Stationary semi-solid battery module and method of manufacture

Patent metadata

Field	Value
Publication number	US-11888144-B2
Application number	US-202217683557-A
Country	US
Kind code	B2
Filing date	Mar 1, 2022
Priority date	Sep 7, 2011
Publication date	Jan 30, 2024
Grant date	Jan 30, 2024

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, comprising:
combining an active material and an electrolyte to form a semi-solid electrode material;
mixing the semi-solid electrode material to form a mixed semi-solid electrode material;
extruding the mixed semi-solid electrode material into a cavity formed at least in part by a stationary, substantially planar current collector such that the semi-solid electrode material is disposed on a surface of the stationary, substantially planar current collector; and
removing a portion of the semi-solid electrode material to form the electrode.

2. The method of claim 1 , wherein the active material is about 20% to about 75% by volume of the semi-solid electrode material.

3. The method of claim 1 , wherein the electrolyte is about 25% to about 70% by volume of the semi-solid electrode material.

4. The method of claim 1 , wherein the semi-solid electrode material is heated, cooled, and/or vibrated during extrusion of the mixed semi-solid electrode material.

5. The method of claim 1 , wherein the mixing is via kneading, single screw extrusion, twin screw extrusion, centrifugal planetary mixing, and/or a planetary mixing.

6. The method of claim 1 , wherein the extruding is via an extrusion device, further comprising:
moving the extrusion device relative to the substantially planar current collector.

7. The method of claim 1 , further comprising:
disposing a support structure on the surface of the substantially planar current collector to provide support for the semi-solid electrode material.

8. A method comprising:
combining an active material and an electrolyte in a mixer to form a semi-solid electrode material;
transferring the semi-solid electrode material, via an opening of an extrusion device fluidically coupled to the mixer, to a cavity formed at least in part by a stationary, substantially planar current collector such that the semi-solid material is disposed on a surface of the stationary, substantially planar current collector; and
moving the extrusion device from a first position to a second position relative to the substantially planar current collector.

9. The method of claim 8 , wherein the opening of the extrusion device is at least one of a hanger die sheet extrusion die, a winter manifold sheet extrusion die, and a profile-style sheet extrusion die.

10. The method of claim 8 , wherein the active material is about 20% to about 75% by volume of the semi-solid electrode material.

11. The method of claim 8 , wherein the electrolyte is about 25% to about 70% by volume of the semi-solid electrode material.

12. The method of claim 8 , wherein the extrusion device is heated, cooled, and/or vibrated during transfer of the semi-solid electrode material.

13. The method of claim 8 , wherein the mixer includes a kneading machine, a single screw extruder, a twin screw extruder, a centrifugal planetary mixer, and/or a planetary mixer.

14. The method of claim 8 , further comprising:
disposing a support structure on the surface of the substantially planar current collector to provide support for the semi-solid electrode material.

15. A method of forming an electrode, comprising:
combining an active material and an electrolyte to form a semi-solid electrode material;
transferring the semi-solid electrode material via an opening in an extrusion device to a cavity formed at least in part by a stationary, substantially planar current collector such that the semi-solid material is disposed on a surface of the stationary, substantially planar current collector;
moving the extrusion device from a first position to a second position relative to the substantially planar current collector; and
removing a portion of the semi-solid electrode material to form the electrode.

16. The method of claim 15 , wherein the opening of the extrusion device is at least one of a hanger die sheet extrusion die, a winter manifold sheet extrusion die, and a profile-style sheet extrusion die.

17. The method of claim 15 , wherein the active material is about 20% to about 75% by volume of the semi-solid electrode material.

18. The method of claim 15 , wherein the electrolyte is about 25% to about 70% by volume of the semi-solid electrode material.

19. The method of claim 15 , wherein the extrusion device is heated, cooled, and/or vibrated during extrusion of the semi-solid electrode material.

20. The method of claim 15 , wherein the active material and the electrolyte is combined in a kneading machine, a single screw extruder, a twin screw extruder, a centrifugal planetary mixer, and/or a planetary mixer to form the semi-solid electrode material.

21. The method of claim 15 , further comprising:
disposing a support structure on the surface of the substantially planar current collector to provide support for the semi-solid electrode material.

Assignees

• 24M Tech 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

• H01M4/0433 Primary

  Molding · CPC title

• H01M4/0478 Primary

  with dispersions, suspensions or pastes · CPC title

• H01M4/76

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

• H01M10/052

  Li-accumulators · CPC title

• H01M2004/023

  Gel electrode · CPC title