Systems and methods for infusion mixing a slurry-based electrode

Patent metadata

Field	Value
Publication number	US-11961990-B2
Application number	US-202117227577-A
Country	US
Kind code	B2
Filing date	Apr 12, 2021
Priority date	Jan 15, 2016
Publication date	Apr 16, 2024
Grant date	Apr 16, 2024

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 an intermediate material;
compressing the intermediate material to form a compressed intermediate material;
infusing an electrolyte into the compressed intermediate material to form an electrode material; and
dispensing the electrode material onto a current collector to form a final electrode, the final electrode including a mixture of a solid phase and a liquid phase.

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. The method of claim 2 , wherein the vacuum is drawn to reduce pressure to less than or equal to −28 inches Hg.

8. A method of preparing a semi-solid electrode, the method comprising:
mixing an active material and a conductive material in a mixer to form an intermediate material;
compressing the intermediate material to form a compressed intermediate material;
drawing a vacuum on the compressed intermediate material;
transferring an electrolyte to the compressed intermediate material to form an electrode material; and
dispensing the electrode material onto a current collector to form a final electrode, the final electrode including a mixture of a solid phase and a liquid phase.

9. The method of claim 8 , further comprising:
evacuating a vessel in which the compressed intermediate material is disposed to reduce pressure in the vessel.

10. The method of claim 9 , wherein the pressure in the vessel is reduced to an inner-vessel gauge pressure of less than or equal to −28 inches Hg.

11. The method of claim 9 , wherein the evacuation of the vessel is performed prior to infusion of the electrolyte.

12. The method of claim 9 , wherein the evacuation of the vessel is performed during infusion of the electrolyte.

13. A method of preparing a semi-solid electrode, the method comprising:
combining an active material with a conductive material to form an intermediate material;
compressing the 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 an electrode material; and
dispensing the electrode material onto a current collector to form a final electrode, the final electrode including a mixture of a solid phase and a liquid phase.

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 into the compressed intermediate material.

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.

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 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 intermediate material.

Assignees

• 24M Tech Inc
• Kyocera Corp

Inventors

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

Classifications

• H01M4/0416 Primary

  involving impregnation with a solution, dispersion, paste or dry powder (H01M4/0438 takes precedence) · CPC title

• B28B3/006

  Pressing by atmospheric pressure, as a result of vacuum generation or by gas or liquid pressure acting directly upon the material, e.g. jets of compressed air (moulds for treating with gases or degassing B28B7/44; compacting concrete by means of vacuum in general E04G21/061) · CPC title

• B28B3/20

  wherein the material is extruded {(extrusion moulding of plastics B29C48/00)} · CPC title

• B28B11/04

  for coating {or applying engobing layers}(glazing, engobing C04B) · CPC title

• B30B11/027

  Particular press methods or systems · CPC title