US 11,728,517 B2
Hybrid solid-state cell with a 3D porous cathode structure
Steven Zhichao Shi, Santa Clara, CA (US); and Philip Eugene Rogren, Half Moon Bay, CA (US)
Assigned to Sakuu Corporation, San Jose, CA (US)
Filed by Sakuu Corporation, San Jose, CA (US)
Filed on Nov. 8, 2022, as Appl. No. 17/983,047.
Application 17/983,047 is a division of application No. 17/515,348, filed on Oct. 29, 2021, granted, now 11,527,779.
Application 16/702,417 is a division of application No. 16/262,058, filed on Jan. 30, 2019, granted, now 10,535,900, issued on Jan. 14, 2020.
Application 17/515,348 is a continuation in part of application No. 17/179,719, filed on Feb. 19, 2021, granted, now 11,165,101, issued on Nov. 2, 2021.
Application 17/179,719 is a continuation of application No. 16/898,126, filed on Jun. 10, 2020, granted, now 10,971,760, issued on Apr. 6, 2021.
Application 16/898,126 is a continuation in part of application No. 16/702,417, filed on Dec. 3, 2019, abandoned.
Claims priority of provisional application 62/624,476, filed on Jan. 31, 2018.
Prior Publication US 2023/0055465 A1, Feb. 23, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. H01M 10/0585 (2010.01); H01M 10/052 (2010.01); H01M 10/0562 (2010.01); B29C 64/106 (2017.01); H01M 4/64 (2006.01); B33Y 80/00 (2015.01); H01M 50/30 (2021.01); H01M 50/183 (2021.01); H01M 4/66 (2006.01); H01M 4/62 (2006.01); H01M 4/04 (2006.01)
CPC H01M 10/0585 (2013.01) [B29C 64/106 (2017.08); B33Y 80/00 (2014.12); H01M 4/0402 (2013.01); H01M 4/0416 (2013.01); H01M 4/0471 (2013.01); H01M 4/62 (2013.01); H01M 4/624 (2013.01); H01M 4/625 (2013.01); H01M 4/626 (2013.01); H01M 4/64 (2013.01); H01M 4/661 (2013.01); H01M 4/663 (2013.01); H01M 4/664 (2013.01); H01M 4/666 (2013.01); H01M 10/052 (2013.01); H01M 10/0562 (2013.01); H01M 50/183 (2021.01); H01M 50/30 (2021.01); H01M 50/394 (2021.01); H01M 2300/0068 (2013.01)] 27 Claims
OG exemplary drawing
 
1. A method for forming a 3D porous cathode structure for an electrochemical cell including a cathode, an anode, an electrolyte separator, comprised of a ceramic material, located between the cathode and anode, and a cathode current collector, wherein the cathode comprising the 3D porous cathode structure is located between the cathode current collector and the electrolyte separator, the method comprising:
mixing a first precursor material and a second precursor material together to form a mixture;
depositing the mixture as a layer where the cathode is to be formed; and
sintering the mixture to form the 3D porous cathode structure with ionically conducting electrolyte strands extending through the cathode from the cathode current collector to the electrolyte separator, pores extending through the cathode from the cathode current collector to the electrolyte separator, and an electronically conducting network extending on sidewall surfaces of the pores from the cathode current collector to the electrolyte separator,
wherein the second precursor material is a sacrificial material configured to decompose during formation of the pores by the sintering using the second precursor material, and the first precursor material is a material which forms a coating of the electronically conducting network on the sidewall surfaces of the pores formed by sintering the second precursor material.