Electrochemical cells with multiple separators, and methods of producing the same

Patent metadata

Field	Value
Publication number	US-12456780-B2
Application number	US-202217733658-A
Country	US
Kind code	B2
Filing date	Apr 29, 2022
Priority date	Apr 29, 2021
Publication date	Oct 28, 2025
Grant date	Oct 28, 2025

Abstract

Embodiments described herein relate to electrochemical cells with multiple separators, and methods of producing the same. A method of producing an electrochemical cell can include disposing an anode material onto an anode current collector, disposing a first separator on the anode material, disposing a cathode material onto a cathode current collector, disposing a second separator onto the cathode material, and disposing the first separator on the second separator to form the electrochemical cell. The anode material and/or the cathode material can be a semi-solid electrode material including an active material, a conductive material, and a volume of liquid electrolyte. In some embodiments, less than about 10% by volume of the liquid electrolyte evaporates during the forming of the electrochemical cell. In some embodiments, the method can further include wetting the first separator and/or the second separator with an electrolyte solution prior to coupling the first separator to the second separator.

First claim

The invention claimed is:

1 . A method of forming an electrochemical cell, the method comprising:
disposing an anode material onto an anode current collector; disposing a first separator on the anode material; disposing a cathode material onto a cathode current collector; disposing a second separator onto the cathode material; wetting at least one of the first separator or the second separator with an electrolyte solution; and disposing the first separator on the second separator to form the electrochemical cell, wherein at least one of the anode material or the cathode material is a semi-solid electrode material including an active material, a conductive material, and a volume of a liquid electrolyte; and wherein less than about 10% by volume of the liquid electrolyte and less than about 10% by volume of the electrolyte solution evaporates during the forming of the electrochemical cell.

2 . The method of claim 1 , wherein wetting the at least one of the first separator and the second separator is via spraying.

3 . The method of claim 1 , wherein less than about 10% of a total volume of a combination of the electrolyte solution and the liquid electrolyte evaporates during the forming of the electrochemical cell.

4 . The method of claim 1 , wherein at least one of the first separator or the second separator is composed of a material with a porosity of less than about 1%.

5 . The method of claim 1 , wherein the cathode current collector, the cathode material, and the second separator collectively form a cathode, the method further comprising:
conveying the cathode along a conveyor.

6 . The method of claim 5 , wherein the anode current collector, the anode material, and the first separator collectively form an anode, and wherein the conveyor is a first conveyor, the method further comprising:
conveying the anode along a second conveyor.

7 . The method of claim 5 , wherein the anode current collector, the anode material, and the first separator collectively form an anode, the method further comprising:
conveying the anode along the conveyor.

8 . The method of claim 1 , wherein the semi-solid electrode material is a first semi-solid electrode material, the method further comprising:
disposing a second semi-solid electrode material between the first separator and the second separator.

9 . The method of claim 8 , further comprising:
measuring a voltage between the second semi-solid electrode material and at least one of the anode current collector or the cathode current collector.

10 . A method of forming an electrochemical cell, the method comprising:
disposing a semi-solid cathode material onto a cathode current collector, the semi-solid cathode material including an active material, a conductive material, and a volume of non-aqueous liquid electrolyte, disposing an anode material onto an anode current collector; disposing a first separator on the semi-solid cathode; disposing a second separator on the anode material; dispensing an electrolyte solution on at least one of the first separator or the separator; and disposing the first separator on the second separator to form an electrochemical cell, wherein less than about 10% by volume of the electrolyte solution evaporates during the forming of the electrochemical cell.

11 . The method of claim 10 , wherein less than about 10% by volume of the non-aqueous liquid electrolyte evaporates during the forming of the electrochemical cell.

12 . The method of claim 10 , wherein dispensing the electrolyte solution is via spraying.

13 . The method of claim 10 , wherein less than about 10% of a total volume of a combination of the electrolyte solution and the non-aqueous liquid electrolyte evaporates during the forming of the electrochemical cell.

14 . The method of claim 10 , wherein the electrolyte solution includes a solid-state electrolyte.

15 . The method of claim 10 , wherein at least one of the first separator or the second separator has a porosity of less than about 1%.

16 . The method of claim 10 , wherein the cathode current collector, the cathode material, and the second separator collectively form a cathode and the anode current collector, the anode material, and the first separator collectively form an anode, the method further comprising:
conveying at least one of the cathode or the anode along a conveyor.

Assignees

• 24M Tech Inc

Inventors

• Chen Junzheng
• Ota Naoki
• Disko Jeffry
• D'Angelo Anthony

Classifications

• H01M50/46

  Separators, membranes or diaphragms characterised by their combination with electrodes · CPC title

• H01M4/1397

  of electrodes based on inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy · CPC title

• H01M4/1391

  of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx · CPC title

• H01M50/403

  Manufacturing processes of separators, membranes or diaphragms · CPC title

• H01M50/491

  Porosity · CPC title