Centerless Sintering Setters for Thin Solid-State Electrolytes
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Solution Overview
Problem
Challenges exist in the fabrication of solid-state electrolytes thinner than approximately 100 microns due to issues such as cracks, voids, and inhomogeneities, which affect the performance of thin solid-state electrolytes in batteries.
Innovation Solution
The use of setter plates and bilayers comprising refractory materials, metallic meshes, and shims to sinter solid-state electrolytes without direct contact, maintaining a centerless configuration during the sintering process, which results in high-quality, dense bilayers with low area-specific resistance and high Li+ ion conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If solid-state electrolytes are made thinner to improve ion conduction distance and energy delivery rates, then ion mobility and power delivery are improved, but cracks, voids, and inhomogeneities form during fabrication which deteriorate performance
Solution Approach 1:
The patent introduces a centerless setter with peripheral contact points as an intermediary tool during sintering. This setter applies localized pressure and heat to the thin solid-state electrolyte film without direct center contact, preventing deformation and crack formation while maintaining the thin-film structure necessary for high ion conduction distance reduction
Solution Approach 2:
The patent modifies the sintering process parameters by using a centerless setter configuration that changes the pressure distribution and heating pattern. This allows sintering thin films (<100 microns) without causing mechanical stress-induced cracks, achieving both thinness for improved ion conduction and structural integrity through optimized processing parameters
2Ease of manufacture
If conventional setter plates are used during sintering, then the sintering process can be maintained, but direct contact causes deformation and surface flaws in the thin solid-state electrolyte films
Solution Approach 1:
The patent extracts the problematic center contact function from the traditional setter plate design. By creating a centerless setter with only peripheral contact points, it removes the source of direct mechanical contact that causes deformation and surface flaws, while still maintaining sufficient process stability through peripheral support
Solution Approach 2:
The patent segments the setter plate into a centerless design with distributed peripheral contact points. This segmentation allows the setter to provide localized support at multiple peripheral locations rather than direct center contact, preventing deformation while maintaining process stability through distributed mechanical support
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 method enables the production of thin, dense ceramic electrolyte films with low flatness and surface flaws, retaining stoichiometric lithium in lithium-stuffed garnet structures, achieving high density and small grain size, and improving the performance of solid-state electrolytes in batteries.
Implementation Method 1
methods of sintering oxides and related materials
Data Source
AI summary
Set forth herein are materials, systems, and methods for sintering bilayers that include a layer of a metal and a layer of a ceramic.