entire length (dimension shown in FIGS. 1-3) of the first side 163 of the peeler plate 161, although the third major surface 213 of the carrier 113 may have limited (if any) direct contact with the first side 163 of the peeler plate 161 prior to the edge 167 of the peeler plate 161. Also, as shown, the assembly 125 can comprise the first major surface 223 of the green tape 221 disposed on the fourth major surface 215 of the carrier 113 facing away from the first side 163 of the peeler plate 161.

[0064] As shown in FIGS. 2-4, the peeler plate 161 comprises an edge 167 positioned between (e.g., at an intersection between) the first side 163 and a second side 165 of the peeler plate 161. In aspects, as shown in FIG. 3, the edge 167 of the peeler plate 161 can be characterized by a radius of curvature 301. In further aspects, the radius of curvature 301 of the edge 167 of the peeler plate 161 can be about 800 pm or less, about 600 pm or less, about 500 pm or less, about 400 pm or less, about 300 pm or less, about 250 pm or less, about 200 pm or less, about 150 pm or less, about 100 pm or less, about 80 pm or less, about 70 pm or less, about 25 pm or more, about 30 pm or more, about 35 pm or more, about 40 pm or more, about 45 pm or more, about 50 pm or more, or about 55 pm or more. In further aspects, the radius of curvature 301 of the edge 167 of the peeler plate 161 can be in a range from about 25 pm to about 800 pm, from about 25 pm to about 600 pm, from about 30 pm to about 500 pm, from about 30 pm to about 400 pm, from about 35 pm to about 300 pm, from about 35 pm to about 250 pm, from about 40 pm to about 200 pm, from about 40 pm to about 150 pm, from about 40 pm to about 100 pm, from about 45 pm to about 80 pm, from about 50 pm to about 70 pm, or any range or subrange therebetween. If the edge 167 of the peeler plate 161 is too sharp (e.g., a radius of curvature of about 25 pm or less), the edge 167 can cut the carrier 113, which interferes with separation of the green tape 121 from the carrier 113 (e.g., by releasing the second applied tension - discussed below), can increase costs (e.g., to replace the carrier 113), and / or interrupt processing of the green tape 121. On the other hand, if the edge 167 of the peeler plate 161 does not have a small enough radius of curvature 301 (e.g., 800 pm or more corresponding to 1 / 32 inch), the peeler plate does not reliably (or entirely fails to) separate the carrier 113 from the green tape 121. In preferred aspects, the radius ofcurvature 301 of the edge 167 of the peeler plate 161 can be in a range from about 25 pm to about 800 pm, from about 30 pm to about 400 pm, or from about 40 pm to about 200 pm.

[0065] Also, as shown in FIGS. 2-4, the peeler plate 161 comprises a peeler angle 169 defined as an interior angle between the first side 163 and the second side 165. In aspects, the peeler angle 169 can be about 20° or more, about 25° or more, about 27° or more, about 30° or more, about 32° or more, about 35° or more, about 37° or more, about 45° or less, about 42° or less, about 40° or less, about 37° or less, or about 35° or less. In aspects, the peeler angle 169 can be in a range from about 20° to about 45°, from about 25° to about 42°, from about 30° to about 40°, from about 32° to about 37°, from about 32° to about 35°, or any range or subrange therebetween. The peeler angle 169 serves as a lower bound for an angle 168 between the conveyance direction 143 and a carrier direction 145 that the carrier 113 is conveyed along after the separation (discussed below). Also, it is believed that if the peeler angle is too small (e.g., 20° or less), an incidence of the carrier 113 being cut by the peeler plate 161 may increase, whereas peeler angles within the ranges discussed above in this paragraph have minimal (or no) incidence of cutting the carrier. In preferred aspects, the peeler angle 169 can be in a range from about 25° to about 45° or from about 30° to about 40°.

[0066] As shown in FIGS. 1-3, the peeler plate 161 is configured to separate the green tape 121 from the carrier 113 in the assembly 125 to form a separated green tape 127 and a separated carrier 126, for example, due to one or more of the radius of curvature 301 of the edge 167, the peeler angle 169, an angle 168 between the conveyance direction 143 and a carrier direction 145 that the carrier 113 is conveyed along after the separation (discussed below in this paragraph), and / or the applied tensions (e.g., second applied tension discussed below). In aspects, as shown in FIGS. 1- 4, the separated carrier 126 is conveyed away from the peeler plate 161 (e.g., edge 167) in a carrier direction 145. In further aspects, as shown in FIGS. 2-3, an angle defined between the conveyance direction 143 (e.g., of the assembly 125 immediately prior to the peeler plate 161) and the carrier direction 145 (e.g., of the separated carrier 126 being conveyed away from the peeler plate 161) can be about 25° or more, about 27° or more, about 30° or more, 32° or more, about 35° or more, about 75° or less, about 70° or less, about 65° or less, about 60° or less, about 55° or less, about 50° or less, about 45° or less, about 40° or less, or about 37° or less. In further aspects, an angle defined between the conveyance direction 143 (e.g., of the assembly 125 immediately prior to the peeler plate 161) and the carrier direction 145 (e.g., of the separated carrier 126 being conveyed away from the peeler plate 161) can be in a range from about 25° to about 75°, from about 25° toabout 70°, from about 27° to about 65°, from about 30° to about 60°, from about 30° to about 55°, from about 32° to about 50°, from about 32° to about 45°, from about 35° to about 40°, from about 35° to about 37°, or any range or subrange therebetween. In preferred aspects, the angle 168 can be in a range from about 25° to about 70°, from about 30° to about 60°, or from about 32° to about 50°. In even further aspects, as shown the angle 168 can be greater than peeler angle 169. Alternatively, although not shown, the angle 168 can be substantially equal to the peeler angle 169, for example, with the separated carrier 126 travelling along and / or contacting the second side 165 of the peeler plate 161 as the separated carrier 126 is conveyed in the carrier direction 145.

[0067] In aspects, the separated carrier 126 can be subject to a second applied tension as it is conveyed in the carrier direction 145 by a second conveyance apparatus. For example, a second applied tension can be generated by the speed of a third set of rollers 149 (conveying the separated carrier 126 in the carrier direction 145) being greater than a corresponding speed of the first set of rollers 141 and / or with the second applied tension extending between the peeler plate 161 (e.g., edge 167) and at least the third set of rollers 149. In further aspects, the second applied tension can be about two times (i.e., double) or more and / or three times (i.e., triple) or more the first applied tension. Without wishing to be bound by theory, it is believed that this difference between the first applied tension and the second applied tension (e.g., a factor of 2 or more or 3 or more, or a second applied tension of about 1400 N / m or more) facilitates separation of the green tape and the carrier. In further aspects, the second applied tension can be about 1400 N / m or more (8.0 Ib / in or more), about 1480 N / m or more (8.5 N / m or more), about 1580 N / m or more (9.0 Ib / in or more), about 1660 N / m or more (about 9.5 Ib / in or more), about 1750 N / m or more (10.0 Ib / in or more), about 1840 N / m or more (10.5 Ib / in or more), about 1930 N / m or more (11.0 Ib / in or more), about 2010 N / m or more (11.5 Ib / in or more), about 2450 N / m or less (14.0 Ib / in or less), about 2280 N / m or less (13.0 Ib / in or less), about 2190 N / m or less (12.5 N / m or less), about 2100 N / m or less (12.0 N / m or less), about 2010 N / m or less (11.5 Ib / in or less), about 1930 N / m or less (11.0 Ib / in or less), about 1840 N / m or less (10.5 Ib / in or less), about 1750 N / m or less (10.0 Ib / in or less), about 1660 N / m or less (9.5 Ib / in or less), or about 1580 N / m or less (9.0 Ib / in or less). In further aspects, the second applied tension can be in a range from about 1400 N / m to about 2450 N / m, from about 1400 N / m to about 2280 N / m, from about 1400 N / m to about 2190 N / m, from about 1400 N / m to about 2100 N / m, from about 1480 N / m to about 2010 N / m, from about 1580 N / m to about 1930 N / m, from about 1660 N / m to about 1840 N / m, from about 1750 N / m to about 1840 N / m, or anyrange or subrange therebetween. In preferred aspects, the second applied tension can be in a range from about 1400 N / m to about 2280 N / m or from about 1400 N / m to about 2100 N / m. In further aspects, as shown in FIGS. 1 and 5, the carrier 113 can be spooled around a core 114 (e.g., to be reused) after being conveyed in the carrier direction 145.

[0068] As shown in FIGS. 1-2 and 4-5, while the second conveyance apparatus conveys the separated carrier 126 in the carrier direction 145 away from the peeler plate 161, the separated green tape 127 is conveyed away from the peeler plate 161 (e.g., edge 167) in a second direction 147. In aspects, as shown, the second direction 147 (that the separated green tape 127 is conveyed away from the peeler plate 161) can be substantially the same as and / or the same as the conveyance direction 143. In other words, a direction of travel for the green tape 121 in the assembly 125 (immediately before separation at the edge 167 of the peeler plate 161) and a direction of travel for the green tape 121 as the separated green tape 127 (immediately after separation at the edge 167 of the peeler plate 161) can be substantially the same and / or the same (e.g., does not change). In further aspects, as shown in FIG. 4, a direction of travel of the separated green tape 127 further downstream can change direction, for example, being conveyed along a driven dancer 403 rotating in direction 405. In further aspects, as shown in FIG. 4 by dashed lines, the separated green tape 127 can be rolled up as a spool 151 about a core 152, where a take-up region 153 between the second set of rollers 135 and the core 152 can be subject to a different (or substantially no) applied tension relative to the first applied tension.

[0069] Alternatively or additionally, as shown in FIGS. 1 and 5, after the green tape 121 is separated from the assembly 125 as the separated green tape 127, the separated green tape 127 can sintered to form a sintered tape 129 (e.g., ceramic tape and / or ceramic article). In aspects, sintering the separated green tape 127 can comprise heating the separated green tape 127 in an oven 137 (e.g., furnace, lehr) comprising one or more heating elements 138a and / or 138b. In further aspects, the sintering can comprise one or more heating steps, for example, heating to removing organic material from the green tape (e.g., debinding) followed by further heating to allow the ceramic particles to fuse without melting (e.g., sintering), although both debinding and sintering can be performed in a single heating step in other aspects. In further aspects, sintering the separated green tape can comprise heating the separated green tape at a temperature of about 700°C or more, about 750°C or more, about 800°C or more, about 850°C or more, about 900°C or more, about 950°C or more, about 1000°C or more, about 1050°C or more, about 1100°C or more, about 1200°C ormore, about 1650°C or less, about 1600°C or less, about 1550°C or less, about 1500°C or less, about 1450°C or less, about 1400°C or less, about 1400°C or less, about 1350°C or less, about 1300°C or less, about 1250°C or less, about 1200°C or less, about 1150°C or less, about 1100°C or less, about 1050°C or less, about 1000°C or less, about 950°C or less, or about 900°C or less. In further aspects, sintering the separated green tape can comprise heating the separated green tape a temperature in a range from about 700°C to about 1650°C, from about 700°C to about 1600°C, from about 750°C to about 1550°C, from about 750°C to about 1500°C, from about 800°C to about 1450°C, from about 800°C to about 1400°C, from about 850°C to about 1350°C, from about 850°C to about 1300°C, from about 900°C to about 1250°C, from about 950°C to about 1200°C, from about 950°C to about 1150°C, from about 1000°C to about 1100°C, from about 1000°C to about 1050°C, or any range or subrange therebetween. In further aspects, heating the separated green tape (e.g., at one more of the temperatures mentioned above in this paragraph) can occur for a period of time of about 90 minutes or less, 75 minutes or less, 60 minutes or less, 50 minutes or less, 45 minutes or less, 40 minutes or less, 35 minutes or less, 30 minutes or less, 25 minutes or less, 20 minutes or less, 15 minutes or less, 10 minutes or less, 2 minutes or more, 3 minutes or more, 5 minutes or more, 7 minutes or more, 10 minutes or more, 12 minutes or more, 15 minutes or more, 17 minutes or more, 20 minutes or more, 25 minutes or more, or 30 minutes or more. In further aspects, heating the separated green tape (e.g., at one more of the temperatures mentioned above in this paragraph) can occur for a period of time in a range from 2 minutes to 90 minutes, from 3 minutes to 75 minutes, from 5 minutes to 60 minutes, from 7 minutes to 50 minutes, from 10 minutes to 45 minutes, from 12 minutes to 40 minutes, from 15 minutes to 35 minutes, from 17 minutes to 30 minutes, from 20 minutes to 25 minutes, or any range or subrange therebetween. Heating the separated green tape for 90 minutes or less (e.g., from 5 minutes to 60 minutes) can reduce resource requirements and / or increase a throughput of the method.

[0070] Aspects of methods of making a separating a green tape from a carrier in accordance with the aspects of the present disclosure will now be discussed. As discussed above with reference to FIGS. 1 and 4-5, methods can comprise conveying an assembly 125 comprising the green tape 121 disposed on the carrier 113 in the conveyance direction 143 with the first applied tension, which can be within one or more of the corresponding ranges discussed above. Methods can further comprise conveying the assembly 125 along the first side 163 of the peeler plate 161 with the carrier 113 facing the first side 163 of the peeler plate 161. Then, methods comprise separating thegreen tape 121 and the carrier 113 at the edge 167 (i.e., positioned between the first side 163 and the second side 165) of the peeler plate 161 to form a separated green tape 127 and a separated carrier 126. In aspects, as discussed above with reference to FIG. 3, the edge 167 of the peeler plate 161 can comprise the radius of curvature 301 within one or more of the corresponding ranges discussed above. In aspects, as discussed above with reference to FIGS. 2-4, the peeler plate 161 can comprise a peeler angle 169 that can be within one or more of the corresponding ranges discussed above. As shown in FIGS. 1-2 and 4-5, after the separation at the edge 167 of the peeler plate 161, methods can further comprise conveying the separated green tape 127 in substantially the conveyance direction 143 (e.g., second direction 147 can be substantially the same and / or the same as the conveyance direction 143). The separated green tape 127 can be subjected to a tension that is substantially equal to and / or the same as the first applied tension. Also, as shown in FIGS. 1-5, after the separation at the edge 167 of the peeler plate 161, methods can further comprise conveying the separated carrier 126 away from the edge 167 in the carrier direction 145 with a second applied tension. The second applied tension can be greater than the first applied tension (e.g., by a factor of 2 or more, or a factor of 3 or more). Alternatively or additionally, the second applied tension can be within one or more of the corresponding ranges discussed above. Alternatively or additionally, an angle formed between the conveyance direction 143 and the carrier direction 145 can be within one or more of the corresponding ranges discussed above.

[0071] Aspects of methods of making a sintered tape in accordance with the aspects of the present disclosure will now be discussed. In aspects, methods comprise providing a precursor solution comprising ceramic particles 107 and a binder system 105, where the composition of the precursor solution (and / or components thereof) can comprise one or more aspects discussed above with reference to the ceramic particles, the binder system, and / or components thereof. As discussed above with reference to FIG. 1, methods can comprise casting a green tape (e.g., solventcontaining green tape 123) on the carrier 113. In aspects, methods can comprise removing the solvent (e.g., solvent annealing, heating, and / or drying) from the solvent-containing green tape 123 to form the green tape (e.g., solvent-free green tape) as part of the assembly 125 with the carrier 113. Then, methods can comprise the methods of separating the green tape from the carrier as discussed in the previous paragraph (e.g., separating the green tape and the carrier at an edge of the peeler plate to form a separated green tape and a separated carrier, conveying the separated green tape in substantially the conveyance direction, and conveying the separated carrier awayfrom the edge in a carrier direction with a second applied tension, where the second applied tension is greater than the first applied tension). Further, the separated green tape can be sintered (e.g., heating at a temperature and for a period of time within one or more of the corresponding ranges discussed above) to form a sintered tape (e.g., ceramic article, ceramic tape).

[0072] Alternative methods of making a sintered tape in accordance with the aspects of the present disclosure will now be discussed. In aspects, as shown in FIG. 5, methods comprise providing the assembly 125 of the green tape 121 disposed on the carrier 113, which can be provided from the spool 511 and / or otherwise acquired (e.g., by purchase or by previously casting the green tape). The composition of the green tape (and / or components thereof) can comprise one or more aspects discussed above with reference to the ceramic particles, the binder system, and / or components thereof. Then, methods can comprise the methods of separating the green tape from the carrier as discussed in the previous paragraph (e.g., separating the green tape and the carrier at an edge of the peeler plate to form a separated green tape and a separated carrier, conveying the separated green tape in substantially the conveyance direction, and conveying the separated carrier away from the edge in a carrier direction with a second applied tension, where the second applied tension is greater than the first applied tension). Further, the separated green tape can be sintered (e.g., heating at a temperature and for a period of time within one or more of the corresponding ranges discussed above) to form a sintered tape (e.g., ceramic article, ceramic tape).EXAMPLES

[0073] Various aspects will be further clarified by the following working embodiments in accordance with aspects of the present disclosure. Green tapes comprising lithium cobaltite (LCO) comprising a tape thickness (i.e., of the dried or solvent-free green tape) of 15 pm and 50 pm were formed on an 80 pm thick silicone covered PET carrier. These assemblies (Assembly A with the 15 pm thick LCO green tape, and Assembly B with the 50 pm thick LCO tape) were tested on the following separation apparatus.

[0074] Comparative Example AA: A peeler plate comprising a radius of curvature of the edge of 800 pm (1 / 32 inch) was used with a first applied tension of 350 N / m (2 Ib / in), a second applied tension of 1580 N / m (9 lb / in)), and a peeler angle of 35° with the carrier configured to follow both the first side and the second side of the peeler. The peeler plate for Comparative Example AA successfully separate Assembly B but failed to separate Assembly A.

[0075] Example 1: A peeler plate comprising a radius of curvature of the edge of 43 pm (was used with a first applied tension of 350 N / m (2 Ib / in), a second applied tension of 1580 N / m (9 Ib / in), and a peeler angle of 35° with the carrier configured to follow both the first side and the second side of the peeler. The peeler plate for Example 2 successfully separated both Assembly A and Assembly B.

[0076] Example 2: A peeler plate comprising a radius of curvature of the edge of 61 pm (was used with a first applied tension of 530 N / m (3 Ib / in), a second applied tension of 2100 N / m (12 Ib / in)), and a peeler angle of 35°. The peeler plate for Example 2 successfully separated both Assembly A and Assembly B.

[0077] Comparative Example BB: A peeler plate comprising a radius of curvature of the edge of 20 pm (was used with a first applied tension of 530 N / m (3 Ib / in), a second applied tension of 2100 N / m (12 Ib / in)), and a peeler angle of 35° with the carrier configured to follow both the first side and the second side of the peeler. The peeler plate for Comparative Example BB cut the carrier for both Assembly A and Assembly B.

[0078] Table 1 presents the results of testing Examples 1-2 and Comparative Examples AA-BB with Assembly A and Assembly B. As shown, Examples 1 and 2 successfully separated both Assembly A and Assembly B. In contrast, Comparative Example AA failed to separate Assembly A while Comparative Example BB cut the carrier for both assemblies.Table 1 : Results of Testing Examples 1 -2 and Comparative Examples AA-BB

[0079] The above observations can be combined to provide a separation apparatus for separating a green tape from a carrier and methods for doing the same. While the peeler plate can be used with a green tape of any thickness, the peeler plate and / or associated aspects have the advantageous effect of being able to separate thin green tapes (e.g., with a green tape thickness from 5 pm to 50pm or from 5 pm to 20 pm) from carriers, which cannot be reliably performed by known methods, especially in a continuous operation. Without wishing to be bound by theory, thin green tapes have reduced stiffness and / or reduced ability to tolerate pulling forces (relative to thicker green tapes), which makes it difficult to separate the green tape from the carrier. To separate the carrier from the green tape, the green tape and the carrier need to travel in different directions, but a low stiffness green tape is prone to follow the direction that the carrier travels. At the same, the reduced ability to tolerate pulling forces of thin green tapes means that green tape can be easily damaged, for example by applied forces and / or tensions.

[0080] The peeler plate is configured to separate a green tape from a carrier, for example, due to one or more of the radius of curvature of the edge, the peeler angle, an angle between a conveyance direction of the green tape and a carrier direction that the carrier is conveyed along after the separation, and / or the applied tensions. If the edge of the peeler plate is too sharp (e.g., a radius of curvature of about 25 pm or less), the edge can cut the carrier, which interferes with separation of the green tape from the carrier (e.g., by releasing the second applied tension - discussed below), can increase costs (e.g., to replace the carrier), and / or interrupt processing of the green tape. On the other hand, if the edge of the peeler plate does not have a small enough radius of curvature (e.g., 800 pm or more corresponding to 1 / 32 inch), the peeler plate does not reliably (or entirely fails to) separate the carrier from the green tape. The peeler angle serves as a lower bound for an angle between the conveyance direction and a carrier direction that the carrier is conveyed along after the separation (discussed below). Also, it is believed that if the peeler angle is too small (e.g., 20° or less), an incidence of the carrier being cut by the peeler may increase, whereas peeler angles within the ranges discussed above in this paragraph have minimal (or no) incidence of cutting the carrier. Without wishing to be bound by theory, it is believed that this difference between the first applied tension and the second applied tension (e.g., a factor of 2 or more or 3 or more, or a second applied tension of about 1400 N / m or more) facilitates separation of the green tape and the carrier.

[0081] Directional terms as used herein — for example, up, down, right, left, front, back, top, bottom — are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

[0082] It will be appreciated that the various disclosed aspects may involve features, elements, or steps that are described in connection with that aspect. It will also be appreciated that a feature,element, or step, although described in relation to one aspect, may be interchanged or combined with alternate aspects in various non-illustrated combinations or permutations.

[0083] It is also to be understood that, as used herein the terms “the,” “a,” or “an,” mean “at least one,” and should not be limited to “only one” unless explicitly indicated to the contrary. For example, reference to “a component” comprises aspects having two or more such components unless the context clearly indicates otherwise. Likewise, a “plurality” is intended to denote “more than one.”

[0084] As used herein, the term “about” means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and / or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. Ranges can be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, aspects include from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. Whether or not a numerical value or endpoint of a range in the specification recites “about,” the numerical value or endpoint of a range is intended to include two aspects: one modified by “about,” and one not modified by “about.” It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint and independently of the other endpoint.

[0085] The terms “substantial,” “substantially,” and variations thereof as used herein are intended to note that a described feature is equal or approximately equal to a value or description. For example, a “substantially planar” surface is intended to denote a surface that is planar or approximately planar. Moreover, as defined above, “substantially similar” is intended to denote that two values are equal or approximately equal. In aspects, “substantially similar” may denote values within about 10% of each other, for example, within about 5% of each other, or within about 2% of each other.

[0086] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred.

[0087] While various features, elements, or steps of particular aspects may be disclosed using the transitional phrase “comprising,” it is to be understood that alternative aspects, including those that may be described using the transitional phrases “consisting of’ or “consisting essentially of,” are implied. Thus, for example, implied alternative aspects to an apparatus that comprises A+B+C include aspects where an apparatus consists of A+B+C and aspects where an apparatus consists essentially of A+B+C. As used herein, the terms “comprising” and “including,” and variations thereof shall be construed as synonymous and open-ended unless otherwise indicated.

[0088] The above aspects, and the features of those aspects, are exemplary and can be provided alone or in any combination with any one or more features of other aspects provided herein without departing from the scope of the disclosure.

[0089] It will be apparent to those skilled in the art that various modifications and variations can be made to the present disclosure without departing from the spirit and scope of the disclosure. Thus, it is intended that the present disclosure cover the modifications and variations of the aspects herein provided they come within the scope of the appended claims and their equivalents.

Claims

CLAIMSWhat is claimed is:

1. A method of separating a green tape from a carrier comprising: conveying an assembly comprising the green tape disposed on the carrier in a conveyance direction with a first applied tension; conveying the assembly along a first side of a peeler plate, the carrier facing the first side of the peeler plate; separating the green tape and the carrier at an edge of the peeler plate to form a separated green tape and a separated carrier, the edge positioned between the first side and a second side; conveying the separated green tape in substantially the conveyance direction; and conveying the separated carrier away from the edge in a carrier direction with a second applied tension, the second applied tension is greater than the first applied tension.

2. The method of claim 1, wherein the edge of peeler plate comprises a radius of curvature from about 25 micrometers to about 800 micrometers.

3. The method of claim 2, wherein the radius of curvature is from about 30 micrometers to about 400 micrometers.

4. The method of any one of claims 2-3, wherein the radius of curvature is from about 40 micrometers to about 200 micrometers.

5. The method of any one of claims 1-4, wherein a peeler angle defined at the edge between the first side and the second side is in a range from about 25° to about 45°.

6. The method of claim 5, wherein the peeler angle is in a range from about 30° to about 40°.

7. The method of any one of claims 1 -6, wherein an angle between the conveyance direction and the carrier direction is in a range from about 25° to about 75°.

8. The method of claim 7, wherein the angle between the conveyance direction and the carrier direction is in a range from about 30° to about 60°.

9. The method of any one of claims 1-8, wherein the second applied tension is two times or more the first applied tension.

10. The method of claim 9, wherein the second applied tension is three times or more the first applied tension.

11. The method of any one of claims 1-10, wherein the first applied tension is about 800 Newtons per linear meter N / m (4.6 pounds per linear inch Ib / in) or less.

12. The method of claim 11, wherein the first applied tension is in a range from about 350 N / m (2 Ib / in) to about 610 N / m (3.5 Ib / in).

13. The method of any one of claims 1-12, wherein the second applied tension is about 1400 Newtons per linear meter N / m (8 pounds per linear inch Ib / in) or more.

14. The method of claim 13, wherein the second applied tension is in a range from about 1400 N / m (8 Ib / in) to about 2100 N / m (12 Ib / in).

15. The method of any one of claims 1-14, wherein a thickness of the green tape is from about 5 micrometers to about 50 micrometers.

16. The method of claim 15, wherein the thickness is from about 5 micrometers to about 20 micrometers.

17. The method of any one of claims 1-16, wherein the green tape comprises at least one of a zirconia with or without dopants, an alumina, a cordierite, a spinel, fused silica, lead lanthanum zirconate titanate, barium titanate, a lithium garnet, a sodium beta alumina, a lithium cobaltite (LCO), a lithium manganite spinel (LMO), a lithium nickel cobalt aluminate (NCA), a lithiumnickel manganese cobalt oxide (NMC), a lithium iron phosphate (LFP), a lithium cobalt phosphate (LCP), a lithium titanate, a lithium niobium tungstate, a lithium titanium sulfide, or combinations thereof.

18. A method of making a sintered tape comprising: separating a green tape from a carrier using the method of any one of claims 1-17; and sintering the green tape to form a sintered tape.

19. A separation apparatus comprising: a first conveyance apparatus configured to convey an assembly of a green tape and a carrier towards a peeler plate in a conveyance direction with a first applied tension; the peeler plate comprising an edge between a first side and a second side, the peeler plate configured to separate the carrier from the green tape in the assembly to form a separated green tape and a separated carrier; and a second conveyance apparatus configured to convey the separated carrier away from the edge of the peeler plate in a carrier direction with a second applied tension while the separated green tape is configured to travel in substantially the conveyance direction away from the edge of the peeler plate.

20. The separation apparatus of claim 19, wherein the edge of peeler plate comprises a radius of curvature from about 25 micrometers to about 800 micrometers.

21. The separation apparatus of claim 20, wherein the radius of curvature is from about 30 micrometers to about 400 micrometers.

22. The separation apparatus of claims 20-21, wherein the radius of curvature is from about 40 micrometers to about 200 micrometers.

23. The separation apparatus of any one of claims 19-22, wherein a peeler angle defined at the edge between the first side and the second side is in a range from about 25° to about 45°.

124. The separation apparatus of claim 23, wherein the peeler angle is in a range from about 30' to about 40°.

25. The separation apparatus of any one of claims 19-24, wherein an angle between the conveyance direction and the carrier direction is in a range from about 25° to about 75°.

26. The separation apparatus of claim 25, wherein the angle between the conveyance direction and the carrier direction is in a range from about 30° to about 60°.

27. The separation apparatus of any one of claims 19-26, wherein the second conveyance apparatus is configured to apply the second applied tension that is two times or more the first applied tension that the first conveyance apparatus is configured to apply to the carrier.

28. The separation apparatus of claim 27, wherein the second applied tension is three times or more the first applied tension.

29. The separation apparatus of any one of claims 19-28, wherein the separation apparatus is configured to separate the green tape with a thickness is from about 5 micrometers to about 50 micrometers from the carrier.

30. The separation apparatus of claim 29, wherein the separation apparatus is configured to separate the green tape with the thickness from about 5 micrometers to about 20 micrometers from the carrier.

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