Continuous Sintering of Thin Ceramic Bilayers Under Tension
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Solution Overview
Problem
Existing methods lack efficient processes for producing thin film ceramics or ceramic bilayers, particularly lithium-stuffed garnet, and there is a need for high-throughput continuous sintering techniques such as roll-to-roll methods.
Innovation Solution
A process involving a green bilayer under tension, moving through multiple heating zones, with controlled atmospheric conditions, to produce a sintered bilayer with less than 100 μm thickness, using a continuous processing apparatus with features like front rollers, furnaces, and tension control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch sintering methods are used for lithium-stuffed garnet, then the ceramic can be produced with proper microstructure, but the production throughput is low and cannot meet high-volume manufacturing needs
Solution Approach 1:
The sintering process is divided into multiple heating zones (first heating zone for debindering, second heating zone for sintering) along the continuous transport path, allowing different thermal treatments to occur simultaneously at different locations, thereby enabling high-throughput continuous processing while maintaining proper microstructure development
Solution Approach 2:
The green bilayer is continuously fed through the processing apparatus, moving through debindering and sintering zones without interruption, maintaining continuous production flow. The tension application (1 N to 300 N per meter of web width) ensures continuous contact with heating zones, eliminating batch processing interruptions and achieving high productivity
2Stability of the object's composition
If high tension is applied to the green bilayer during processing, then the bilayer remains flat and stable, but the organic binder may be compromised and lithium loss may occur
Solution Approach 1:
The tension parameter is optimized to a specific range (1 N to 300 N per meter of web width) that provides sufficient mechanical stability for flat processing without exceeding thresholds that would cause binder degradation or lithium evaporation. This precise parameter control resolves the contradiction between stability and substance retention
3Loss of substance
If the green bilayer is processed without tension, then the organic binder and lithium are protected from loss, but the bilayer develops poor flatness and handling becomes difficult
Solution Approach 1:
Applying controlled tension within the optimized range (1 N to 300 N per meter of web width) simultaneously improves flatness (shape parameter) while staying below the threshold that would cause binder degradation or lithium loss (substance retention parameter), thus resolving the contradiction between shape and substance preservation
4Manufacturing precision
If conventional sintering processes are used for thin film ceramics, then the ceramic density can be achieved, but surface flaws and defects occur
Solution Approach 1:
The green bilayer is pre-formed with proper composition and structure before entering the sintering zone. The continuous feeding process ensures uniform preparation, and the preliminary debindering in the first heating zone removes organics before sintering, preventing surface defects while achieving dense microstructure in the second heating 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 thin film ceramics with low flatness and retention of stoichiometric lithium, avoiding surface flaws and defects, while maintaining microstructural integrity.
Implementation Method 1
moving the green bilayer through a first heating zone to produce a debindered bilayer
Implementation Method 2
moving the debindered bilayer through a second heating zone to prepare a sintered bilayer
Implementation Method 3
wherein the temperature in the second heating zone is 1050° C. to 1250° C.
Data Source
AI summary
Set forth herein are processes for making sintered bilayers and sintered bilayers made by such processes. The process includes rapidly sintering thin bilayers that comprise a green body layer on a metal layer in order to produce bilayers that have a sintered oxide layer on a metal layer.