Continuous Sintering of Lithium-Stuffed Garnet Electrolyte Films
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Solution Overview
Problem
There is a lack of adequate public disclosures for methods of sintering lithium-stuffed garnet in a thin film or bilayer format using high-throughput continuous sintering methods such as roll-to-roll methods.
Innovation Solution
A continuous manufacturing line (CML) is described, which includes a front roller, an end roller, and at least one sealed furnace with sections for binder burn-out, bisque, and sintering, along with an atmospheric controller to manage conditions like gas flow rate, direction, composition, pressure, and their combinations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch sintering methods are used for lithium-stuffed garnet, then processing quality can be maintained, but processing time is long and throughput is low
Solution Approach 1:
The sintering process is divided into multiple sequential zones within a single continuous furnace: binder burnout zone, bisque sintering zone, and final sintering zone. Each zone operates at different temperature ranges and atmospheric conditions, allowing simultaneous processing of multiple process stages in a continuous manner, thereby dramatically increasing throughput while maintaining quality
Solution Approach 2:
The patent implements a continuous sintering line where the green body moves continuously through the furnace on a moving belt or roller system. The furnace maintains continuous heating zones with controlled atmospheres, eliminating the loading/unloading cycles inherent in batch processing. This continuous operation enables high-volume production with consistent quality control throughout the process
2Productivity
If rapid processing is implemented, then productivity increases, but control over atmospheric conditions becomes more difficult
Solution Approach 1:
The furnace is divided into multiple sealed zones, each with independent atmospheric control systems. This segmentation allows each zone to maintain precise atmospheric conditions (oxidizing, reducing, or inert) simultaneously, even as material moves rapidly through the system. Each zone's atmosphere is controlled independently through separate gas injection and flow management systems
Solution Approach 2:
The patent incorporates sensors and control systems that continuously monitor atmospheric conditions (oxygen partial pressure, temperature, gas composition) in each furnace zone. Real-time feedback control adjusts gas flow rates and heating power to maintain desired atmospheric conditions despite rapid material throughput, ensuring reliable process control at high speeds
3Adaptability or versatility
If thin film format is used, then device integration is improved, but sintering uniformity becomes more challenging
Solution Approach 1:
The patent employs localized heating zones with independently controlled temperature profiles tailored to the specific requirements of thin film sintering. The furnace provides enhanced temperature uniformity across the film surface through carefully designed heating element arrangements and atmospheric circulation patterns, ensuring consistent sintering throughout the thin film structure while accommodating various device integration configurations
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
The CML enables high-quality, rapidly processed ceramic electrolyte films with low flatness and retention of stoichiometric lithium in lithium-stuffed garnet, achieving high density and small grain size, and allowing for faster processing times compared to known methods.
Implementation Method 1
a sintering section
Implementation Method 2
at least one sealed furnace, between the front roller and the end roller, wherein the at least one furnace comprises (a) a binder burn-out section; (b) a bisque section; and (c) a sintering section
Implementation Method 3
at least one atmospheric controller which controls at least one condition in the furnace selected from the group consisting of gas flow rate, flow direction, gas composition, pressure
Data Source
AI summary
Provided herein are rapid, high quality film sintering processes that include high-throughput continuous sintering of lithium-lanthanum zirconium oxide (lithium-stuffed garnet). 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 lithium-lanthanum zirconium oxide 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).