Patent ID: 7255961
Filing Date: 2007-08-14
Classification: B32B,B82Y,C04B,H01M,Y02E

Abstract:
1. A process for forming a three-layered thin film composite solid electrolyte comprising the steps of: (a) tape casting a series of sheets or films, each said sheet formed from one of at least two slip composites, each said slip composite containing an electrolyte where the electrolyte of each said slip composite has a coefficient of thermal expansion, said coefficient for each said electrolyte in each said slip composite is identical within +/−5%, wherein one of the said slip composites is formed with an added combustible pore former (a “Porous Material”) and another of said slip composites is formed without said pore former material (a “Non Porous Material”); (b) laminating said series of sheets to create a layered structure having at least three layers, where said series of layers alternate between layers formed from said Non-Porous Materials and layers formed from said Porous Materials; and (c) sintering said layered structure at a final sintering temperature to densify said layer formed from said Non Porous Materials to create an ionically conductive layer, whereas said final sintering temperature is about 1500-1600° C.