Continuous Sintering of Ceramic Bilayers for Flat Thin Electrolyte Films
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Solution Overview
Problem
There is a need for processes to make thin film ceramics or ceramic bilayers, particularly lithium-stuffed garnet, in a thin film or bilayer format, and for high-throughput continuous sintering methods such as roll-to-roll processes.
Innovation Solution
A process involving a green bilayer under tension, moving through multiple heating zones, with specific temperature and time controls, to produce a sintered bilayer with less than 100 μm thickness, using a continuous processing apparatus with features like furnaces, rollers, and tension control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch sintering methods are used for lithium-stuffed garnet, then sintering can be achieved, but production throughput is low and cannot meet high-volume demand
Solution Approach 1:
The patent implements continuous sintering processing where green bodies are continuously fed through a furnace and sintered without interruption. This continuous operation eliminates the start-stop nature of batch processing, significantly increasing production throughput while maintaining sintering quality through controlled temperature and atmosphere throughout the continuous process.
Solution Approach 2:
The sintering process is divided into multiple heating zones (first heating zone for initial heating, second heating zone for main sintering, cooling zone) along the continuous path. This segmentation allows different stages of sintering to occur simultaneously at different locations, enabling high throughput while maintaining process control and quality.
2Manufacturing precision
If thin film ceramics are produced using conventional methods, then thin films can be made, but surface flatness deteriorates and defects increase
Solution Approach 1:
The patent employs a conveyor system that maintains the green bodies at a consistent height and orientation throughout the sintering process. This equipotential approach ensures uniform heat distribution and prevents warping or tilting that would cause surface irregularities, achieving high surface flatness while simplifying process control.
Solution Approach 2:
A conveyor mechanism serves as an intermediary between the green bodies and the heating zones, providing controlled support and movement. This intermediary device ensures precise positioning and uniform exposure to heat sources, preventing surface defects while managing the complexity of continuous processing through automated conveyance.
3Productivity
If continuous sintering is implemented, then production throughput increases, but process control and apparatus complexity increase
Solution Approach 1:
The conveyor system performs multiple functions simultaneously: it transports green bodies through the furnace, maintains their positioning, provides support during heating, and enables consistent spacing between bodies. This multi-functionality increases throughput while avoiding the need for separate control mechanisms for each function, thereby managing apparatus complexity.
Solution Approach 2:
The patent combines the transport and heating functions into a single integrated continuous process. The conveyor and heating zones work as a unified system where movement and thermal processing occur simultaneously, increasing productivity while reducing the need for separate batch operations and their associated complex control systems.
4Reliability
If high temperature sintering is applied, then ceramic sintering is achieved, but lithium stoichiometry may be compromised and surface flaws occur
Solution Approach 1:
The patent employs controlled parameter changes through multiple heating zones with different temperature profiles. The first heating zone uses moderate temperatures for initial drying and binder removal, while the second heating zone applies higher temperatures for sintering. This staged parameter change maintains lithium stoichiometry by preventing excessive temperature exposure while achieving complete sintering.
Solution Approach 2:
The first heating zone performs preliminary actions of drying and binder removal before the main sintering process. This preliminary treatment prepares the green bodies for sintering by removing volatile components that could cause surface flaws during high-temperature processing, thereby protecting lithium stoichiometry while enabling effective sintering in the second zone.
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
Achieves high-quality, rapid production of sintered ceramic films with low flatness and retention of stoichiometric lithium, avoiding surface flaws and defects, and enabling high throughput.
Implementation Method 1
heating a green bilayer as the green bilayer moves through at least one furnace
Implementation Method 2
moving the debindered bilayer through a second heating zone to prepare a sintered bilayer; wherein the temperature in the second heating zone is 1050° C. to 1250° C.
Implementation Method 3
providing a green bilayer, comprising a green body layer and a metal layer, under tension of 1 N to 300 N per meter of web width
Data Source
AI summary
Provided herein are processing apparatuses for producing high-quality films of sintered ceramics. The instant disclosure sets forth equipment and processes for making high quality, rapidly processed ceramic electrolyte films. These processes include high-throughput continuous sintering of oxides for use as electrolyte films. In certain processes, the film is not in contact with any surface as it sinters (i.e., during the sintering phase).Set forth herein are processes for making and using bilayers comprising a green body layer on a metal layer and bilayers comprising a sintered oxide layer on a metal layer. Set forth herein are processes for rapidly sintering thin bilayers comprising a green body layer on a metal layer in order to produce bilayers comprising a sintered oxide layer on a metal layer.