US 11,942,622 B2
Methods of fabricating porous ceramic electrodes for solid state battery applications
Michael Tucker, Piedmont, CA (US); and Fengyu Shen, San Leandro, CA (US)
Assigned to THE REGENTS OF THE UNIVERSITY OF CALIFORNIA, Oakland, CA (US)
Filed by THE REGENTS OF THE UNIVERSITY OF CALIFORNIA, Oakland, CA (US)
Filed on Sep. 17, 2021, as Appl. No. 17/478,509.
Claims priority of provisional application 63/080,169, filed on Sep. 18, 2020.
Prior Publication US 2022/0093904 A1, Mar. 24, 2022
Int. Cl. H01M 4/131 (2010.01); H01M 4/66 (2006.01); H01M 4/80 (2006.01); H01M 10/058 (2010.01)
CPC H01M 4/131 (2013.01) [H01M 4/664 (2013.01); H01M 4/801 (2013.01); H01M 10/058 (2013.01)] 4 Claims
OG exemplary drawing
 
1. A method of forming a porous tape structure, the method comprising:
(a) forming a slurry of LLZO powder, a binder and a solvent;
(b) tape casting the slurry on a substrate to form a LLZO tape;
(c) applying a sacrificial layer on the LLZO tape to produce a bi-layered LLZO tape;
(d) immersing the bi-layered LLZO tape in water to induce solvent/water exchange;
(e) removing the bi-layered LLZO tape from the water and drying the bi-layered LLZO tape; and
(f) heating the bi-layered LLZO tape to remove the sacrificial layer and sinter the LLZO tape to produce a sintered LLZO tape;
(g) wherein a sintered LLZO tape with elongate pores with a length aligned perpendicularly to a top surface of the sintered LLZO tape is produced;
(h) wherein the water for solvent/water exchange further comprises a lithium salt selected from the group consisting of Li2CO3, LiCl, LiOH, LiNO3 and Li2SO4; and
(i) wherein lithium loss from solid materials during solvent exchange is inhibited.