Lithium stuffed garnet setter plates for solid electrolyte fabrication
Setter plates are fabricated from Li-stuffed garnet materials having the same, or substantially similar, compositions as a garnet Li-stuffed solid electrolyte. The Li-stuffed garnet setter plates, set forth herein, reduce the evaporation of Li during a sintering treatment step and/or reduce the loss of Li caused by diffusion out of the sintering electrolyte. Li-stuffed garnet setter plates, set forth herein, maintain compositional control over the solid electrolyte during sintering when, upon heating, lithium is prone to diffuse out of the solid electrolyte.
1. A setter plate for fabricating solid electrolytes of a rechargeable battery, the setter plate comprising at least two members selected from the group consisting of Li 2 ZrO 3 , Li 2 SiO 3 , LiLaO 2 , LiAlO 2 , Li 2 O, Li 3 PO 4 , and a Li-stuffed garnet compound characterized by the formula Li A La B M′ c M″ D Zr E O F , wherein 4<A<8.5, 1.5<B<4, 0≤C≤2, 0≤D≤2; 0≤E<2, 10<F<13, and M′ and M″ are each, independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, and Ta;
a surface defined by a first lateral dimension from 1 cm to 96 cm and a second lateral dimension from 1 cm to 96 cm; and
a thickness from 0.1 mm to 100 mm.
2. The setter plate of claim 1 , wherein the first lateral dimension is from 3 cm to 30 cm and the second lateral dimension is from 3 cm to 30 cm.
3. The setter plate of claim 1 , wherein the thickness is from 0.1 mm to 10 mm.
4. The setter plate of claim 1 , wherein the surface has a surface roughness from 1.0 μm Ra to 4 μm Ra, wherein Ra is an arithmetic average of absolute values of sampled surface roughness amplitudes.
5. The setter plate of claim 1 , having a flatness of between 0.1 μm and 100 μm.
6. The setter plate of claim 1 , having a flatness of between 0.5 μm and 20 μm.
7. A setter plate used for fabricating solid electrolytes of a rechargeable battery, the setter plate comprising:
an oxide material with lithium concentration greater than 0.02 mol/cm 3 and a melting point above 1100° C.;
a surface defined by a first lateral dimension from 3 cm to 30 cm and a second lateral dimension from 3 cm to 30 cm; and
a thickness from 0.1 mm to 100 mm,
wherein the oxide material comprises at least two members selected from the group consisting of Li 2 ZrO 3 , LiLaO 2 , LiAlO 2 , Li 2 O, Li 3 PO 4 , and a Li-stuffed garnet compound characterized by the formula Li A La B M′ c M″ D Zr E O F , wherein 4<A<8.5, 1.5<B<4, 0≤C≤2, 0≤D≤2; 0≤E<2, 10<F<13, and M′ and M″ are each, independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, and Ta.
8. The setter plate of claim 7 , wherein the oxide material comprises LiLaO 2 .
9. The setter plate of claim 7 , wherein the oxide material further comprises Al 2 O 3 .
10. The setter plate of claim 7 , wherein the oxide material further comprises ZrO 2 .
11. The setter plate of claim 7 , wherein the oxide material further comprises La 2 O 3 .
12. The setter plate of claim 7 , wherein the oxide material comprises LiAlO 2 .
13. The setter plate of claim 7 , wherein the oxide material comprises Li 2 O.
14. The setter plate of claim 7 , wherein the oxide material comprises Li 3 PO 4 .
15. The setter plate of claim 7 , wherein the oxide material comprises at least two members selected from the group consisting of LiLaO 2 , LiAlO 2 , Li 2 O, Li 3 PO 4 , a Li-stuffed garnet compound characterized by the formula Li x La y Zr z O t .qAl 2 O 3 , wherein 4<x<10, 1<y<4, 1<z<3, 6<t<14, 0<q<1, and a combination thereof.
16. The setter plate of claim 1 , wherein the setter plate comprises a Li-stuffed garnet compound characterized by the formula Li A La B M′ c M″ D Zr E O F , wherein 4<A<8.5, 1.5<B<4, 0≤C≤2, 0≤D≤2; 0≤E<2, 10<F<13, and M′ and M″ are each, independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, and Ta.
17. The setter plate of claim 7 , wherein the setter plate comprises a Li-stuffed garnet compound characterized by the formula Li A La B M′ c M″ D Zr E O F , wherein 4<A<8.5, 1.5<B<4, 0≤C≤2, 0≤D≤2; 0≤E<2, 10<F<13, and M′ and M″ are each, independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, and Ta.