| CPC H01M 10/0562 (2013.01) [C04B 35/62218 (2013.01); C04B 35/6264 (2013.01); C04B 35/62655 (2013.01); C04B 35/6268 (2013.01); C04B 41/0072 (2013.01); C04B 2235/6025 (2013.01); C04B 2235/606 (2013.01); C04B 2235/608 (2013.01); C04B 2235/658 (2013.01); C04B 2235/77 (2013.01)] | 17 Claims |
|
1. A process for making a high density green tape, the process comprising:
(a) providing a slurry comprising a source powder;
(b) mixing the slurry with a binder solution in a non-reactive environment;
(c) casting the slurry to form a green tape in a non-reactive environment; and
(d) drying the green tape in a non-reactive environment to achieve a geometric density greater than 2.9 g/ml; wherein the at least one source powder is selected from the group consisting of lithium-stuffed garnet, chemical precursors to lithium-stuffed garnet, and lithium-stuffed garnet with aluminum oxide dopants;
wherein at least one source has a particle size distribution d50 of 100 nm-200 nm, 200 nm-300 nm, 300 nm-400 nm, 400 nm-500 nm, 500 nm-600 nm, 600 nm-700 nm, 700 nm-800 nm, 800 nm-900 nm, 900 nm-1 μm, 1 μm-2 μm, or 2 μm-3 μm;
wherein the non-reactive environment comprises nitrogen gas or argon gas, or a combination thereof, and a humidity at −10° C. to −20° C., at −20° C. to −30° C., at −30° C. to −40° C., at −40° C. to −50° C., or at −50° C. to −60° C. dew point;
wherein the process further comprises milling at least one source powder in a non-reactive environment in an anhydrous aprotic solvent;
wherein the aprotic solvent is selected from the group consisting of: benzene, toluene, xylene, ethyl acetate, tetrahydrofuran, dioxane, and 1,2-dimethoxyethane; and
further comprising milling the source powder until the source powder has a particle size distribution d50 of 100 nm-200 nm, 200 nm-300 nm, 300 nm-400 nm, 400 nm-500 nm, 500 nm-600 nm, 600 nm-700 nm, or 700 nm-750 nm.
|