Stationary semi-solid battery module and method of manufacture

Patent metadata

Field	Value
Publication number	US-10566603-B2
Application number	US-201514926760-A
Country	US
Kind code	B2
Filing date	Oct 29, 2015
Priority date	Sep 7, 2011
Publication date	Feb 18, 2020
Grant date	Feb 18, 2020

Abstract

A method of manufacturing an electrochemical cell includes transferring an anode semi-solid suspension to an anode compartment defined at least in part by an anode current collector and an separator spaced apart from the anode collector. The method also includes transferring a cathode semi-solid suspension to a cathode compartment defined at least in part by a cathode current collector and the separator spaced apart from the cathode collector. The transferring of the anode semi-solid suspension to the anode compartment and the cathode semi-solid to the cathode compartment is such that a difference between a minimum distance and a maximum distance between the anode current collector and the separator is maintained within a predetermined tolerance. The method includes sealing the anode compartment and the cathode compartment.

First claim

The invention claimed is:

1. A method of forming an electrode, the method comprising:
receiving, at an extruder and from a reservoir, a flow of an electrode material;
disposing a support structure on a surface of a substantially planar current collector, wherein the support structure is configured to provide mechanical support of the electrode material during transfer of the electrode material;
transferring the electrode material, via an opening of the extruder, to a surface of the substantially planar current collector,
moving the extruder from a first position to a second position relative to the substantially planar current collector; and
removing a portion of the electrode material to form the electrode.

2. The method of claim 1 , wherein the support structure defines an opening configured to receive the electrode material.

3. The method of claim 2 , wherein the support structure is configured to direct a flow of the electrode material.

4. The method of claim 1 , wherein the transferring the electrode material is in a direction that is normal to the surface of the current collector.

5. The method of claim 1 , wherein the opening of the extruder is at least one of a hanger die sheet extrusion die, a winter manifold sheet extrusion die, and a profile-style sheet extrusion die.

6. The method of claim 1 , wherein the extruder includes a plurality of conduits.

7. The method of claim 1 , further comprising: applying pressure to the electrode material during transferring of the electrode material.

8. The method of claim 1 , wherein the electrode material is gravity-fed during transferring of the electrode material.

9. The method of claim 1 , wherein the extruder is at least one of heated and vibrated during transferring of the electrode material.

10. The method of claim 1 , wherein the opening of the extruder has a shape that corresponds to a geometry of the electrode.

11. The method of claim 1 , wherein the electrode material is a mixture that includes an active material, a conductive material and an electrolyte.

12. The method of claim 1 , wherein the extruder is monolithically formed.

13. A method of forming an electrode, the method comprising:
receiving, at an injection tool and from a reservoir, an electrode material;
disposing a support structure on a surface of a substantially planar current collector, the support structure and the substantially planar current collector at least partially defining a cavity, wherein the support structure is configured to provide mechanical support of the electrode material during flow of the electrode material;
placing a nozzle of the injection tool at least partially into the cavity;
flowing the electrode material, via the nozzle of the injection tool, onto a surface of the substantially planar current collector to define an electrode; and
mechanically post-processing the electrode to make the electrode uniform.

14. The method of claim 13 , wherein the electrode material comprises a substantially uniform suspension.

15. The method of claim 13 , wherein the electrode material comprises a slurry.

16. The method of claim 13 , wherein the nozzle comprises a slot.

17. The method of claim 13 , further comprising:
moving the injection tool from a first position to a second position relative to the substantially planar current collector.

18. A method of forming an electrode, the method comprising:
receiving, at an injection tool and from a reservoir, an electrode material;
disposing a support structure on a surface of a substantially planar current collector, wherein the support structure is configured to provide mechanical support of the electrode material during discharge of the electrode material;
discharging the electrode material, via a movable nozzle of the injection tool, onto a surface of substantially planar current collector to define an electrode
moving the injection tool from a first position to a second position relative to the substantially planar current collector; and
subsequently removing a portion of the electrode.

19. The method of claim 18 , further comprising flowing the electrode material onto the surface of the current collector via a port.

20. The method of claim 18 , wherein the electrode has a polygonal shape.

21. The method of claim 18 , wherein the electrode material is at least one of a flowable anodic semi-solid and a flowable cathodic semi-solid.

Assignees

• 24M Technologies Inc

Inventors

• Slocum Alexander H
• Doherty Tristan
• Bazzarella Ricardo
• Cross Iii James C
• Limthongkul Pimpa
• Duduta Mihai
• Disko Jeffry
• Yang Allen
• Wilder Throop
• Carter William Craig
• Chiang Yet-Ming

Classifications

• H01M10/052

  Li-accumulators · CPC title

• H01M4/76

  Containers for holding the active material, e.g. tubes, capsules · CPC title

• H01M4/0478 Primary

  with dispersions, suspensions or pastes · CPC title

• Y10T29/4911

  including sealing · CPC title

• H01M2004/023

  Gel electrode · CPC title