Systems and methods for infusion mixing a slurry based electrode

Patent metadata

Field	Value
Publication number	US-11005087-B2
Application number	US-201715407669-A
Country	US
Kind code	B2
Filing date	Jan 17, 2017
Priority date	Jan 15, 2016
Publication date	May 11, 2021
Grant date	May 11, 2021

Abstract

Embodiments described in this application relate generally to a system, an apparatus and/or methods for manufacturing electrodes by infusion electrolyte into compacted electrode materials. In some embodiments, a working electrode materials can be produced using an infusion mixing and manufacturing process. In some embodiments, a single-sided finished electrode can be produced directly from a dry powder mixture using an infusion mixing and manufacturing process. In some embodiments, a double-sided finished electrode can be produced directly from a dry powder mixture using an infusion mixing and manufacturing process. The electrodes produced by an infusion mixing and manufacturing process generally perform better than those produced by non-infusion processes.

First claim

The invention claimed is:

1. A method of preparing a semi-solid electrode, the method comprising:
combining an active material with a conductive material to form a dry powder intermediate material;
compressing the dry powder intermediate material to form a compressed intermediate material;
infusing an electrolyte into the compressed intermediate material to form a semi-solid material; and
dispensing the semi-solid material onto a current collector to form the semi-solid electrode,
wherein the semi-solid electrode remains semi-solid after the dispensing.

2. The method of claim 1 , further comprising:
drawing a vacuum on the compressed intermediate material.

3. The method of claim 2 , wherein the vacuum is drawn prior to infusion of the electrolyte.

4. The method of claim 2 , wherein the vacuum is drawn during infusion of the electrolyte.

5. The method of claim 1 , wherein the electrolyte is infused via a plurality of inlet ports.

6. The method of claim 1 , further comprising:
drawing a vacuum on the compressed intermediate material via a plurality of outlet ports.

7. A method of preparing a semi-solid electrode, the method comprising:
combining an active material and a conductive material in a vessel of a mixer;
mixing the active material and the conductive material in the mixer to form a mixed dry powder;
after the mixing, compressing the mixed dry powder;
after the compressing, evacuating the vessel to reduce pressure in the vessel;
after the evacuating, transferring an electrolyte to the vessel to form a semi-solid working electrode material; and
dispensing the semi-solid working electrode material from the vessel and onto a current collector to form the semi-solid electrode,
wherein the semi-solid electrode remains semi-solid after the dispensing.

8. The method of claim 7 , further comprising:
evacuating the vessel to reduce pressure in the vessel to near vacuum.

9. The method of claim 8 , wherein evacuation of the vessel to reduce pressure in the vessel achieves an inner-vessel gauge pressure of less than or equal to −28 inches Hg.

10. The method of claim 8 , wherein the vacuum is drawn prior to infusion of the electrolyte.

11. The method of claim 8 , wherein the vacuum is drawn during infusion of the electrolyte.

12. The method of claim 7 , wherein the working electrode material is dispensed through a flow control mechanism.

13. A method of preparing a semi-solid electrode, the method comprising:
combining an active material with a conductive material to form a dry powder intermediate material;
compressing the dry powder intermediate material to form a compressed intermediate material;
transferring a wetting agent to the compressed intermediate material;
infusing an electrolyte into the compressed intermediate material to form a semi-solid material; and
dispensing the semi-solid material onto a current collector to form the semi-solid electrode,
wherein the semi-solid electrode remains semi-solid after the dispensing.

14. The method of claim 13 , further comprising:
drawing a vacuum on the compressed intermediate material prior to transferring the wetting agent to the intermediate material.

15. The method of claim 13 , further comprising:
drawing a vacuum on the compressed intermediate material prior to infusion of the electrolyte.

16. The method of claim 13 , further comprising:
drawing a vacuum on the compressed intermediate material during a first time period prior to transferring the wetting agent to the intermediate material; and
drawing a vacuum on the compressed intermediate material during a second time period prior to transferring the wetting agent to the intermediate material.

17. The method of claim 13 , further comprising:
drawing a vacuum on the compressed intermediate material to achieve an inner-chamber gauge pressure of less than or equal to −28 inches Hg to evacuate air from the compressed intermediate material prior to transfer of the wetting agent to the chamber.

18. The method of claim 13 , further comprising:
drawing a vacuum on the compressed intermediate material to achieve an inner-chamber gauge pressure of less than or equal to −28 inches Hg to evacuate wetting agent from the compressed intermediate material prior to the electrolyte infusion.

19. The method of claim 13 , wherein the active material and the conductive material are combined in a vessel of a mixer and mixed to form the dry powder intermediate material.

Assignees

• Ota Naoki
• Fukushima Takaaki
• Wakai Yutaka
• Tamaki Motoi
• Simon Sean
• Varamo Nicholas
• Le Duy
• Tan Taison
• Mishima Hiromitsu
• 24M Technologies Inc
• Kyocera Corp

Inventors

• Ota Naoki
• Fukushima Takaaki
• Wakai Yutaka
• Tamaki Motoi
• Simon Sean
• Varamo Nicholas
• Le Duy
• Tan Taison
• Mishima Hiromitsu

Classifications

• B30B11/027

  Particular press methods or systems · CPC title

• H01G11/30

  characterised by their material · CPC title

• H01G11/50

  specially adapted for lithium-ion capacitors, e.g. for lithium-doping or for intercalation · CPC title

• H01G11/86

  specially adapted for electrodes (carbonisation or activation of carbon for the manufacture of electrodes H01G11/34) · CPC title

• H01M4/139

  Processes of manufacture · CPC title