Method for Producing Ceramic Cathode Layers on Current Collectors

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This patent describes a novel method for producing ceramic cathode layers, particularly for use in lithium-ion batteries. The method involves applying a suspension containing ceramic materials onto an electrically conductive substrate, followed by a controlled heating process in reducing and oxidizing atmospheres. This process allows for the formation, densification (sintering), and reoxidation of the ceramic layer, ultimately resulting in a carbon-free, fully ceramic cathode with tunable thickness and composition, suitable for high-performance batteries.

Use CasesContent extracted from patent full text and abstract with AI.

• Manufacturing of advanced lithium-ion batteries with ceramic cathodes for mobile phones, laptops, and electric vehicles.
• Production of solid-state batteries with improved safety and performance.
• Application in energy storage systems for renewable energy integration.
• Development of high-capacity batteries for medical devices and aerospace applications.
• Use in manufacturing ceramic components with tailored properties for other electronic applications.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables production of thick, fully ceramic cathode layers without carbon additives, improving cycle life and thermal stability.
• Allows flexible control over the cathode layer thickness and composition, enhancing design options.
• Improves battery safety by reducing flammable organic materials and increasing temperature stability.
• Facilitates higher achievable current densities and storage capacities through composite electrode designs.
• Simplifies manufacturing by allowing use of common coating techniques and adaptable to various substrates.
• Reduces degradation and capacity loss of batteries thanks to improved material stability and interface quality.

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Patent Abstract

The invention relates to a method for producing a ceramic cathode layer on an electrically conducting substrate, in which first a coating in the form of a suspension, comprising at least one suspending agent and at least one ceramic material, is applied to this electrically conducting substrate. This is followed by heating the coating in a reducing atmosphere such that the ceramic material is fully or partially reduced to a fusible reaction product. After that, the coating is heated in a reducing atmosphere to temperatures above the melting point of the reaction product, thereby forming a molten substance. This is followed by densifying or sintering of the coating in a reducing atmosphere at temperatures that lie 100°C above the melting temperature of the reaction product. A reoxidation of the densified or sintered coating subsequently takes place in an oxidizing atmosphere in a temperature range between 400 and 1200°C, wherein the reaction product is oxidized again and reacts again into the original composition of the ceramic material used.