Patents by Inventor Michael Edward Badding

Michael Edward Badding has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11469446
    Abstract: The disclosure relates to ceramic lithium ion electrolyte membranes and processes for forming them. The ceramic lithium electrolyte membrane may comprise at least one ablative edge. Exemplary processes for forming the ceramic lithium ion electrolyte membranes comprise fabricating a lithium ion electrolyte sheet and cutting at least one edge of the fabricated electrolyte sheet with an ablative laser.
    Type: Grant
    Filed: October 22, 2020
    Date of Patent: October 11, 2022
    Assignee: Corning Incorporated
    Inventors: Michael Edward Badding, Indrajit Dutta, Lanrik Wayne Kester, Xinghua Li
  • Publication number: 20220320576
    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.
    Type: Application
    Filed: June 20, 2022
    Publication date: October 6, 2022
    Inventors: Bruce Gardiner Aitken, Michael Edward Badding, George Halsey Beall, Curtis Robert Fekety, Lanrik Wayne Kester, Robert Michael Morena, Zhen Song
  • Publication number: 20220297344
    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.
    Type: Application
    Filed: May 6, 2022
    Publication date: September 22, 2022
    Inventors: Michael Edward Badding, William Joseph Bouton, Lanrik Wayne Kester, Thomas Dale Ketcham, Andrew Peter Kittleson, Dale Charles Marshall, Gary Edward Merz, Eric Lee Miller, Emmanuel Chima Okpara, Conor James Walsh
  • Publication number: 20220278364
    Abstract: Electrolyte for a solid-state battery includes a body having grains of inorganic material sintered to one another, where the grains include lithium. The body is thin, has little porosity by volume, and has high ionic conductivity.
    Type: Application
    Filed: May 19, 2022
    Publication date: September 1, 2022
    Inventors: Michael Edward Badding, Jacqueline Leslie Brown, Jennifer Anella Heine, Thomas Dale Ketcham, Gary Edward Merz, Eric Lee Miller, Zhen Song, Cameron Wayne Tanner, Conor James Walsh
  • Publication number: 20220255208
    Abstract: The THz waveguides disclosed herein are used to transmit signals having a THz frequency in the range from 0.1 THz to 10 THz and include an alumina core surrounded by an optional cladding. The core may have a diameter (D1) in the range from 10 ?m to 500 ?m and may be comprised of a ceramic ribbon having a dielectric constant (Dk). The optional cladding may have a dielectric constant (Dk) less than the core. The THz waveguides can be formed using a continuous firing process and nano-perforation technology that enables access to a wide form factor range. In one example, rectangular waveguides, or ribbons, may be fabricated in the 10 ?m to 200 ?m thick range at widths in the range from sub-millimeters to several meters and lengths in the range from millimeters to several hundred meters.
    Type: Application
    Filed: April 22, 2022
    Publication date: August 11, 2022
    Inventors: Michael Edward Badding, Ming-Jun Li, Karan Mehrotra, Cheng-Gang Zhuang
  • Patent number: 11411245
    Abstract: Electrolyte for a solid-state battery includes a body having grains of inorganic material sintered to one another, where the grains include lithium. The body is thin, has little porosity by volume, and has high ionic conductivity.
    Type: Grant
    Filed: August 7, 2019
    Date of Patent: August 9, 2022
    Assignee: Corning Incorporated
    Inventors: Michael Edward Badding, Zhen Song, Jacqueline Leslie Brown, Jennifer Anella Heine, Thomas Dale Ketcham, Gary Edward Merz, Eric Lee Miller, Cameron Wayne Tanner, Conor James Walsh
  • Publication number: 20220242742
    Abstract: A process of forming a sintered article includes heating a green portion of a tape of polycrystalline ceramic and/or minerals in organic binder at a binder removal zone to a temperature sufficient to pyrolyze the binder; horizontally conveying the portion of tape with organic binder removed from the binder removal zone to a sintering zone; and sintering polycrystalline ceramic and/or minerals of the portion of tape at the sintering zone, wherein the tape simultaneously extends through the removal and sintering zones.
    Type: Application
    Filed: April 12, 2022
    Publication date: August 4, 2022
    Inventors: Michael Edward Badding, William Joseph Bouton, Douglas Edward Brackley, Lanrik Wayne Kester, Thomas Dale Ketcham, Eric Lee Miller, Cameron Wayne Tanner, James William Zimmermann
  • Publication number: 20220209288
    Abstract: An air stable solid garnet composition, comprising: a bulk composition and a surface protonated composition on at least a portion of the bulk composition as defined herein, and the protonated surface composition is present on at least a portion of the exterior surface of the bulk composition at a thickness of from 0.1 to 10,000 nm. Also disclosed is a composite electrolyte structure, and methods of making and using the composition and the composite electrolyte structure.
    Type: Application
    Filed: March 17, 2022
    Publication date: June 30, 2022
    Inventors: Michael Edward Badding, Xinyuan Liu, Yanxia Ann Lu
  • Publication number: 20220209289
    Abstract: An air stable solid garnet composition, comprising: a bulk composition and a surface protonated composition on at least a portion of the bulk composition as defined herein, and the protonated surface composition is present on at least a portion of the exterior surface of the bulk composition at a thickness of from 0.1 to 10,000 nm. Also disclosed is a composite electrolyte structure, and methods of making and using the composition and the composite electrolyte structure.
    Type: Application
    Filed: March 17, 2022
    Publication date: June 30, 2022
    Inventors: Michael Edward Badding, Xinyuan Liu, Yanxia Ann Lu
  • Publication number: 20220181628
    Abstract: A lithium-sulfur battery includes a substrate; a sulfur cathode disposed on the substrate; a coating layer disposed on the cathode; a first interlayer disposed on the coating layer; a solid-state electrolyte disposed on the first interlayer; a second interlayer disposed on the electrolyte; and a lithium anode disposed on the second interlayer, such that the coating layer is further disposed within pores of the cathode.
    Type: Application
    Filed: April 14, 2020
    Publication date: June 9, 2022
    Inventors: Michael Edward Badding, Jun Jin, Zhen Song, Jianing Wang, Zhaoyin Wen, Tongping Xiu
  • Patent number: 11351697
    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.
    Type: Grant
    Filed: October 2, 2019
    Date of Patent: June 7, 2022
    Assignee: Corning Incorporated
    Inventors: Michael Edward Badding, William Joseph Bouton, Lanrik Wayne Kester, Thomas Dale Ketcham, Andrew Peter Kittleson, Dale Charles Marshall, Gary Edward Merz, Eric Lee Miller, Emmanuel Chima Okpara, Conor James Walsh
  • Patent number: 11342649
    Abstract: The THz waveguides disclosed herein are used to transmit signals having a THz frequency in the range from 0.1 THz to 10 THz and include an alumina core surrounded by an optional cladding. The core may have a diameter (D1) in the range from 10 ?m to 500 ?m and may be comprised of a ceramic ribbon having a dielectric constant (Dk). The optional cladding may have a dielectric constant (Dk) less than the core. The THz waveguides can be formed using a continuous firing process and nano-perforation technology that enables access to a wide form factor range. In one example, rectangular waveguides, or ribbons, may be fabricated in the 10 ?m to 200 ?m thick range at widths in the range from sub-millimeters to several meters and lengths in the range from millimeters to several hundred meters.
    Type: Grant
    Filed: August 25, 2020
    Date of Patent: May 24, 2022
    Assignee: Corning Incorporated
    Inventors: Michael Edward Badding, Ming-Jun Li, Karan Mehrotra, Cheng-Gang Zhuang
  • Publication number: 20220149369
    Abstract: An energy device has an electrode including lithium cobaltite (LCO) grains, where the LCO grains are sintered to one another forming a self-supporting sheet with porous passages. The porous passages wind and branch through the sheet. The energy device further includes a solid electrolyte comprising lithium phosphosulfide (LPS) overlaying a major surface of the sheet and extending into the porous passages. The sheet serves as mechanical support for the solid electrolyte, allowing for high temperature joining of the LPS to the LCO without binder in the LPS.
    Type: Application
    Filed: January 26, 2022
    Publication date: May 12, 2022
    Inventors: Michael Edward Badding, Ryan David Bayliss, Jennifer Anella Heine, Cameron Wayne Tanner
  • Patent number: 11325837
    Abstract: A process of forming a sintered article includes heating a green portion of a tape of polycrystalline ceramic and/or minerals in organic binder at a binder removal zone to a temperature sufficient to pyrolyze the binder; horizontally conveying the portion of tape with organic binder removed from the binder removal zone to a sintering zone; and sintering polycrystalline ceramic and/or minerals of the portion of tape at the sintering zone, wherein the tape simultaneously extends through the removal and sintering zones.
    Type: Grant
    Filed: August 19, 2021
    Date of Patent: May 10, 2022
    Assignee: Corning Incorporated
    Inventors: Michael Edward Badding, William Joseph Bouton, Douglas Edward Brackley, Lanrik Wayne Kester, Thomas Dale Ketcham, Eric Lee Miller, Cameron Wayne Tanner, James William Zimmermann
  • Patent number: 11309581
    Abstract: An air stable solid garnet composition, comprising: a bulk composition and a surface protonated composition on at least a portion of the bulk composition as defined herein, and the protonated surface composition is present on at least a portion of the exterior surface of the bulk composition at a thickness of from 0.1 to 10,000 nm. Also disclosed is a composite electrolyte structure, and methods of making and using the composition and the composite electrolyte structure.
    Type: Grant
    Filed: January 7, 2019
    Date of Patent: April 19, 2022
    Assignee: Corning Incorporated
    Inventors: Michael Edward Badding, Xinyuan Liu, Yanxia Ann Lu
  • Patent number: 11296355
    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.
    Type: Grant
    Filed: April 13, 2018
    Date of Patent: April 5, 2022
    Assignees: Corning Incorporated, Shanghai Institute of Ceramics, Chinese Academy of Sciences
    Inventors: Michael Edward Badding, Yinghong Chen, Xiao Huang, Cai Liu, Xinyuan Liu, Yanxia Ann Lu, Zhen Song, Zhaoyin Wen, Tongping Xiu, Nathan Michael Zink
  • Patent number: 11276879
    Abstract: A solid electrolyte including: a lithium ion inorganic conductive layer; and an amorphous phase on a surface of the lithium ion inorganic conductive layer, wherein the amorphous phase is an irradiation product of the lithium ion inorganic conductive layer. Also, the method of preparing the same, and a lithium battery including the solid electrolyte.
    Type: Grant
    Filed: August 2, 2018
    Date of Patent: March 15, 2022
    Assignees: SAMSUNG ELECTRONICS CO., LTD., CORNING INCORPORATED
    Inventors: Jusik Kim, Michael Edward Badding, Hyunseok Kim, Zhen Song, Taehwan Yu
  • Patent number: 11271201
    Abstract: An energy device has an electrode including lithium cobaltite (LCO) grains, where the LCO grains are sintered to one another forming a self-supporting sheet with porous passages. The porous passages wind and branch through the sheet. The energy device further includes a solid electrolyte comprising lithium phosphosulfide (LPS) overlaying a major surface of the sheet and extending into the porous passages. The sheet serves as mechanical support for the solid electrolyte, allowing for high temperature joining of the LPS to the LCO without binder in the LPS.
    Type: Grant
    Filed: July 24, 2019
    Date of Patent: March 8, 2022
    Assignee: Corning Incorporated
    Inventors: Michael Edward Badding, Ryan David Bayliss, Jennifer Anella Heine, Cameron Wayne Tanner
  • Publication number: 20220045355
    Abstract: A sintered composite ceramic, including: a lithium-garnet major phase; and a grain growth inhibitor minor phase, such that the grain growth inhibitor minor phase has a metal oxide in a range of 0.1 wt. % to 10 wt. % based on the total weight of the sintered composite ceramic.
    Type: Application
    Filed: August 6, 2021
    Publication date: February 10, 2022
    Inventors: Michael Edward Badding, Yinghong Chen, Aaron David DeGeorge, Ying Shi, Zhen Song
  • Publication number: 20210408591
    Abstract: A battery includes a substrate; a composite cathode disposed on the substrate; a solid-state electrolyte disposed on the composite cathode; and a lithium anode disposed on the solid-state electrolyte, such that the composite cathode comprises a gel polymer electrolyte layer and a porous cathode active material layer. A method of forming a cathode for a solid-state battery includes mixing an active cathode material, at least one of a conductive carbon component and an electronic conductive component, and a polymer binder to form a slurry; immersing the slurry in an alcohol reagent to form a porous disc structure by phase conversion; and immersing the porous disc structure in a liquid electrolyte to form the cathode.
    Type: Application
    Filed: June 24, 2021
    Publication date: December 30, 2021
    Inventors: Michael Edward Badding, Mingli Cai, Jun Jin, Zhen Song, Zhaoyin Wen, Tongping Xiu, Liu Yao