Abstract: Solid lithium-ion ceramic electrolyte membranes have an average thickness of less than 200 micrometers. A constituent electrolyte material has an average grain size of less than 10 micrometers. The solid lithium-ion ceramic electrolyte is free-standing. Alternatively, solid lithium-ion electrolyte membranes have a composition represented by Li1+x?yMxM?2?x?yM??y(PO4)3, where M is a 3+ ion, M? is a 4+ ion, M?? is a 5+ ion, 0?x?2 and 0?y?2.

Abstract: Lithium-containing polycrystalline ceramic sheets include grains having an average grain size of less than 5 ?m, a relative density greater than 90%, and a thickness of up to 200 ?m. In aspects, the lithium-containing polycrystalline ceramic sheets include an outer edge of the sheet that has no height variations greater than 1 mm from baseline in a perimeter trace. In aspects, the lithium-containing polycrystalline ceramic sheets include microstructural features of an outer edge of the sheet are no greater than about ? the thickness of the sheet. In aspects, the lithium-containing polycrystalline ceramic sheets include an outer edge of the sheet that is enriched in lithium relative to a bulk of the sheet.

Abstract: A method of manufacturing ceramic tape includes a step of directing a tape of partially-sintered ceramic into a furnace. The tape is partially-sintered such that grains of the ceramic are fused to one another yet the tape still includes at least 10% porosity by volume, where the porosity refers to volume of the tape unoccupied by the ceramic. The method further includes steps of conveying the tape through the furnace and further sintering the tape as the tape is conveyed through the furnace. The porosity of the tape decreases during the further sintering step.

Abstract: A lithium-metal battery, includes: a substrate; a cathode disposed on the substrate; a garnet solid-state electrolyte disposed on the cathode; and a lithium anode disposed on the garnet solid-state electrolyte, such that a modification layer is disposed at an interface of the lithium anode and garnet solid-state electrolyte, the modification layer includes: a first portion; and a second portion, such that the first portion has a lithium component and the second portion has a garnet component. A method of forming a lithium-metal battery, includes: stacking a garnet source with at least one lithium source; and heating the stack at a temperature of at least 300° C. for a time in a range of 1 sec to 20 min to form a modification layer, such that the modification layer is disposed at an interface of the garnet source and the lithium source.

Abstract: An all-solid secondary battery including: a cathode layer including a cathode active material layer; an anode layer; and a solid electrolyte layer between the cathode layer and the anode layer, and the solid electrolyte layer including a solid electrolyte, wherein the anode layer includes an anode current collector, a first anode active material layer in contact with the solid electrolyte layer, and a second anode active material layer between the anode current collector and the first anode active material layer, wherein the first anode active material layer is a lithium-containing first metal layer, wherein the second anode active material layer includes a carbon-containing anode active material or a carbon-containing anode active material and a second metal, and wherein a surface of the solid electrolyte layer adjacent to the first anode active material layer has a porosity of 40 percent or less.

Abstract: A cathode configured for a solid-state battery includes a body having grains of inorganic material sintered to one another, wherein the grains comprise lithium. A thickness of the body is from 3 ?m to 100 ?m. The first major surface and the second major surface have an unpolished granular profile such that the profile includes grains protruding outward from the respective major surface with a height of at least 25 nm and no more than 150 ?m relative to recessed portions of the respective major surface at boundaries between the respective grains.

Abstract: A roll-to-roll sintering system for wide inorganic tape material may include a spool on which is wound a continuous tape material comprising a green tape material and a backing layer, a take-up reel, and a heating station including at least one furnace. The heating station is configured to receive an unwound length of the continuous tape. The heating station further includes a first curved section such that the continuous tape material is bent through a radius of curvature of 0.01 m to 13,000 m, and at least two rollers defining the first curved section over which the continuous tape material is bent. The heating station is controlled to provide at least a portion of the heating station with an air free atmosphere, that being at least one of vacuum, hydrogen, or helium.

Abstract: A cathode configured for a solid-state battery includes a body having grains of inorganic material sintered to one another, wherein the grains comprise lithium. A thickness of the body is from 3 ?m to 100 ?m. The first major surface and the second major surface have an unpolished granular profile such that the profile includes grains protruding outward from the respective major surface with a height of at least 25 nm and no more than 150 ?m relative to recessed portions of the respective major surface at boundaries between the respective grains.

Abstract: A composite ceramic including: a lithium garnet major phase; and a grain growth inhibitor minor phase, as defined herein. Also disclosed is a method of making composite ceramic, pellets and tapes thereof, a solid electrolyte, and an electrochemical device including the solid electrolyte, as defined herein.

Abstract: A method of manufacturing ceramic tape includes a step of directing a tape of partially-sintered ceramic into a furnace. The tape is partially-sintered such that grains of the ceramic are fused to one another yet the tape still includes at least 10% porosity by volume, where the porosity refers to volume of the tape unoccupied by the ceramic. The method further includes steps of conveying the tape through the furnace and further sintering the tape as the tape is conveyed through the furnace. The porosity of the tape decreases during the further sintering step.

Abstract: A manufacturing system includes a tape advancing through the manufacturing system and a station of the manufacturing system. The tape includes a first portion having grains of an inorganic material bound by an organic binder. The station of the manufacturing system receives the first portion of the tape and prepares the tape for sintering by chemically changing the organic binder and/or removing the organic binder from the first portion of the tape, leaving the grains of the inorganic material, to form a second portion of the tape and, at least in part, prepare the tape for sintering.

Abstract: A cathode for a lithium-sulfur battery includes a sulfur-based composite layer having a porosity in a range of 60% to 99%; and a conductive polymer disposed atop the composite layer and within pores of the composite layer. Moreover, a method of forming a cathode for a lithium-sulfur battery includes providing a substrate; disposing a sulfur-based slurry layer on the substrate; freeze-drying the slurry layer to form a sulfur-based composite layer having a porosity in a range of 60% to 99%; and disposing a conductive polymer atop the composite layer and within pores of the composite layer.

Abstract: A cathode configured for a solid-state battery includes a body having grains of inorganic material sintered to one another, wherein the grains comprise lithium. A thickness of the body is from 3 ?m to 100 ?m. The first major surface and the second major surface have an unpolished granular profile such that the profile includes grains protruding outward from the respective major surface with a height of at least 25 nm and no more than 150 ?m relative to recessed portions of the respective major surface at boundaries between the respective grains.

Abstract: Passivated Li7La3Zr2O12 (LLZO) particles, tape casting powders and slip compositions including the particles, methods of forming the particles, methods of tape casting using the particles, green tapes including the particles, cast LLZO films formed from the particles, and lithium batteries including the cast LLZO film. A passivated LLZO particle includes an LLZO core, wherein the LLZO is optionally doped with one or more elements. The passivated LLZO particle also includes a shell including H-LLZO, H3O+-LLZO, and/or Li2CO3.

Abstract: A method of manufacturing ceramic tape includes a step of directing a tape of partially-sintered ceramic into a furnace. The tape is partially-sintered such that grains of the ceramic are fused to one another yet the tape still includes at least 10% porosity by volume, where the porosity refers to volume of the tape unoccupied by the ceramic. The method further includes steps of conveying the tape through the furnace and further sintering the tape as the tape is conveyed through the furnace. The porosity of the tape decreases during the further sintering step.

Abstract: A solid electrolyte including an inorganic lithium ion conductive film and a porous layer on a surface of the inorganic lithium ion conductive film, wherein the porous layer includes a first porous layer and a second porous layer, and the second porous layer is disposed between the inorganic lithium ion conductive film and the first porous layer, and wherein the first porous layer has a size greater which is than a pore size of the second porous layer.

Abstract: Batteries include a cathode, a solid-state electrolyte, and an anode. In aspects, the anode comprises an alloy including from about 50 atom % to about 90 atom % lithium, from about 5 atom % to about 50 atom % of a first component, and from about 0.1 atom % to about 10 atom % of a second component. In aspects, the anode includes from about 20 atom % to about 99 atom % of a first component and from about 1 atom % to about 20 atom % of a second component. The first component is selected from a group consisting of magnesium, silver, and combinations thereof. The second component is selected from a group consisting of calcium, aluminum, gallium, boron, carbon, silicon, tin, zinc, indium, antimony, silver, and combinations thereof. An amount of the first component is greater than an amount of the second component. The solid-state electrolyte is positioned between the cathode and the anode.

Abstract: Batteries include a current collector, a cathode, an interlayer disposed on the cathode, a solid-state electrolyte disposed on the interlayer, and a lithium anode disposed on the solid-state electrolyte. In aspects, the interlayer includes a lithium salt and a sulfone compound within a polymeric matrix. In aspects, the interlayer includes a lithium salt and a sulfone compound. In aspects, methods of forming a battery comprise disposing a precursor solution comprising a lithium salt, a sulfone compound, and a monomer on a first major surface of a cathode. Methods can further include curing the precursor solution to form an interlayer including the lithium salt and the sulfone compound within a polymeric matrix. In aspects, methods can include disposing a lithium salt and a sulfone compound on a first major surface of a cathode. Methods further include disposing a solid-state electrolyte over the first major surface of the cathode.

Abstract: Batteries include a cathode, an interlayer disposed on the cathode, a solid-state electrolyte disposed on the interlayer, and a lithium anode disposed on the solid-state electrolyte. The interlayer includes a deep-eutectic-solvent-based electrolyte including a lithium salt and a sulfone compound. Methods of forming a battery comprising disposing a deep-eutectic-solvent-based electrolyte comprising a lithium salt and a sulfone compound on a first major surface of a cathode. Methods further comprising disposing a solid-state electrolyte over the first major surface of the cathode. The deep-eutectic-solvent-based electrolyte is positioned between the cathode and the solid-state electrolyte.

Abstract: A manufacturing system includes a tape advancing through the manufacturing system and a station of the manufacturing system. The tape includes a first portion having grains of an inorganic material bound by an organic binder. The station of the manufacturing system receives the first portion of the tape and prepares the tape for sintering by chemically changing the organic binder and/or removing the organic binder from the first portion of the tape, leaving the grains of the inorganic material, to form a second portion of the tape and, at least in part, prepare the tape for sintering.