Set forth herein are garnet material compositions, e.g., lithium-stuffed garnets and lithium-stuffed garnets doped with alumina, which are suitable for use as electrolytes and catholytes in solid state battery applications. Also set forth herein are lithium-stuffed garnet thin films having fine grains therein. Disclosed herein are novel and inventive methods of making and using lithium-stuffed garnets as catholytes, electrolytes and/or anolytes for all solid state lithium rechargeable batteries. Also disclosed herein are novel electrochemical devices which incorporate these garnet catholytes, electrolytes and/or anolytes. Also set forth herein are methods for preparing novel structures, including dense thin (<50 um) free standing membranes of an ionically conducting material for use as a catholyte, electrolyte, and, or, anolyte, in an electrochemical device, a battery component (positive or negative electrode materials), or a complete solid state electrochemical energy storage device. Also, the methods set forth herein disclose novel sintering techniques, e.g., for heating and/or field assisted (FAST) sintering, for solid state energy storage devices and the components thereof.

Set forth herein are garnet material compositions, e.g., lithium-stuffed garnets and lithium-stuffed garnets doped with alumina, which are suitable for use as electrolytes and catholytes in solid state battery applications. Also set forth herein are lithium-stuffed garnet thin films having fine grains therein. Disclosed herein are novel and inventive methods of making and using lithium-stuffed garnets as catholytes, electrolytes and/or anolytes for all solid state lithium rechargeable batteries. Also disclosed herein are novel electrochemical devices which incorporate these garnet catholytes, electrolytes and/or anolytes. Also set forth herein are methods for preparing novel structures, including dense thin (<50 um) free standing membranes of an ionically conducting material for use as a catholyte, electrolyte, and, or, anolyte, in an electrochemical device, a battery component (positive or negative electrode materials), or a complete solid state electrochemical energy storage device. Also, the methods set forth herein disclose novel sintering techniques, e.g., for heating and/or field assisted (FAST) sintering, for solid state energy storage devices and the components thereof.

Set forth herein are garnet material compositions, e.g., lithium-stuffed garnets and lithium-stuffed garnets doped with alumina, which are suitable for use as electrolytes and catholytes in solid state battery applications. Also set forth herein are lithium-stuffed garnet thin films having fine grains therein. Disclosed herein are novel and inventive methods of making and using lithium-stuffed garnets as catholytes, electrolytes and/or anolytes for all solid state lithium rechargeable batteries. Also disclosed herein are novel electrochemical devices which incorporate these garnet catholytes, electrolytes and/or anolytes. Also set forth herein are methods for preparing novel structures, including dense thin (<50 um) free standing membranes of an ionically conducting material for use as a catholyte, electrolyte, and, or, anolyte, in an electrochemical device, a battery component (positive or negative electrode materials), or a complete solid state electrochemical energy storage device. Also, the methods set forth herein disclose novel sintering techniques, e.g., for heating and/or field assisted (FAST) sintering, for solid state energy storage devices and the components thereof.

The present disclosure relates to solid-state electrolytes and methods of making the same. The method includes admixing a sulfate precursor including one or more of Li.sub.2SO.sub.4 and Li.sub.2SO.sub.4.H.sub.2O with one or more carbonaceous capacitor materials. The first admixture is calcined to form an electrolyte precursor that is admixed with one or more additional components to form the solid-state electrolyte. When a ratio of the sulfate precursor to the one or more carbonaceous capacitor materials in the first admixture is about 1:2, the electrolyte precursor consists essentially of Li.sub.2S. When a ratio of the sulfate precursor to the one or more carbonaceous capacitor materials in the first admixture is less than about 1:2, the electrolyte precursor is a composite precursor including a solid-state capacitor cluster including the one or more carbonaceous capacitor materials and a sulfide coating including Li.sub.2S disposed on one or more exposed surfaces of the solid-state capacitor cluster.

Set forth herein are garnet material compositions, e.g., lithium-stuffed garnets and lithium-stuffed garnets doped with alumina, which are suitable for use as electrolytes and catholytes in solid state battery applications. Also set forth herein are lithium-stuffed garnet thin films having fine grains therein. Disclosed herein are novel and inventive methods of making and using lithium-stuffed garnets as catholytes, electrolytes and/or anolytes for all solid state lithium rechargeable batteries. Also disclosed herein are novel electrochemical devices which incorporate these garnet catholytes, electrolytes and/or anolytes. Also set forth herein are methods for preparing novel structures, including dense thin (<50 um) free standing membranes of an ionically conducting material for use as a catholyte, electrolyte, and, or, anolyte, in an electrochemical device, a battery component (positive or negative electrode materials), or a complete solid state electrochemical energy storage device. Also, the methods set forth herein disclose novel sintering techniques, e.g., for heating and/or field assisted (FAST) sintering, for solid state energy storage devices and the components thereof.

Set forth herein are garnet material compositions, e.g., lithium-stuffed garnets and lithium-stuffed garnets doped with alumina, which are suitable for use as electrolytes and catholytes in solid state battery applications. Also set forth herein are lithium-stuffed garnet thin films having fine grains therein. Disclosed herein are novel and inventive methods of making and using lithium-stuffed garnets as catholytes, electrolytes and/or anolytes for all solid state lithium rechargeable batteries. Also disclosed herein are novel electrochemical devices which incorporate these garnet catholytes, electrolytes and/or anolytes. Also set forth herein are methods for preparing novel structures, including dense thin (<50 um) free standing membranes of an ionically conducting material for use as a catholyte, electrolyte, and, or, anolyte, in an electrochemical device, a battery component (positive or negative electrode materials), or a complete solid state electrochemical energy storage device. Also, the methods set forth herein disclose novel sintering techniques, e.g., for heating and/or field assisted (FAST) sintering, for solid state energy storage devices and the components thereof.

Methods for producing ceramic films Yttria Stabilized Zirconia (3YSZ) and aluminum titanate (Al.sub.2TiO.sub.5), and the physical properties of these films are described. The films produced have thicknesses and integrity suitable for handling and corrosion resistance to electrolytes, porosity, ion permeability and electrical resistivity suitable for use as separators between positive and negative layers for forming electrical batteries, particularly lithium batteries.

The present invention provides a sequential and efficient method of assembling a battery with a desired number of layers while reliably separating positive and negative electrode sides from each other with one or more separator structures. According to the invention, the method of assembling a battery includes stacking one or multiple combinations each comprising a frame and a positive electrode plate to be disposed in a region defined by the frame and one or multiple combinations each comprising a frame and a negative electrode plate to be disposed in a region defined by the frame, once or alternately, such that the positive and adjacent negative electrode plates are separated from each other by a separator structure and the periphery of the separator structure is held between the adjacent frames. The separator structure includes a separator exhibiting hydroxide ion conductivity and water impermeability.

A metal-ion battery cell is provided that comprises anode and cathode electrodes, a separator, and an electrolyte. The anode electrode may, for example, have a capacity loading in the range of about 2 mAh/cm2 to about 10 mAh/cm2 and comprise anode particles that (i) have an average particle size in the range of about 0.2 microns to about 40 microns, (ii) exhibit a volume expansion in the range of about 8 vol. % to about 180 vol. % during one or more charge-discharge cycles of the battery cell, and (iii) exhibit a specific capacity in the range of about 600 mAh/g to about 2600 mAh/g. The electrolyte may comprise, for example, (i) one or more metal-ion salts and (ii) a solvent composition that comprises one or more low-melting point solvents that each have a melting point below about −70° C. and a boiling point above about +70° C.

A metal-ion battery cell is provided that comprises anode and cathode electrodes, a separator, and an electrolyte. The anode electrode may, for example, have a capacity loading in the range of about 2 mAh/cm2 to about 10 mAh/cm2 and comprise anode particles that (i) have an average particle size in the range of about 0.2 microns to about 40 microns, (ii) exhibit a volume expansion in the range of about 8 vol. % to about 180 vol. % during one or more charge-discharge cycles of the battery cell, and (iii) exhibit a specific capacity in the range of about 600 mAh/g to about 2600 mAh/g. The electrolyte may comprise, for example, (i) one or more metal-ion salts and (ii) a solvent composition that comprises one or more low-melting point solvents that each have a melting point below about −70° C. and a boiling point above about +70° C.