Battery component fabrication method and system

Patent metadata

Field	Value
Publication number	US-2025259985-A1
Application number	US-202418436172-A
Country	US
Kind code	A1
Filing date	Feb 8, 2024
Priority date	Feb 8, 2024
Publication date	Aug 14, 2025
Grant date	—

Abstract

A battery component fabrication method includes compressing a powder mixture to provide a composite film layer, surface treating the composite film layer, and compressing the composite film layer together with a foil layer to provide an electrode. The electrode provided by the method can be considered a dry electrode for a lithium-ion battery.

First claim

What is claimed is:

1 . A battery component fabrication method, comprising:
compressing a powder mixture to provide a composite film layer; surface treating the composite film layer; and compressing the composite film layer together with a foil layer to provide an electrode.

2 . The battery component fabrication method of claim 1 , wherein the electrode is a lithium-ion battery electrode.

3 . The battery component fabrication method of claim 1 , wherein the surface treating comprises plasma surface modification.

4 . The battery component fabrication method of claim 1 , wherein the surface treating comprises corona treatment that uses a corona discharge plasma.

5 . The battery component fabrication method of claim 1 , wherein the surface treating comprises a laser treatment.

6 . The battery component fabrication method of claim 1 , wherein the surface treating comprises a light treatment.

7 . The battery component fabrication method of claim 1 , wherein the composite film layer is a first composite film layer compressed against a first side of the foil layer and, further comprising compressing another powder mixture to provide a second composite film layer, surface treating the second composite film layer, and compressing the second composite film layer against an opposite second side of the foil layer.

8 . The battery component fabrication method of claim 1 , wherein the powder mixture includes a binder material.

9 . The battery component fabrication method of claim 1 , wherein the powder mixture is a dry powder mixture.

10 . The battery component fabrication method of claim 1 , wherein the composite film layer is a dry electrode.

11 . The battery component fabrication method of claim 1 , further comprising heating during the compressing.

12 . The battery component fabrication method of claim 1 , further comprising compressing the powder mixture by calendering the powder mixture.

13 . The battery component fabrication method of claim 1 , further comprising compressing the powder mixture using at least one roller of a calender.

14 . The battery component fabrication method of claim 13 , wherein the at least one roller is a heated roller that heats powder mixture during the compressing.

15 . The battery component fabrication method of claim 1 , further comprising heating the composite film layer and the foil layer when compressing the composite film layer together with the foil layer.

16 . The battery component fabrication method of claim 1 , wherein further comprising winding the composite film layer and the foil layer after compressing the composite film layer together with the foil layer.

17 . A battery component fabrication system, comprising:
a powder compression station that compresses a dry power into a composite film layer; a surface treatment station that surface treats a side of the composite film layer; and an electrode compression station that compresses the side of the composite film layer against a foil layer to provide an electrode.

18 . The battery component fabrication system of claim 17 , wherein the electrode is a lithium-ion battery electrode.

19 . The battery component fabrication system of claim 17 , wherein the surface treatment station is a plasma surface modification.

20 . The battery component fabrication system of claim 17 , wherein the side is a first side, and the surface additionally treats an opposite, second side of the composite film layer.

Assignees

• Ford Global Tech Llc

Inventors

• Lee Donghyun
• Jeon Insik
• Martini Gary Thomas
• Park Jonghwan

Classifications

• H01M4/0404

  by coating on electrode collectors · CPC title

• H01M4/139

  Processes of manufacture · CPC title

• H01M4/0416

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

• H01M10/0525

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• H01M2220/20

  Batteries in motive systems, e.g. vehicle, ship, plane · CPC title