Apertured Sheet-Ceramic Component for Low-Temperature Sintering
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Solution Overview
Problem
High-temperature sintering processes for energy storage and conversion devices, such as solid-state lithium-ion battery cells, result in undesirable side effects like chemical decomposition and evaporative loss of lithium, and pose challenges in achieving uniform thickness and attachment of sintered components to substrates.
Innovation Solution
A component comprising a ceramic material with a sheet having through-thickness apertures, where the sheet is partially or wholly embedded in the sintered body, allowing for attachment and reduced internal resistance, and a method involving a slurry deposition on the apertured sheet followed by pressure and heat application to densify the ceramic material at temperatures no more than 200°C above the solvent's boiling point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-temperature sintering (>1000°C) is used to produce adequately sintered ceramic components, then sintering quality and density are improved, but chemical decomposition, reaction between materials forming deleterious secondary phases, and evaporative loss of volatile species occur
Solution Approach 1:
The invention fundamentally changes the sintering temperature parameter from conventional high temperatures (>1000°C) to low temperatures (≤200°C above solvent boiling point, typically ≤250°C absolute). This parameter change enables sintering without the harmful chemical decomposition and secondary phase formation that occur at high temperatures, while still achieving adequate densification through the cold sintering mechanism involving solvent wetting, pressure application, and controlled heating.
Solution Approach 2:
The invention utilizes phase transitions of a solvent (liquid → vapor) as the core mechanism of cold sintering. The solvent is applied in liquid form to wet the ceramic particles, then during heating the solvent undergoes phase transition to vapor, driving the densification and bonding of particles at low temperatures. This phase transition mechanism replaces the conventional thermal diffusion mechanism that requires high temperatures.
2Volume of stationary object
If high-temperature sintering is used, then ceramic component density is improved, but evaporative loss of lithium and other volatile species increases
Solution Approach 1:
The invention changes the temperature parameter from high (>1000°C) to low (≤250°C), which directly prevents the evaporative loss of lithium and other volatile species while still achieving adequate density through the cold sintering mechanism. The low temperature parameter ensures that volatile components remain in the condensed phase rather than evaporating.
3Temperature
If cold sintering is used to reduce sintering temperature, then chemical decomposition and lithium loss are reduced, but the process requires use of a die which limits device size and makes thickness control more difficult
Solution Approach 1:
The invention extracts and removes the die constraint from the cold sintering process. Instead of requiring confinement within a die, the method applies uniaxial pressure to the particle-solvent mixture without lateral constraints. This extraction of the die element eliminates the limitations on device size and thickness control while maintaining the low-temperature cold sintering benefits.
Solution Approach 2:
The invention inverts the conventional cold sintering approach by removing the confining die structure. Rather than applying pressure within lateral constraints, the method applies uniaxial pressure in an open configuration, allowing the sintered component to maintain its own dimensional integrity. This inversion eliminates the die-related complexities while preserving the low-temperature sintering advantage.
4Manufacturing precision
If uniaxial pressure is applied without die walls, then device size and thickness control are improved, but the mixture expands laterally under pressure causing detachment of sintered component from substrate
Solution Approach 1:
The invention applies local quality by providing lateral constraints only at specific locations where attachment to the substrate is required, rather than applying uniform constraints throughout. The confining structure is localized to the interface region, allowing free expansion in non-critical areas while maintaining attachment strength where needed. This localized application of constraints resolves the contradiction between thickness control and attachment strength.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the attachment of sintered components to substrates, reduces internal resistance, and minimizes lithium loss, enabling the production of more efficient energy storage devices with improved energy density and structural integrity.
Implementation Method 1
wetted at least one inorganic compound in particle form with a solvent that can partially solubilise the inorganic compound
Implementation Method 2
applying pressure and heat to the wetted particles of the inorganic compound to evaporate the solvent and densify the inorganic compound
Implementation Method 3
evaporate the solvent and densify the inorganic compound to form the sintered material
Data Source
AI summary
A component for use in an energy storage device or an energy conversion device comprises a first part and a second part, wherein the first part comprises particles of a ceramic material, and the second part is provided by a sheet having a plurality of through-thickness apertures. The second part is at least partially embedded in the first part.