Apparatus and methods for forming semi-solid electrodes with high active solid loading and electrochemical cells including the same

Abstract

Embodiments described herein generally relate to devices and methods for forming semi-solid electrodes with high active solid loading by removing excess electrolyte. In some embodiments, a semi-solid electrode material can be formed by mixing an active material and optionally a conductive material in a liquid electrolyte to form a suspension. In some embodiments, the semi-solid electrode material can be disposed onto a current collector to form an intermediate electrode. In some embodiments, the semi-solid electrode material can have a first composition in which the ratio of electrolyte to active material is between about 10:1 and about 1:1. In some embodiments, a method for converting the semi-solid electrode material from the first composition to a second composition includes removing a portion of the electrolyte from the semi-solid electrode material.

Description

[0001] Cross-references to related applications

[0002] This application claims priority and benefit to U.S. Provisional Application No. 62 / 963,908, filed January 21, 2020, entitled “APPARATUSES AND PROCESSES FOR FORMING A SEMI-SOLIDELECTRODE HAVING HIGH ACTIVE SOLIDS LOADING AND ELECTROCHEMICAL CELLSINCLUDING THE SAME”, the disclosure of which is incorporated herein by reference in its entirety. Background Technology

[0003] Semi-solid electrodes can sometimes have lower energy densities than conventional electrodes, whose electrode materials are often rolled after being applied to the current collector. Therefore, semi-solid electrodes, which can have better conductivity and a lower risk of ion trapping within the electrode material compared to conventional electrodes, are often made thicker to achieve the same capacity. Summary of the Invention

[0004] The embodiments described herein generally relate to apparatus and methods for forming a semi-solid electrode with an increased active solids loading by removing excess electrolyte. In some embodiments, a method for converting a semi-solid electrode material from a first composition to a second composition includes removing a portion of the electrolyte from the semi-solid electrode material. In some embodiments, the semi-solid electrode material may be deployed on a current collector to form an intermediate electrode. In some embodiments, the method further includes mechanically compressing the intermediate electrode to remove a portion of the electrolyte from the semi-solid electrode material. In some embodiments, the method may include deploying the intermediate electrode between a mold and a base of a mechanical press and moving the mold toward the base until a compressive force is supplied to the intermediate electrode. In some embodiments, an absorbent material may be deployed within the mechanical press, for example, between at least one of the mold and the base, to absorb a portion of the electrolyte removed from the intermediate electrode. In some embodiments, the portion from which the electrolyte is removed from the intermediate electrode forms a finished electrode having a higher active solids loading than the previously described semi-solid electrode material and the electrode composed therefrom.

[0005] In some embodiments, the semi-solid electrode material can be formed by mixing an active material and optionally a conductive material in a liquid electrolyte to form an electrode material comprising a mixture of solid and liquid phases. In some embodiments, the semi-solid electrode material can be deployed on a current collector to form an intermediate electrode. In some embodiments, the intermediate electrode can include a semi-solid electrode material having a first composition, wherein the ratio of electrolyte to active material is between approximately 10:1 and approximately 1:1. In some embodiments, the intermediate electrode can be mechanically compressed to form a finished electrode comprising a semi-solid electrode material having a second composition, wherein the ratio of electrolyte to active material is between approximately 5:1 and approximately 1:3. Attached Figure Description

[0006] Figure 1 The illustration shows a method for manufacturing a semi-solid electrode according to an embodiment.

[0007] Figures 2A-2E The illustration shows a method for manufacturing a semi-solid electrode according to an embodiment.

[0008] Figures 3A-3E The illustration shows a method for manufacturing a semi-solid electrode according to an embodiment.

[0009] Figures 4A-4F The illustration shows a method for manufacturing a semi-solid electrode according to an embodiment.

[0010] Figure 5A and 5B The illustration shows a method for additional use of the semi-solid electrode according to an embodiment. Detailed Implementation

[0011] Embodiments described herein generally relate to methods for forming a semi-solid electrode material having a high active solid loading, and methods for forming an electrochemical cell including the electrode material. In some embodiments, a semi-solid electrode can be formed by mechanically compressing a semi-solid electrode material of an active material and a conductive material in a liquid electrolyte. In some embodiments, the active material can include particles of an active material. In some embodiments, the active particles can be substantially free of any coating. In some embodiments, the conductive material can include particles of a conductive material. In some embodiments, the conductive material can be free or substantially free of conductive fibers. In some embodiments, the semi-solid electrode material can include a first volume of a liquid electrolyte such that the semi-solid electrode material is flowable during fabrication of the semi-solid electrode. In some embodiments, the semi-solid electrode material can be mechanically compressed so as to extract a portion of the liquid electrolyte and form the semi-solid electrode material having a second volume of the liquid electrolyte that is less than the first volume of the liquid electrolyte. In some embodiments, the mechanical compression includes compressing the semi-solid electrode material between a compression mold and a substrate. In some embodiments, a semi-permeable membrane can be disposed between the semi-solid electrode material and at least one of the substrate and the compression mold such that a portion of the liquid electrolyte can be extracted without removing any of the active material or the conductive material. In some embodiments, removing the portion of the liquid electrolyte from the semi-solid electrode material can form the semi-solid electrode material having a higher active solid content, e.g., greater than about 70 wt% of the active material.

[0012] Conventional electrode materials are typically manufactured by coating a metal substrate (e.g., a current collector) with an electrode slurry composed of an active material, a conductive additive, and a binder dissolved or dispersed in a solvent or water; evaporating the solvent or water; and calendering the dried solid matrix to a specified thickness. The electrode is then cut, packaged with other components, infiltrated with an electrolyte, and the entire package is sealed. Such methods generally involve complex and expensive manufacturing steps, such as casting the electrode. These methods for producing electrodes result in lower battery capacity, lower energy density, and a high ratio of non-active ingredients to active material. Furthermore, the use of a binding agent in known electrode formulations increases the degree of bending and decreases the ionic conductivity of the electrode. In some embodiments, the electrodes described herein can be free or substantially free of a binding agent.

[0013] Because the electrolyte is infused after the calendered conventional electrode material, a significant amount of effort is typically required to infuse the electrolyte after the electrochemical cell is formed. Conventional methods for infusing calendered electrode material with liquid electrolyte include using high pressure or long infusion times to achieve sufficient penetration of the liquid electrolyte into the electrode material. Typically, conventional electrodes are therefore calendered to only about 20% porosity to facilitate infusion of electrolyte into the calendered electrode material. As a result, there is a tradeoff between the energy density of the finished electrode and the degree of densification of the electrode material. In other words, because conventional electrode materials after calendering are typically more dense, they can be more difficult to penetrate with liquid electrolyte. As a result, conventional electrode materials are often not fully wetted by electrolyte after infusion, meaning that the energy density achieved can be substantially lower than the theoretical energy density.

[0014] Semi-solid electrodes and cells formed therefrom can often be manufactured thicker (with higher capacity) without experiencing the conductivity problems of thicker conventional electrodes. However, the energy density of semi-solid electrodes can be lower than conventional electrodes, in part because conventional electrodes are typically calendered and the slurrying solvent is removed during a drying step. Semi-solid electrodes are typically not dried or calendered because the electrode is formed from a slurry of active material and optionally conductive material in a liquid electrolyte, in which case a drying or calendering step would remove all or substantially all of the electrolyte from the electrode. Thus, there is an ongoing need for semi-solid electrodes and electrochemical cells formed therefrom with higher active solid loading.

[0015] As described herein, in some embodiments, the semi-solid electrode is prepared by initially slurrying an active material, optionally a conductive material, and a liquid electrolyte into a semi-solid electrode material. Because the semi-solid electrode material already contains a liquid electrolyte in contact with the active material, the actual energy density of the finished electrode can be substantially similar to the theoretical energy density.

[0016] As used in this specification, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, the term “a member” is intended to mean a single member or a combination of members, “a material” is intended to mean a singular or multiple materials or a combination thereof.

[0017] The term "substantially," when used in connection with "cylindrical," "linear," and / or other geometric relationships, is intended to convey that the structure so defined is nominally cylindrical, linear, etc. As one example, a portion of a support member that is described as "substantially linear" is intended to convey that while linearity of the portion is desired, some non-linearity can occur in the "substantially linear" portion. Such non-linearity can be due to manufacturing tolerances or other practical considerations such as, for example, pressure or force applied to the support member. Thus, geometric configurations modified by the term "substantially" include such geometric properties within plus or minus 5% of the stated geometric configuration. For example, a "substantially linear" portion is a portion that defines an axis or centerline that is within plus or minus 5% of linear.

[0018] As used herein, the terms "set" and "plurality" can refer to a plurality of features or a single feature having a plurality of portions. For example, when referring to a set of electrodes, the set of electrodes can be considered to be one electrode having a plurality of portions, or the set of electrodes can be considered to be a plurality of distinct electrodes. Further, for example, when referring to a plurality of electrochemical cells, the plurality of electrochemical cells can be considered to be a plurality of distinct electrochemical cells or one electrochemical cell having a plurality of portions. Thus, a set or plurality of portions can include portions that are either continuous or discontinuous with one another. A plurality of particles or a plurality of materials can also be made from a plurality of articles that are produced separately and subsequently coupled together (e.g., via mixing, an adhesive, or any suitable method).

[0019] As used herein, the terms "about" and "approximately" generally refer to plus or minus 10% of the stated value, e.g., about 250 μιη would include 225 μιη to 275 μιη, and about 1000 μιη would include 900 μιη to 1100 μιη.

[0020] As used herein, the term "semi-solid" refers to a material that is a mixture of a liquid phase and a solid phase, such as, for example, a granular suspension, a slurry, a colloidal suspension, an emulsion, a gel, or a micelle. As used herein, the term "semi-solid electrode material" refers to a mixture of at least a solid active material and a liquid electrolyte.

[0021] As used herein, the terms "activated carbon network" and "networked carbon" relate to a general qualitative state of an electrode. For example, an electrode having an activated carbon network (or networked carbon) is such that the carbon particles within the electrode exhibit individual particle morphology and arrangement with respect to one another that facilitates electrical contact and conductivity between the particles. In contrast, the terms "unactivated carbon network" and "un-networked carbon" relate to an electrode in which the carbon particles exist as either single particle islands or multi-particle agglomerate islands that can not be sufficiently connected to provide adequate electrical conductivity through the electrode.

[0022] In some embodiments, a method of manufacturing a semi-solid electrode with high active solid loading includes mixing an active material and a conductive material with a liquid electrolyte to form a semi-solid electrode material and deploying the semi-solid electrode material on a current collector. The method can further include deploying a semi-permeable membrane on an exposed surface of the semi-solid electrode material and compressing the semi-solid electrode material to extract a portion of the liquid electrolyte. In some embodiments, the semi-solid electrode can be compressed using a mechanical press. In some embodiments, the semi-permeable membrane can be configured to absorb the portion of the liquid electrolyte extracted during compression. In some embodiments, an absorbent material can be used to absorb at least some of the extracted liquid electrolyte during mechanical pressing of the semi-solid electrode. In some embodiments, mechanically compressing the semi-solid electrode material includes compressing the semi-solid material between a compression mold and a base. In some embodiments, the absorbent material can be deployed on an exposed surface of the semi-permeable membrane, on a contact surface of the compression mold, on a contact surface of the base, or any combination thereof. In some embodiments, the compressed semi-solid electrode material includes greater than about 70 wt% active material. In some embodiments, the semi-solid electrode material after mixing has a first composition in which the liquid electrolyte comprises about 50 wt% to about 80 wt% of the semi-solid electrode material, and the semi-solid electrode material after compression has a second composition in which the liquid electrolyte comprises about 10 wt% to about 45 wt% of the semi-solid electrode material. In some embodiments, the semi-solid electrode material after mixing has a first ratio of liquid electrolyte to active material of between about 10: 1 and about 1 : 1, and the semi-solid electrode material after compression has a second ratio of liquid electrolyte to active material of between about 5: 1 and about 1 :3. In some embodiments, the semi-solid electrode material after mixing has a first active material molarity of between about 5 M and about 15 M, and the semi-solid electrode material after compression has a second active material molarity of between about 16 M and about 24 M. In some embodiments, the semi-solid electrode material after mixing has a first energy density of between about 3 mAh / g and about 5 mAh / g, and the semi-solid electrode material after compression has a second energy density of between about 6 mAh / g and about 14 mAh / g.

[0023] In some embodiments, a method of manufacturing a semi-solid electrode with a high active solid loading can include mixing an active material and a conductive material with a liquid electrolyte to form a semi-solid electrode material having a first thickness, inserting the semi-solid electrode material between a current collector and a semi-permeable membrane, and mechanically compressing the semi-solid electrode material such that the semi-solid electrode material has a second thickness that is less than the first thickness. In some embodiments, the first thickness is between about 100 μιη and about 2,000 μιη. In some embodiments, the second thickness is between about 5 μιη and about 50 μιη. In some embodiments, the mechanical compression is achieved by mechanically compressing the semi-solid electrode material between a base and a die of a mechanical press.

[0024] In some embodiments, a method of manufacturing a semi-solid electrode with a high active solid loading can include mixing an active material and a conductive material with a liquid electrolyte to form a semi-solid electrode material having a first volume, inserting the semi-solid electrode material between a current collector and a semi-permeable membrane, and mechanically compressing the semi-solid electrode material such that the semi-solid electrode material has a second volume that is less than the first volume.

[0025] In some embodiments, a method of manufacturing a semi-solid electrode with a high active solid loading can include mixing an active material and a conductive material with a liquid electrolyte to form a semi-solid electrode material having a first composition including between about 50 wt% and about 80 wt% of the liquid electrolyte, inserting the semi-solid electrode material between a current collector and a semi-permeable membrane, and mechanically compressing the semi-solid electrode material until the semi-solid electrode material has a second composition including between about 10 wt% and about 45 wt% of the liquid electrolyte.

[0026] In some embodiments, a method of manufacturing a semi-solid electrode with a high active solid loading can include mixing an active material and a conductive material with a liquid electrolyte to form a first semi-solid electrode material having a first density, inserting the first semi-solid electrode material between a current collector and a semi-permeable membrane, and mechanically compressing the first semi-solid electrode material to form a second semi-solid electrode material having a second density that is greater than the first density. In some embodiments, the first density can be less than about 2 g / cm 3 3 3 3 3 3 3 3 ​​​​​​​​3 or less than about 1 g / cm 3 , including all values and ranges therebetween. In some embodiments, the second density is between about 2.1 g / cm 3 and about 5 g / cm 3 , between about 2.2 g / cm 3 and about 4.5 g / cm 3 , between about 2.3 g / cm 3 and about 4 g / cm 3 , between about 2.4 g / cm 3 and about 3.5 g / cm 3 , between about 2.5 g / cm 3 and about 3 g / cm 3 , between about 2.5 g / cm 3 and about 5 g / cm 3 , between about 3 g / cm 3 and about 5 g / cm 3 , between about 3.5 g / cm 3 and about 5 g / cm 3 , between about 4 g / cm 3 and about 5 g / cm 3 , between about 4.5 g / cm 3 and about 5 g / cm 3 , between about 2.1 g / cm 3 and about 4.5 g / cm 3 , between about 2.1 g / cm 3 and about 4 g / cm 3 , between about 2.1 g / cm 3 and about 3.5 g / cm 3 , between about 2.1 g / cm 3 and about 3 g / cm 3 , or between about 2.1 g / cm 3 and about 2.5 g / cm 3 , including all values and ranges therebetween. In some embodiments, the second density is greater than about 2.1 g / cm 3 , greater than about 2.5 g / cm 3 , greater than about 3 g / cm 3 , greater than about 3.5 g / cm 3 , greater than about 4 g / cm 3 , greater than about 4.5 g / cm 3 , greater than about 5 g / cm 3 , greater than about 5.5 g / cm 3 , or greater than about 6 g / cmincluding all values and ranges therebetween. In some embodiments, the energy density of the second semi-solid electrode material is greater than about 5 mAh / g, greater than about 6 mAh / g, greater than about 7 mAh / g, greater than about 8 mAh / g, greater than about 9 mAh / g, greater than about 10 mAh / g, greater than about 11 mAh / g, greater than about 12 mAh / g, greater than about 13 mAh / g, greater than about 14 mAh / g, or greater than about 15 mAh / g, including all values and ranges therebetween.

[0027] In some embodiments, the method of manufacturing a semi-solid electrode with high active solid loading can include using recycled electrochemical cell material. In some embodiments, the recycled electrochemical cell material can include used electrochemical cell material, partially used electrochemical cell material, conductive electrochemical cell scrap, and / or any other electrochemical cell material that can be reused. In some embodiments, mechanically compressing the recycled electrochemical cell material can increase the overall electrical conductivity and / or active material fraction of the recycled electrochemical cell material. In some embodiments, the method of manufacturing a semi-solid electrode with high active solid loading can include using at least about 5 wt%, at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 35 wt%, at least about 40 wt%, at least about 45 wt%, at least about 50 wt%, at least about 55 wt%, at least about 60 wt%, at least about 65 wt%, at least about 70 wt%, at least about 75 wt%, at least about 80 wt%, at least about 85 wt%, at least about 90 wt%, or at least about 95 wt% recycled electrochemical cell material.

[0028] Figure 1A method 10 of forming a semi-solid electrode is illustrated that includes a higher active solid loading than conventional electrodes while remaining flowable during electrode fabrication. The method 10 can include dispensing a semi-solid electrode material onto a current collector at 11 to form an intermediate electrode. In some embodiments, dispensing the semi-solid electrode material can include drop-casting the semi-solid electrode material onto a moving current collector to form or substantially form the electrode. In some embodiments, dispensing the semi-solid electrode material can include extruding the semi-solid electrode material from a moving extrusion nozzle or the like onto a stationary current collector. In some embodiments, the semi-solid electrode material can be dispensed via a stationary dispensing mechanism onto a stationary current collector, for example, in discrete portions, which can then be spread across the surface of the current collector by any suitable method to form or substantially form the electrode. In some embodiments, the current collector material can be apportioned into a plurality of current collectors such that each of the plurality of current collectors is separated from the other current collectors. Discrete portions of the semi-solid electrode material can then be deployed onto the surface of each individualized current collector to form or substantially form the electrode. In some embodiments, the electrode formed according to step 11 of method 10 includes an intermediate electrode material such that the electrode can be operable in an electrochemical cell, but with a lower active solid loading than desired for a finished electrode. The electrode formed can be a positive electrode, anode, negative electrode, cathode, or any other electrode or component of an electrochemical cell. As described herein, the electrode can be a semi-solid electrode including at least an active material and / or an electrically conductive material in a liquid electrolyte.

[0029] In some embodiments, the semi-solid electrode material can include any suitable combination of active materials and / or electrically conductive materials in a liquid electrolyte, such as those compositions described in further detail in U.S. Patent Nos. 8,993,159; 9,178,200; 9,184,464; 9,203,092; 9,362,583; 9,385,392; 9,401,501; 9,437,864; 9,484,569; 9,812,674; 9,825,280; 9,831,518; and 9,831,522, the entire disclosures of which are incorporated herein by reference. Examples of methods of manufacturing semi-solid electrodes and electrochemical cells having semi-solid electrodes are described in further detail in U.S. Provisional Patent Application No. 62 / 695,483, filed July 9, 2018, entitled “Continuous and Semi-Continuous Methods of Semi-Solid Electrode and Battery Manufacturing” (hereinafter the “‘483 Application”), the entire disclosure of which is incorporated herein by reference.

[0030] In some embodiments, to form a semi-solid electrode material that can be more easily disposed on a current collector, the semi-solid electrode material can have a first composition in which the ratio of electrolyte to active material is between about 10: 1 and about 1 : 1, about 9: 1 and about 2: 1, about 8: 1 and about 3: 1, about 7: 1 and about 4: 1, about 6: 1 and about 5: 1, about 10: 1 and about 2: 1, about 10: 1 and about 3: 1, about 10: 1 and about 4: 1, about 10: 1 and about 5: 1, about 10: 1 and about 6: 1, about 10: 1 and about 7: 1, about 10: 1 and about 8: 1, about 10: 1 and about 9: 1, about 9: 1 and about 1 : 1, about 8: 1 and about 1 : 1, about 7: 1 and about 1 : 1, about 6: 1 and about 1 : 1, about 5: 1 and about 1 : 1, about 4: 1 and about 1 : 1, about 3: 1 and about 1 : 1, or about 2: 1 and about 1 : 1, including all values and ranges therebetween. In some embodiments, when the semi-solid electrode material has the first composition, the semi-solid electrode material can be more easily handled and dispensed onto a current collector due to the relatively low viscosity as compared to the desired viscosity of the semi-solid electrode material in the finished electrode.

[0031] In some embodiments, the first composition of the semi-solid electrode material can have an energy density of between about 0.1 mAh / g and about 10 mAh / g, between about 0.5 mAh / g and about 9.5 mAh / g, between about 1 mAh / g and about 9 mAh / g, between about 1.5 mAh / g and about 8.5 mAh / g, between about 2 mAh / g and about 8 mAh / g, between about 2.5 mAh / g and about 7.5 mAh / g, between about 3 mAh / g and about 7 mAh / g, between about 0.1 mAh / g and about 9.5 mAh / g, between about 0.1 mAh / g and about 9 mAh / g, between about 0.1 mAh / g and about 8.5 mAh / g, between about 0.1 mAh / g and about 8 mAh / g, between about 0.1 mAh / g and about 7.5 mAh / g, between about 0.1 mAh / g and about 7 mAh / g, between about 0.1 mAh / g and about 6.5 mAh / g, between about 0.1 mAh / g and about 6 mAh / g, between about 0.5 mAh / g and about 10 mAh / g, between about 1 mAh / g and about 10 mAh / g, between about 1.5 mAh / g and about 10 mAh / g, between about 2 mAh / g and about 10 mAh / g, between about 2.5 mAh / g and about 10 mAh / g, between about 3 mAh / g and about 10 mAh / g, between about 3.5 mAh / g and about 10 mAh / g, between about 4 mAh / g and about 10 mAh / g, between about 4.5 mAh / g and about 10 mAh / g, between about 5 mAh / g and about 10 mAh / g, between about 5.5 mAh / g and about 10 mAh / g, between about 6 mAh / g and about 10 mAh / g, between about 6.5 mAh / g and about 10 mAh / g, or between about 7 mAh / g and about 10 mAh / g, including all values and ranges therebetween. In some embodiments, the first composition of the semi-solid electrode material can have an energy density of less than about 10 mAh / g, about 9.5 mAh / g, about 9 mAh / g, about 8.5 mAh / g, about 8 mAh / g, about 7.5 mAh / g, about 7 mAh / g, about 6.5 mAh / g, about 6 mAh / g, about 5.5 mAh / g, about 5 mAh / g, about 4.5 mAh / g, about 4 mAh / g, about 3.5 mAh / g, about 3 mAh / g, about 2.5 mAh / g, about 2 mAh / g, about 1.5 mAh / g, about 1 mAh / g, about 0.5 mAh / g, or about 0.1 mAh / g, including all values and ranges therebetween.

[0032] In some embodiments, the semi-solid electrode material disposed on the surface of the current collector can have a thickness, where the thickness is a dimension of the semi-solid electrode material in a direction perpendicular to the surface of the current collector. In some embodiments, the semi-solid electrode material, prior to being mechanically compressed, can have a thickness of between about 51 pm and about 3,000 pm, between about 75 pm and about 2,500 pm, between about 100 pm and about 2,000 pm, between about 150 pm and about 1,500 pm, between about 200 pm and about 1,000 pm, between about 250 pm and about 750 pm, between about 51 pm and about 2,500 pm, between about 51 pm and about 2,000 pm, between about 51 pm and about 1,500 pm, between about 51 pm and about 1,000 pm, between about 100 pm and about 3,000 pm, between about 200 pm and about 3,000 pm, between about 300 pm and about 3,000 pm, between about 400 pm and about 3,000 pm, between about 500 pm and about 3,000 pm, between about 750 pm and about 3,000 pm, between about 1,000 pm and about 3,000 pm, between about 1,500 pm and about 3,000 pm, between about 2,000 pm and about 3,000 pm, or between about 2,500 pm and about 3,000 pm, including all values and ranges therebetween. In some embodiments, the semi-solid electrode material, prior to being mechanically compressed, can have a thickness of greater than about 51 pm, about 75 pm, about 100 pm, about 150 pm, about 200 pm, about 250 pm, about 300 pm, about 400 pm, about 500 pm, about 750 pm, about 1,000 pm, about 1,500 pm, about 2,000 pm, about 2,500 pm, or about 3,000 pm, including all values and ranges therebetween.

[0033] Method 10 can include mechanically compressing the semi-solid electrode material to extract a portion of the liquid electrolyte at 12. In some embodiments, the semi-solid electrode material, after extracting the portion of the liquid electrolyte, can have a second composition. In some embodiments, the mechanical compression of the semi-solid electrode material can cause a deformation (e.g., a volume reduction, a thickness reduction, a length reduction, a height reduction, a combination thereof, etc.) of at least a portion of the semi-solid electrode material and no or substantially no deformation of the current collector. In some embodiments, the mechanical compression of the intermediate electrode material can cause removal of the portion of the electrolyte from the semi-solid electrode material.

[0034] In some embodiments, mechanical compression may include deploying an intermediate electrode between a die and a base of a mechanical press, and moving the die toward the base until a compressive force is applied to the intermediate electrode. In some embodiments, the die and base may be configured to have the same or substantially the same shape and dimensions as the intermediate electrode. In some embodiments, the mechanical press may be a stamping press including a motor and a piston configured to apply a moving force to the die, the dimensions of which are designed and configured to apply a compressive force to the intermediate electrode held in place by the base. In some embodiments, the intermediate electrode may be positioned in the mechanical press such that an exposed surface or a portion of an exposed surface of the current collector abuts the base, while an exposed surface or a portion of the exposed surface of the semi-solid electrode abuts the die. In some embodiments, the intermediate electrode may be positioned in the mechanical press such that an exposed surface or a portion of the exposed surface of the semi-solid electrode material abuts a substrate, while an exposed surface or a portion of the exposed surface of the current collector abuts the die. In some embodiments, the base and / or the die may have contact surfaces. In some embodiments, the base and / or the die may have interface regions between the contact surfaces of the base and / or the contact surfaces of the die and the current collector and / or the semi-solid electrode material.

[0035] In some embodiments, the contact surfaces of the mold and / or the base may include cavities such that, during mechanical compression of the intermediate electrode, the removed electrolyte or a portion thereof may be retained inside or communicate through the cavity. In some embodiments, during mechanical compression of the intermediate electrode, the removed electrolyte or a portion thereof may be conveyed from the semi-solid electrode material through a porous current collector and into or through the cavity. In some embodiments, the removed electrolyte or a portion thereof may be conveyed from the semi-solid electrode material, around the end or edge of the current collector, and from between the base and the mold. In some embodiments, the removed electrolyte or a portion thereof may be conveyed from the semi-solid electrode material in the direction opposite to the current collector and into or through the cavity. In some embodiments, the removed electrolyte or a portion thereof may be conveyed from the semi-solid electrode material via one of more pathways described herein. In some embodiments, the cavity may be fluidly coupled to a drain port such that the removed electrolyte conveyed to or through the cavity may be removed from the mechanical press via the drain port. In some embodiments, the cavity may be fluidly coupled to a reservoir such that the removed electrolyte conveyed to or through the cavity may be removed from the mechanical press via the reservoir. In some embodiments, the removed electrolyte held in the reservoir may be reusable and / or recyclable for use in other semi-solid electrodes or elsewhere.

[0036] In some embodiments, a semi-permeable membrane can be disposed on or around the semi-solid electrode material such that, during mechanical compression of the intermediate electrode, the semi-permeable membrane allows electrolyte to be transported out of the semi-solid electrode material while not allowing active material, conductive material, etc. to be transported out of the semi-solid electrode material. In some embodiments, the semi-permeable membrane can be a sheet or other planar structure that is configured to be removed from on or around the semi-solid electrode material before or after the intermediate electrode is removed from the mechanical press and before the mechanically compressed electrode is incorporated into an electrochemical cell, etc. In some embodiments, the semi-permeable membrane can be a conventional separator material that is configured to allow at least some flux of liquid electrolyte therethrough. In some embodiments, the semi-permeable membrane can be any material that allows at least some flux of liquid electrolyte therethrough while being fully or substantially chemically inert to the composition of the semi-solid electrode material and / or the current collector. In some embodiments, the semi-permeable membrane can absorb at least a portion of the extracted liquid electrolyte such that the liquid electrolyte cannot, cannot substantially, or can only partially be absorbed back into the semi-solid electrode material.

[0037] In some embodiments, removing the portion of electrolyte from the intermediate electrode forms a finished electrode having a higher loading of active solids than the previously described semi-solid electrode material and electrodes composed thereof. Without wishing to be bound by any particular theory, removing a portion of electrolyte (e.g., an excess portion of liquid electrolyte) can reduce the volume of the semi-solid electrode material on the current collector by removing electrolyte and by compression of the porosity and voids without a corresponding reduction in the electrical conductivity of the semi-solid electrode material. In some embodiments, the reduction in porosity can include a reduction in porosity from between about 20% and about 50% to between about 5% and about 30%, including all values and ranges therebetween.

[0038] In some embodiments, the second composition of the semi-solid electrode material can have a ratio of electrolyte to active material that is less than the first composition. In some embodiments, the second composition of the semi-solid electrode material can have a ratio of electrolyte to active material of between about 5: 1 and about 1 :3, between about 4: 1 and about 1 :2, between about 3: 1 and about 1 : 1, between about 5: 1 and about 1 :2, between about 5: 1 and about 1 : 1, between about 5: 1 and about 2: 1, between about 5: 1 and about 3: 1, between about 5: 1 and about 4: 1, between about 4: 1 and about 1 :3, between about 3: 1 and about 1 :3, between about 2: 1 and about 1 :3, between about 1 : 1 and about 1 :3, or between about 1 :2 and about 1 :3, including all values and ranges therebetween.

[0039] In some embodiments, the second composition of the semi-solid electrode material may have a concentration between approximately 5 mAh / g and approximately 24 mAh / g, between approximately 6 mAh / g and approximately 23 mAh / g, between approximately 7 mAh / g and approximately 22 mAh / g, between approximately 8 mAh / g and approximately 21 mAh / g, between approximately 9 mAh / g and approximately 20 mAh / g, between approximately 10 mAh / g and approximately 19 mAh / g, between approximately 11 mAh / g and approximately 18 mAh / g, between approximately 12 mAh / g and approximately 17 mAh / g, between approximately 13 mAh / g and approximately 16 mAh / g, between approximately 14 mAh / g and approximately 15 mAh / g, and so on. Between approximately 5 mAh / g and approximately 23 mAh / g, between approximately 5 mAh / g and approximately 22 mAh / g, between approximately 5 mAh / g and approximately 21 mAh / g, between approximately 5 mAh / g and approximately 20 mAh / g, between approximately 5 mAh / g and approximately 19 mAh / g, between approximately 5 mAh / g and approximately 18 mAh / g, between approximately 5 mAh / g and approximately 17 mAh / g, between approximately 5 mAh / g and approximately 16 mAh / g, between approximately 5 mAh / g and approximately 15 mAh / g, between approximately 5 mAh / g and approximately 14 mAh / g, between approximately 5 mAh / g and approximately 13 mAh / g, between ...13 mAh / g, between approximately 5 mAh / g and approximately 23 mAh / g, between approximately 5 mAh / g and approximately 23 mAh / g, between approximately 5 mAh / g and approximately 23 mAh / g, between approximately 5 mAh / g and approximately 14 mAh / g, between approximately 5 mAh / g and approximately 13 mAh / g, between approximately 5 mAh / Between approximately 12mAh / g, between approximately 5mAh / g and approximately 11mAh / g, between approximately 5mAh / g and approximately 10mAh / g, between approximately 5mAh / g and approximately 9mAh / g, between approximately 5mAh / g and approximately 8mAh / g, between approximately 5mAh / g and approximately 7mAh / g, between approximately 5mAh / g and approximately 6mAh / g, between approximately 6mAh / g and approximately 24mAh / g, between approximately 7mAh / g and approximately 24mAh / g, between approximately 8mAh / g and approximately 24mAh / g, between approximately 9mAh / g and approximately 24mAh / g, between approximately 10mAh / g and approximately 24mAh / g, large Between approximately 11 mAh / g and approximately 24 mAh / g, between approximately 12 mAh / g and approximately 24 mAh / g, between approximately 13 mAh / g and approximately 24 mAh / g, between approximately 14 mAh / g and approximately 24 mAh / g, between approximately 15 mAh / g and approximately 24 mAh / g, between approximately 16 mAh / g and approximately 24 mAh / g, between approximately 17 mAh / g and approximately 24 mAh / g, between approximately 18 mAh / g and approximately 24 mAh / g, between approximately 19 mAh / g and approximately 24 mAh / g, between approximately 20 mAh / g and approximately 24 mAh / g, between approximately 21 mAh / g and approximately 24 mAh / g.An energy density of between about 22 mAh / g and about 24 mAh / g, or between about 23 mAh / g and about 24 mAh / g, including all values and ranges therebetween. In some embodiments, the first composition of the semi-solid electrode material can have an energy density greater than about 5 mAh / g, about 6 mAh / g, about 7 mAh / g, about 8 mAh / g, about 9 mAh / g, about 10 mAh / g, about 11 mAh / g, about 12 mAh / g, about 13 mAh / g, about 14 mAh / g, about 15 mAh / g, about 16 mAh / g, about 17 mAh / g, about 18 mAh / g, about 19 mAh / g, about 20 mAh / g, about 21 mAh / g, about 22 mAh / g, about 23 mAh / g, or about 24 mAh / g, including all values and ranges therebetween.

[0040] In some embodiments, the semi-solid electrode material can have a thickness, after being mechanically compressed, of between about 1 pm and about 50 pm, between about 2 pm and about 49 pm, between about 3 pm and about 48 pm, between about 4 pm and about 47 pm, between about 5 pm and about 46 pm, between about 6 pm and about 45 pm, between about 7 pm and about 44 pm, between about 8 pm and about 43 pm, between about 9 pm and about 42 pm, between about 10 pm and about 41 pm, between about 15 pm and about 40 pm, between about 20 pm and about 30 pm, between about 2 pm and about 50 pm, between about 3 pm and about 50 pm, between about 4 pm and about 50 pm, between about 5 pm and about 50 pm, between about 6 pm and about 50 pm, between about 7 pm and about 50 pm, between about 8 pm and about 50 pm, between about 9 pm and about 50 pm, between about 10 pm and about 50 pm, between about 11 pm and about 50 pm, between about 12 pm and about 50 pm, between about 13 pm and about 50 pm, between about 14 pm and about 50 pm, between about 15 pm and about 50 pm, between about 20 pm and about 50 pm, between about 25 pm and about 50 pm, between about 30 pm and about 50 pm, between about 35 pm and about 50 pm, between about 40 pm and about 50 pm, or between about 45 pm and about 50 pm, including all values and ranges therebetween. In some embodiments, the semi-solid electrode material can have a thickness, after being mechanically compressed, of less than about 50 pm, about 49 pm, about 48 pm, about 47 pm, about 46 pm, about 45 pm, about 44 pm, about 43 pm, about 42 pm, about 41 pm, about 40 pm, about 39 pm, about 38 pm, about 37 pm, about 36 pm, about 35 pm, about 34 pm, about 33 pm, about 32 pm, about 31 pm, about 30 pm, about 29 pm, about 28 pm, about 27 pm, about 26 pm, about 25 pm, about 24 pm, about 23 pm, about 22 pm, about 21 pm, about 20 pm, about 19 pm, about 18 pm, about 17 pm, about 16 pm, about 15 pm, about 14 pm, about 13 pm, about 12 pm, about 11 pm, about 10 pm, about 9 pm, about 8 pm, about 7 pm, about 6 pm, about 5 pm, about 4 pm, about 3 pm, about 2 pm, or about 1 pm, including all values and ranges therebetween.

[0041] Method 10 can optionally include absorbing the extracted portion of the liquid electrolyte at 13 with an absorbent material. In some embodiments, the absorbent material can be disposed within the mechanical press, for example, between the middle electrode and at least one of the platen and the base, to absorb at least a portion of the electrolyte removed from the middle electrode. In some embodiments, the absorbent material can be an integral part of the mechanical press. In some embodiments, the absorbent material can be coupled to the platen of the mechanical press such that the extracted liquid electrolyte is absorbed by the absorbent material when the platen compresses the semi-solid electrode material against the current collector positioned on the base. In some embodiments, the absorbent material can be coupled to the base of the mechanical press. In some embodiments, the current collector can be at least partially porous such that the liquid electrolyte removed from the semi-solid electrode material during compression of the middle electrode can pass through the current collector and into the absorbent material. In some embodiments, the absorbent material can be reusable. In some embodiments, the first middle electrode can be mechanically compressed and the liquid electrolyte removed can be absorbed by the absorbent material. After the mechanical compression of the middle electrode, the finished electrode can be removed from the mechanical press. The mechanical press can then be operated to the closed position such that the platen and / or the base are moved such that the absorbent material is compressed between them, thereby removing the extracted liquid electrolyte from the liquid electrolyte. In some embodiments, after the extracted liquid electrolyte is removed from the absorbent material, the mechanical press can be returned to the open position and a second middle electrode can be disposed between the base and the platen for mechanical compression. In some embodiments, after the middle electrode is pressed in the mechanical press, the extracted liquid electrolyte can be removed from the absorbent material and the same middle electrode can be pressed a second time until a sufficient amount of liquid electrolyte is removed to achieve the desired composition of the finished electrode.

[0042] In some embodiments, the absorbent material can include any fibrous material, cotton fibers, rice hulls, superhydrophobic sawdust, cellulose-based materials, superabsorbent polymers, zeolite materials, aerogels, nanocellulose aerogels, hydrogels, polyurethane, polypropylene, polyethylene, and cross-linked polymers, nanoparticles, carbon nanotubes, poly(dimethylsiloxane), sepiolite, talc, montmorillonite, a mixture of peat moss, charcoal, and sawdust, combinations thereof, and the like.

[0043] In some embodiments, an absorbent material can be used in addition to a base and / or a press mold having a cavity. In some embodiments, an absorbent material can be used in place of a base and / or a press mold having a cavity. In some embodiments, a cavity can be at least partially filled with an absorbent material such that when extracted electrolyte is conveyed into the cavity, the absorbent material can capture all, substantially all, most, some, or a portion of the extracted electrolyte from at least reabsorbing back into the semi-solid electrode material. In some embodiments, an absorbent material can be positioned such that when extracted electrolyte or a portion thereof is conveyed through the cavity, for example, through the cavity and into a reservoir or drain fluidly coupled thereto, the absorbent material can capture all, substantially all, most, some, or a portion of the extracted electrolyte to prevent at least that portion from being conveyed back into the cavity and / or at least that portion from reabsorbing back into the semi-solid electrode material. In some embodiments, an absorbent material can be positioned around the edges of a base, press mold, and / or intercalation electrode such that any portion of electrolyte removed from the semi-solid electrode material via the edges of the intercalation electrode can be captured, substantially captured, or at least partially captured by the absorbent material. In some embodiments, an absorbent material can be inserted between a press mold or base and a semi-permeable membrane. In some embodiments, an absorbent material can be inserted between a porous current collector and a base or press mold. In some embodiments, an absorbent material can be positioned in more than one configuration described herein, for example, an absorbent material can be placed between a base and a current collector, between a press mold and a semi-permeable membrane positioned on an exposed surface of a semi-solid electrode material, around the edges of an intercalation electrode, such that all or substantially all of the removed excess electrolyte can be captured by the absorbent material.

[0044] In some embodiments, once the composition of the semi-solid electrode material matches or substantially matches the desired composition of the semi-solid electrode material in the finished electrode, the electrode can be removed from the mechanical press. In some embodiments, the electrode can be weighed before being mechanically pressed, then can be mechanically pressed for a first period of time to remove a first portion of electrolyte, then weighed again, the difference between the first weight and the second weight can be operable to determine the mass of electrolyte removed. If the mass of electrolyte removed substantially corresponds to the desired volume or mass of electrolyte to be removed, then the electrode can be considered a finished electrode and ready for further processing or incorporation into an electrochemical cell. If the mass of electrolyte removed does not substantially correspond to the desired volume or mass of electrolyte to be removed, then the electrode can be mechanically pressed for a second period of time to remove a second portion of electrolyte, then weighed a third time, the difference between the second weight and the third weight can be operable to determine the mass of electrolyte removed during the second period of time. If the mass of electrolyte removed during the first period of time plus the mass of electrolyte removed during the second period of time equals or substantially equals the desired mass of electrolyte to be removed from the semi-solid electrode material, then the electrode can be considered a finished electrode. Mechanical compression of the intermediate electrode can continue in this iterative manner until the total volume or mass of electrolyte removed equals or substantially equals the desired volume or mass of electrolyte to be removed. In some embodiments, in the event that more than the desired amount of electrolyte is removed from the electrode, electrolyte can be reapplied to the semi-solid electrode. In some embodiments, reapplication of electrolyte can be accomplished via spraying, dripping, or any other suitable method of application.

[0045] In some embodiments, the finished electrode can include an electrode tab that is electrically connected to the current collector and configured to transport electrons into or out of the electrode. In some embodiments, the electrode tab can extend beyond the current collector and / or the insulating material. In some embodiments, the electrode tab can be electrically coupled to the current collector prior to deploying the semi-solid electrode material onto the current collector. In some embodiments, the battery can include an integrated electrode tab, which can eliminate the need for (i) a separate tab component (e.g., an electrical lead), (ii) connecting a dedicated tab to the current collector, and (iii) a dedicated tab sealing operation. Instead, in some embodiments, an electrical tab or lead can be provided as an extension of the current collector integral with the current collector. In some embodiments, the tab or lead can be defined by removing material from a larger area of current collector material, thereby defining the current collector and the tab or lead.

[0046] Method 10 optionally includes smoothing and / or leveling the surface of the electrode (e.g., cathode) at 14 to prevent void spaces between the electrode and the separator in the finished electrochemical cell. The contact between the electrode and the absorbent material can cause the surface of the electrode to be rough and uneven. Smoothing and / or leveling the surface of the electrode can cause the surface of the electrode to be flush with the surface that will eventually contact the surface of the electrode (e.g., the surface of the separator, the surface of the current collector, the surface of a second electrode). Configuring these surfaces to be flush with one another can help prevent overpotential losses caused by void spaces between the surfaces. In some embodiments, the surface of the electrode can be smoothed and / or leveled with a doctor blade, spatula, or any other suitable smoothing device.

[0047] Method 10 optionally includes coupling the finished electrode (e.g., cathode) with a second finished electrode (e.g., anode) at 15, with a separator interposed, to form a finished electrochemical cell. In other words, once the finished electrode has been singulated and excess electrolyte has been removed, the finished electrode can be assembled into an electrochemical cell with a second finished electrode that exhibits an opposite redox reaction. In other words, a cathode and an anode can be coupled together with a separator disposed therebetween.

[0048] In some embodiments, a separator can be disposed between an anode and a cathode. In some embodiments, the separator can be coupled to at least one of the anode and the cathode with an adhesive. In some embodiments, one anode, one cathode, and one separator can be stacked together to form a unit cell assembly. Each unit cell assembly can also include a conductive tab (also referred to as a lead) to couple the electrodes to an external circuit. Multiple unit cell assemblies are then stacked or arranged together to form a battery cell. In some embodiments, the number of unit cell assemblies in the battery cell can vary depending on, for example, the desired capacity and / or thickness of the resulting battery cell. These stacked unit cell assemblies are electrically connected in parallel, and the respective tabs in each unit cell assembly are typically welded together via a welding process such as resistance welding, laser and ultrasonic welding, seam welding, electron beam welding, and the like.

[0049] Method 10 optionally includes pressing the electrochemical cell or stack of electrochemical cells to ensure contact throughout the electrochemical cell or stack of electrochemical cells. Applying a force to the electrochemical cell or stack of electrochemical cells can help reduce or substantially eliminate void spaces in the electrochemical cell or stack of electrochemical cells. These void spaces can be between the electrodes and the separator, between the electrodes and the current collector, and / or at the interfaces between the electrochemical cells.

[0050] In some embodiments, the prepared electrochemical cell can be vacuum sealed in a prismatic pouch that can provide airtight isolation of the electrochemical cell materials from the environment. Thus, the pouch can be used to avoid leakage of harmful materials, such as electrolyte solvents and / or corrosive salts, into the surrounding environment, and can prevent water and / or oxygen from permeating into the cell. Other functions of the pouch can include, for example, compression packaging of the inner layers, voltage isolation for safety and handling, and mechanical protection of the cell components. In some embodiments, during the vacuum pouch sealing, electrolyte can be injected into the stacked cell assembly, and then the cell assembly and electrolyte can be sealed into the pouch. In some embodiments, if the semi-solid electrode material can already contain the full desired amount of electrolyte, no electrolyte can be added during the pouch sealing step.

[0051] In some embodiments, the sealed cell unit can then be subjected to a formation process, in which an initial charging operation can be performed to create a stable solid- electrolyte-interphase (SEI) layer that can passivate the electrode-electrolyte interface and prevent side reactions. In some embodiments, several charge and discharge cycles can be performed to ensure that the capacity of the battery meets the required specifications. In some embodiments, a degassing step can be performed to release gases introduced or generated during the initial charging phase or during electrochemical reactions in the cell formation step. The presence of entrained gases in the electrodes generally reduces the electrical conductivity and density of the electrodes, and limits the amount of active electrochemical material that can be placed in the battery cell, and can cause dendrite growth that can corrode the battery performance of lithium batteries. In some embodiments, dendrite formation can result in a reduction in cycle life and a reduction in overall safety performance. In some embodiments, after the release of entrained gases, a resealing step can be taken to reseal the battery cell.

[0052] Figures 2A-2EA method 20 of forming a semi-solid electrode material 230b with a higher active material concentration and higher energy density is illustrated without requiring an electrolyte priming step and / or a drying step. The method 20 includes forming an intermediate electrode at 21 by first deploying a stencil 220a, 220b (collectively, "stencil 220") onto a current collector 210 (e.g., a foil current collector). The current collector 210 can be any suitable conductive material configured to transport ions / electrons between an electrode material and a source or sink. In some embodiments, the stencil 220 can include any material through which the semi-solid electrode material cannot transport. In some embodiments, the stencil 220 can have dimensions designed and configured to extend circumferentially around or substantially around the current collector 210 or around an outer dimension of the current collector 210. In some embodiments, the stencil 220 can have the same or substantially the same dimensions as the current collector 210. In some embodiments, the stencil 220 can include a masking material, such as those described in the '483 application. In some embodiments, the masking material can be a tape or similar material that can be applied onto or around the current collector 210 to contain the semi-solid electrode material during deposition of the semi-solid electrode material onto the current collector 210, during subsequent manufacturing steps of the electrochemical cell, and / or during use of the electrochemical cell.

[0053] In some embodiments, instead of or in addition to a masking material, as described above, an inner frame structure can be deployed onto the current collector 210 prior to deploying the semi-solid electrode material onto the current collector 210. In some embodiments, the inner frame can hold the current collector 210 in place or substantially in place during deposition of the semi-solid electrode material. In some embodiments, the inner frame can have at least some z-direction thickness such that the inner frame at least partially defines an interior region in which the semi-solid electrode material can be deployed and held on a surface of the current collector 210.

[0054] In some embodiments, the inner frame can at least partially define a surface area of the finished electrode (e.g., as an interior extent of the inner frame). In some embodiments, the inner frame can at least partially define a thickness of the semi-solid electrode material on the current collector 210 based on a z-direction height of the inner frame.

[0055] In some embodiments, the stencil 220 can include two inner frames, where a first inner frame 220a is deployed directly onto the current collector 210 or onto a masking material on the current collector 210, and a second inner frame 220b can be deployed onto the first inner frame 220a.

[0056] At 22, the method 20 also includes depositing the semi-solid electrode material into the cavity and, optionally, spreading the semi-solid electrode material evenly over the current collector foil. In some embodiments, depositing the semi-solid electrode material onto the current collector 210 can form a semi-solid electrode material 230a having a first composition. In some embodiments, dispensing the semi-solid electrode material can include drip feeding the material onto a moving current collector to form or substantially form an intermediate electrode. In some embodiments, dispensing the semi-solid electrode material can include extruding the semi-solid electrode material from a moving extrusion nozzle or the like onto a stationary current collector 210. In some embodiments, the semi-solid electrode material can be dispensed via a stationary dispensing mechanism onto a stationary current collector 210, for example in discrete portions, and then the discrete portions of semi-solid electrode material can be spread over the surface of the current collector 210 by any suitable method to form or substantially form an intermediate electrode. In some embodiments, the current collector material can be apportioned into a plurality of current collectors 210 such that each of the plurality of current collectors 210 is separated from the others. Discrete portions of semi-solid electrode material can then be deployed onto the surface of each individualized current collector 210 to form or substantially form an intermediate electrode. In some embodiments, the intermediate electrode formed according to step 22 of the method 20 includes an intermediate electrode material, for example the semi-solid electrode material 230a, such that the intermediate electrode can be operated in an electrochemical cell, but it has a lower than desired active solid loading of the finished electrode. The intermediate electrode formed can be a positive electrode, anode, negative electrode, cathode, or any other electrode or component of an electrochemical cell. As described herein, the electrode can be a semi-solid electrode including at least an active material and / or a conductive material in a liquid electrolyte.

[0057] In some embodiments, the semi-solid electrode material can be smoothed or spread along the surface of the exposed portion of the current collector 210. In some embodiments, a doctor blade (also referred to herein as a "doctor's blade") or other straight-bladed instrument can be used to spread the semi-solid electrode material. In some embodiments, the doctor blade and / or inner frame can be operably coupled to a vibration source to vibrate the doctor blade or inner frame during deposition or smoothing of the semi-solid electrode material. The vibration can facilitate dispersion of the semi-solid electrode material during or after the semi-solid electrode material deposition step.

[0058] The method 20 also includes removing the stencil to define the electrode and form the edges of the electrode at 23. In some embodiments, step 23 can include removing the inner frame, the masking material, or both. In some embodiments, removing the stencil material can result in the intermediate electrode having cleaner edges with less, substantially no, or no edge chipping. In some embodiments, a portion of the stencil can be removed, for example the top layer or upper half of the stencil, and the bottom layer or lower half can remain in place on the current collector 210.

[0059] In some embodiments, once the template or a portion thereof has been removed, the intermediate electrode can be weighed and / or the thickness of the intermediate electrode can be measured. In some embodiments, the weight of the intermediate electrode can be compared to a predetermined weight that the intermediate electrode is expected to have. In some embodiments, the thickness (e.g., in the z-direction) of the intermediate electrode can be compared to a predetermined thickness that the intermediate electrode is expected to have. In some embodiments, the predetermined weight and / or the predetermined thickness can be the first weight or the first thickness.

[0060] Method 20 further includes placing the electrode in a mechanical press and applying a compressive force to extract a portion of the electrolyte from the semi-solid electrode material at 24. In some embodiments, the mechanical press can include a base 250a and a press die 250b, where moving the base and / or the press die supplies a compressive force F to the intermediate electrode sufficient to extract a portion of the electrolyte from the semi-solid electrode material 230a. In some embodiments, the mechanical press can include press guides 260, such as channels or walls, such that movement of the base 250a and / or the press die 250b can be controlled during mechanical pressing. In some embodiments, once the portion of the electrolyte is removed by mechanical compression of the intermediate electrode, the electrode can include a semi-solid electrode material 230b having a second composition, where the ratio of active material to electrolyte is higher than when the semi-solid electrode material 230a has the first composition.

[0061] In some embodiments, at least one of the base 250a and the press die 250b can include a cavity, such that the removed electrolyte or a portion thereof can be held within or conveyed through the cavity during mechanical compression of the intermediate electrode. In some embodiments, the removed electrolyte or a portion thereof can be conveyed from the semi-solid electrode material through the porous current collector and into or through the cavity during mechanical compression of the intermediate electrode. In some embodiments, the removed electrolyte or a portion thereof can be conveyed from the semi-solid electrode material, around an end or edge of the current collector, and between the base and the press die. In some embodiments, the removed electrolyte or a portion thereof can be conveyed from the semi-solid electrode material in a direction opposite the current collector 210 and into or through the cavity. In some embodiments, the removed electrolyte or a portion thereof can be conveyed from the semi-solid electrode material 230a via more than one of the pathways described herein. In some embodiments, the cavity can be fluidically coupled to a drain, such that the removed electrolyte conveyed into or through the cavity can be removed from the mechanical press via the drain. In some embodiments, the cavity can be fluidically coupled to a reservoir, such that the removed electrolyte conveyed into or through the cavity can be removed from the mechanical press via the reservoir. In some embodiments, the removed electrolyte held in the reservoir can be reusable and / or recyclable for use in other semi-solid electrodes or elsewhere.

[0062] In some embodiments, a semi-permeable membrane (not shown) can be disposed on or around the semi-solid electrode material such that during mechanical compression of the intermediate electrode, the semi-permeable membrane allows electrolyte to pass out of the semi-solid electrode material while not allowing active materials, conductive materials, etc. to pass out of the semi-solid electrode material. In some embodiments, the semi-permeable membrane can be a sheet or other planar structure that is configured to be removed before or after the intermediate electrode is removed from the mechanical press and when the mechanically compressed electrode is incorporated into an electrochemical cell, etc. In some embodiments, the semi-permeable membrane can be a conventional separator material configured to allow at least some liquid electrolyte to flow therethrough. In some embodiments, the semi-permeable membrane can be any material that allows at least some flux of liquid electrolyte therethrough while being fully or substantially chemically inert to the composition of the semi-solid electrode material 230a and / or the current collector 210. In some embodiments, the semi-permeable membrane can remain on or around the semi-solid electrode material throughout the mechanical compression and construction of the electrochemical cell such that the semi-permeable membrane is included in the finished electrochemical cell.

[0063] In some embodiments, the absorbent material 240 can be disposed between a portion of the intermediate electrode and a component of the mechanical press, e.g., at 24, prior to mechanical pressing of the intermediate electrode. In some embodiments, the absorbent material 240 can be disposed within the mechanical press, e.g., between at least one of the compression mold 250b and the base 250a and the intermediate electrode, to absorb at least a portion of electrolyte removed from the intermediate electrode. In some embodiments, the absorbent material 240 can include at least one of: a fibrous material, cotton fibers, rice hulls, superhydrophobic sawdust, cellulose-based materials, superabsorbent polymers, zeolite materials, aerogels, nanocellulose aerogels, hydrogels, polyurethane, polypropylene, polyethylene, and cross-linked polymers, nanoparticles, carbon nanotubes, polydimethylsiloxane, sepiolite, talc, montmorillonite, a mixture of the following three: sphagnum moss, charcoal, and sawdust, combinations thereof, etc.

[0064] In some embodiments, an absorbent material 240 can be used in addition to a base and / or a press mold having a cavity. In some embodiments, an absorbent material 240 can be used in place of a base and / or a press mold having a cavity. In some embodiments, a cavity can be at least partially filled with an absorbent material such that when extracted electrolyte is transferred into the cavity, the absorbent material 240 can capture all, substantially all, a majority, some, or a portion of the extracted electrolyte to prevent at least that portion from reabsorbing back into the semi-solid electrode material 230b. In some embodiments, the absorbent material 240 can be positioned such that when extracted electrolyte or a portion thereof is transferred through the cavity, for example, through the cavity and into a reservoir or drain fluidly coupled thereto, the absorbent material 240 can capture all, substantially all, a majority, some, or a portion of the extracted electrolyte to prevent at least that portion from being transferred back into the cavity and / or at least that portion from reabsorbing back into the semi-solid electrode material 230b. In some embodiments, the absorbent material 240 can be positioned around the edges of the base 250a, the press mold 250b, and / or the intermediate electrode such that any portion of electrolyte removed from the semi-solid electrode material 230a via the edges of the intermediate electrode can be captured, substantially captured, or at least partially captured by the absorbent material 240. In some embodiments, the absorbent material 240 can be inserted between the press mold 250b or the base 250a and the semi-permeable membrane. In some embodiments, the absorbent material 240 can be inserted between the porous current collector 210 and the base 250a or the press mold 250b. In some embodiments, the absorbent material 240 can be positioned in more than one configuration described herein, for example, the absorbent material 240 can be placed between the base 250a and the current collector 210, between the press mold 250b and a semi-permeable membrane positioned on the exposed surface of the semi-solid electrode material 230a, and around the edges of the intermediate electrode such that all or substantially all of the removed excess electrolyte can be captured by the absorbent material 240.

[0065] Method 20 also includes disassembling the mechanical press assembly and removing the absorbent material 240, the semi-permeable membrane, and / or any remaining template material (e.g., the first inner frame 220a) to form a finished semi-solid electrode having a higher active solid loading. In some embodiments, removing the portion of electrolyte from the intermediate electrode forms a finished electrode having a higher active solid loading than the previously described semi-solid electrode material and electrodes composed thereof. Without wishing to be bound by any particular theory, removing a portion of the electrolyte (e.g., an excess portion of the liquid electrolyte) can reduce the volume of the semi-solid electrode material on the current collector without a corresponding reduction in electrical conductivity across the semi-solid electrode material by removing the electrolyte and by compression through the voids and porosity. In some embodiments, the reduction in porosity can include a reduction in porosity from between about 20% and about 50% to between about 5% and about 30%, including all values and ranges therebetween.

[0066] In some embodiments, the first composition of the semi-solid electrode material 230a can include about 20% to about 80% active material by volume. In some embodiments, the first composition of the semi-solid electrode material 230a can include about 40% to about 80% active material by volume, or 50% to about 80% active material by volume. In some embodiments, the first composition of the semi-solid electrode material 230a can include at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, or at least about 75% active material by volume. In some embodiments, the first composition of the semi-solid electrode material 230a can include no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, or no more than about 25% active material by volume. Combinations of the above-mentioned volume percentages of active material in the first composition of the semi-solid electrode material 230a are also possible (e.g., at least about 20% by volume and no more than about 80% by volume or at least about 30% by volume and no more than about 60% by volume), including all values and ranges therebetween. In some embodiments, the first composition of the semi-solid electrode material 230a can include about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, or about 80% active material by volume.

[0067] In some embodiments, the first composition of the semi-solid electrode material 230a can include about 0.5% to about 25% by volume of the electrically conductive material. In some embodiments, the first composition of the semi-solid electrode material 230a can include about 1.0% to about 6% by volume of the electrically conductive material. In some embodiments, the first composition of the semi-solid electrode material 230a can include at least about 0.5%, at least about 1%, at least about 1.5%, at least about 2%, at least about 2.5%, at least about 3%, at least about 3.5%, at least about 4%, at least about 4.5%, at least about 5%, at least about 5.5%, at least about 6%, at least about 6.5%, at least about 7%, at least about 7.5%, at least about 8%, at least about 8.5%, at least about 9%, at least about 9.5%, at least about 10%, at least about 15%, or at least about 20% by volume of the electrically conductive material. In some embodiments, the first composition of the semi-solid electrode material 230a can include no more than about 25%, no more than about 20%, no more than about 15%, no more than about 10%, no more than about 9.5%, no more than about 9%, no more than about 8.5%, no more than about 8%, no more than about 7.5%, no more than about 7%, no more than about 6.5%, no more than about 6%, no more than about 5.5%, no more than about 5%, no more than about 4.5%, no more than about 4%, no more than about 3.5%, no more than about 3%, no more than about 2.5%, no more than about 2%, no more than about 1.5%, or no more than about 1% by volume of the electrically conductive material. Combinations of the above-mentioned volume percentages of the electrically conductive material in the first composition of the semi-solid electrode material 230a are also possible (e.g., at least about 0.5% by volume and no more than about 25% by volume or at least about 3% by volume and no more than about 10% by volume), including all values and ranges therein. In some embodiments, the first composition of the semi-solid electrode material 230a can include about 0.5%, about 1%, about 1.5%, about 2%, about 2.5%, about 3%, about 3.5%, about 4%, about 4.5%, about 5%, about 5.5%, about 6%, about 6.5%, about 7%, about 7.5%, about 8%, about 8.5%, about 9%, about 9.5%, about 10%, about 15%, about 20%, or about 25% by volume of the electrically conductive material.

[0068] In some embodiments, the first composition of the semi-solid electrode material 230a can include about 25% to about 70% electrolyte by volume. In some embodiments, the first composition of the semi-solid electrode material 230a can include about 30% to about 50%, or about 20% to about 40% electrolyte by volume. In some embodiments, the first composition of the semi-solid electrode material 230a can include at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, or at least about 65% electrolyte by volume. In some embodiments, the first composition of the semi-solid electrode material 230a can include no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, or no more than about 30% electrolyte by volume. Combinations of the above-mentioned volume percentages of electrolyte in the first composition of the semi-solid electrode material 230a are also possible (e.g., at least about 25% and no more than about 70% or at least about 30% and no more than greater than about 50%), including all values and ranges therein. In some embodiments, the first composition of the semi-solid electrode material 230a can include about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, or about 70% electrolyte by volume.

[0069] In some embodiments, the second composition of the semi-solid electrode material 230b can include about 30% to about 85% active material by volume. In some embodiments, the second composition of the semi-solid electrode material 230b can include about 50% to about 85% active material by volume, or 60% to about 85% active material by volume. In some embodiments, the second composition of the semi-solid electrode material 230b can include at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80% active material by volume. In some embodiments, the second composition of the semi-solid electrode material 230b can include no more than about 85%, no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, or no more than about 35% active material by volume. Combinations of the above-mentioned volume percentages of active material in the second composition of the semi-solid electrode material 230b are also possible (e.g., at least about 30% by volume and no more than about 85% by volume, or at least about 40% by volume and no more than about 70% by volume), including all values and ranges therebetween. In some embodiments, the second composition of the semi-solid electrode material 230b can include about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, or about 85% active material by volume.

[0070] In some embodiments, the second composition of the semi-solid electrode material 230b can include about 0.5% to about 30% by volume of the electrically conductive material. In some embodiments, the second composition of the semi-solid electrode material 230b can include about 1.0% to about 6% by volume of the electrically conductive material. In some embodiments, the second composition of the semi-solid electrode material 230b can include at least about 0.5%, at least about 1%, at least about 1.5%, at least about 2%, at least about 2.5%, at least about 3%, at least about 3.5%, at least about 4%, at least about 4.5%, at least about 5%, at least about 5.5%, at least about 6%, at least about 6.5%, at least about 7%, at least about 7.5%, at least about 8%, at least about 8.5%, at least about 9%, at least about 9.5%, at least about 10%, at least about 15%, at least about 20%, or at least about 25% by volume of the electrically conductive material. In some embodiments, the second composition of the semi-solid electrode material 230b can include no more than about 30%, no more than about 25%, no more than about 20%, no more than about 15%, no more than about 10%, no more than about 9.5%, no more than about 9%, no more than about 8.5%, no more than about 8%, no more than about 7.5%, no more than about 7%, no more than about 6.5%, no more than about 6%, no more than about 5.5%, no more than about 5%, no more than about 4.5%, no more than about 4%, no more than about 3.5%, no more than about 3%, no more than about 2.5%, no more than about 2%, no more than about 1.5%, or no more than about 1% by volume of the electrically conductive material. Combinations of the above-mentioned volume percentages of the electrically conductive material in the second composition of the semi-solid electrode material 230b are also possible (e.g., at least about 0.5% by volume and no more than about 30% by volume or at least about 5% by volume and no more than about 10% by volume), including all values and ranges therein. In some embodiments, the second composition of the semi-solid electrode material 230b can include about 0.5%, about 1%, about 1.5%, about 2%, about 2.5%, about 3%, about 3.5%, about 4%, about 4.5%, about 5%, about 5.5%, about 6%, about 6.5%, about 7%, about 7.5%, about 8%, about 8.5%, about 9%, about 9.5%, about 10%, about 15%, about 20%, about 25%, or about 30% by volume of the electrically conductive material.

[0071] In some embodiments, the second composition of the semi-solid electrode material 230b can include about 15% to about 60% electrolyte by volume. In some embodiments, the second composition of the semi-solid electrode material 230b can include about 20% to about 40%, or about 10% to about 30% electrolyte by volume. In some embodiments, the second composition of the semi-solid electrode material 230b can include at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, or at least about 55% electrolyte by volume. In some embodiments, the second composition of the semi-solid electrode material 230b can include no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, no more than about 25%, or no more than about 20% electrolyte by volume. Combinations of the above-mentioned volume percentages of electrolyte in the second composition of the semi-solid electrode material 230b are also possible (e.g., at least about 15% and no more than about 60% or at least about 20% and no more than greater than about 40%), including all values and ranges therebetween. In some embodiments, the second composition of the semi-solid electrode material 230b can include about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, or about 60% electrolyte by volume.

[0072] In some embodiments, the second composition of the semi-solid electrode material 230b can have a ratio of electrolyte to active material that is less than the first composition of the semi-solid electrode material 230a. In some embodiments, the second composition of the semi-solid electrode material 230b can have a v / v ratio of electrolyte to active material between about 5: 1 and about 1 :6, about 5: 1 and about 1 :5, about 5: 1 and about 1 :4, about 5: 1 and about 1 :3, about 4: 1 and about 1 :2, about 3: 1 and about 1 : 1, about 5: 1 and about 1 :2, about 5: 1 about 1 : 1, about 5: 1 and about 2: 1, about 5: 1 and about 3: 1, about 5: 1 and about 4: 1, about 4: 1 and about 1 :3, about 3: 1 about 1 :3, about 2: 1 and about 1 :3, about 1 : 1 and about 1 :3, about 1 :2 and about 1 :3, about 1 :2 and about 1 :4, about 1 :2 about 1 :5, about 1 :2 and about 1 :6, about 1 :3 and about 1 :6, about 1 :4 and about 1 :6, or about 1 :5 and about 1 :6, including all values and ranges therebetween.

[0073] In some embodiments, the weight and / or thickness of the semi-solid electrode can be measured at various points throughout the process of mechanically pressing the intermediate electrode to form the finished electrode. For example, in some embodiments, the weight of the finished electrode can be a second weight and can be compared to the first weight to determine the mass of electrolyte removed during mechanical pressing. In some embodiments, the thickness of the finished electrode can be a second thickness and can be compared to the first thickness to determine the volume of electrolyte removed during mechanical pressing. In some embodiments, if the difference between the first and second weight or the first and second thickness of the semi-solid electrode material 230b is insufficient, then the absorbent material 240 and / or the semi-permeable membrane can be placed back on the semi-solid electrode material and the intermediate electrode can be further mechanically compressed to remove a second portion of electrolyte from the semi-solid electrode material 230b. In some embodiments, the volume or mass of electrolyte removed during mechanical pressing can be used to determine the relative volume or mass percentages of active material, conductive material, and electrolyte in the semi-solid electrode material 230b.

[0074] In some embodiments, once the composition of the semi-solid electrode material 230b matches or substantially matches the desired composition of the semi-solid electrode material 230b in the finished electrode, the electrode can be removed from the mechanical press. In some embodiments, the electrode can be weighed before being mechanically pressed, then can be mechanically pressed for a first period of time to remove a first portion of electrolyte, then weighed again, the difference between the first weight and the second weight can be used to determine the mass of electrolyte removed. If the mass of electrolyte removed substantially corresponds to the desired volume or mass of electrolyte to be removed, then the electrode can be considered a finished electrode and ready for further processing or incorporation into an electrochemical cell (not shown). If the mass of electrolyte removed does not substantially correspond to the desired volume or mass of electrolyte to be removed, then the electrode can be mechanically pressed for a second period of time to remove a second portion of electrolyte, then weighed a third time, the difference between the second weight and the third weight can be used to determine the mass of electrolyte removed during the second period of time. If the mass of electrolyte removed during the first period of time plus the mass of electrolyte removed during the second period of time equals or substantially equals the desired mass of electrolyte to be removed from the semi-solid electrode material, then the electrode can be considered a finished electrode. The mechanical compression of the intermediate electrode can continue in this iterative manner until the total volume or mass of electrolyte removed equals or substantially equals the desired volume or mass of electrolyte to be removed.

[0075] In some embodiments, the finished electrode can include an electrode tab that is electrically connected to the current collector and configured to transport electrons into or out of the electrode. In some embodiments, the electrode tab can extend beyond the current collector and / or the insulating material. In some embodiments, the electrode tab can be electrically coupled to the current collector prior to deploying the semi-solid electrode material onto the current collector. In some embodiments, the battery can include an integrated electrical tab, which can eliminate the need for (i) a separate tab component (e.g., an electrical lead), (ii) connecting a dedicated tab to the current collector, and (iii) a dedicated tab sealing operation. Instead, in some embodiments, an electrical terminal or lead can be provided as an extension of the current collector integral with the current collector. In some embodiments, the tab or lead can be defined by removing material from a larger area of current collector material, thereby defining the current collector and the tab or lead.

[0076] Method 20 optionally includes coupling the finished electrode (e.g., cathode) with a second finished electrode (e.g., anode) with a separator interposed to form a finished electrochemical cell. In other words, once the finished electrode has been singulated and excess electrolyte has been removed, the finished electrode can be assembled into an electrochemical cell with a second finished electrode that exhibits an opposite redox reaction. In other words, a cathode and an anode can be coupled together with a separator disposed therebetween.

[0077] In some embodiments, a separator can be disposed between the anode and the cathode. In some embodiments, the separator can be coupled to at least one of the anode and the cathode with an adhesive. In some embodiments, one anode, one cathode, and one separator can be stacked together to form a unit cell assembly. Each unit cell assembly can also include a conductive tab (also referred to as a lead) to couple the electrodes to an external circuit. Multiple unit cell assemblies are then stacked or arrayed together to form a battery cell. In some embodiments, the number of unit cell assemblies in the battery cell can vary depending on, for example, the desired capacity and / or thickness of the resulting battery cell. These stacked unit cell assemblies are electrically connected in parallel, and the respective tabs in each unit cell assembly are typically welded together via a welding process such as resistance welding, laser and ultrasonic welding, seam welding, electron beam welding, and the like.

[0078] In some embodiments, the prepared electrochemical cell can be vacuum sealed in a prismatic pouch that can provide airtight isolation of the electrochemical cell materials from the environment. Thus, the pouch can be used to avoid leakage of harmful materials, such as electrolyte solvents and / or corrosive salts, into the surrounding environment, and can prevent water and / or oxygen from permeating into the cell. Other functions of the pouch can include, for example, compression packaging of the inner layers, voltage isolation for safety and handling, and mechanical protection of the cell components. In some embodiments, during the vacuum pouch sealing, electrolyte can be injected into the stacked cell assembly, and then the cell assembly and electrolyte can be sealed into the pouch. In some embodiments, if the semi-solid electrode material can already contain the full desired amount of electrolyte, no electrolyte can be added during the pouch sealing step.

[0079] In some embodiments, the sealed cell unit can then be subjected to a formation process, in which an initial charging operation can be performed to create a stable SEI layer that can passivate the electrode-electrolyte interface and prevent side reactions. In some embodiments, several charge and discharge cycles can be performed to ensure that the capacity of the battery meets the required specifications. In some embodiments, a degassing step can be performed to release gases introduced or generated during the initial charging phase or during electrochemical reactions in the cell formation step. The presence of entrained gases in the electrodes generally reduces the electrical conductivity and density of the electrodes, and limits the amount of active electrochemical material that can be placed in the battery cell, and can cause dendrite growth that can corrode the battery performance of lithium batteries. In some embodiments, dendrite formation can result in a reduction in cycle life and a reduction in overall safety performance. In some embodiments after the release of entrained gases, a resealing step can be taken to reseal the battery cell.

[0080] Figures 3A-3EA method 30 of forming a semi-solid electrode material having a higher active material concentration and higher energy density is illustrated without requiring an electrolyte priming step and / or a drying step. The method 30 includes forming an intermediate electrode at 31 by first deploying a stencil 320a, 320b (collectively, "stencils 320") onto a current collector 310 (e.g., a foil current collector). The current collector 310 can be any suitable electrically conductive material configured to transport ions / electrons between the electrode material and a source or sink. In some embodiments, the stencils 320 can include any material through which the semi-solid electrode material cannot transport. In some embodiments, the stencils 320 are dimensioned and configured to extend circumferentially around or substantially around the current collector 310. In some embodiments, the stencils 320 can have the same or substantially the same dimensions as the current collector 310. In some embodiments, the stencils 320 can include masking materials such as those described in the '483 application. In some embodiments, the masking materials can be a tape or similar material that can be applied to or around the current collector 310 to contain the semi-solid electrode material during deposition of the semi-solid electrode material onto the current collector 310.

[0081] In some embodiments, instead of or in addition to the masking materials, as described above, an inner frame structure can be deployed onto the current collector 310 prior to deploying the semi-solid electrode material onto the current collector 310. In some embodiments, the inner frame can hold the current collector 310 in place or substantially in place during deposition of the semi-solid electrode material. In some embodiments, the inner frame can have some thickness in the z-direction such that the inner frame at least partially defines an interior region in which the semi-solid electrode material can be deployed and held on the surface of the current collector 310.

[0082] In some embodiments, the inner frame can at least partially define a surface area of the finished electrode (e.g., as an interior extent of the inner frame). In some embodiments, the inner frame can at least partially define a thickness of the semi-solid electrode material on the current collector 310 based on the z-direction height of the inner frame.

[0083] In some embodiments, the stencils 320 can include two inner frames, where a first inner frame 320a is deployed directly onto the current collector 310 or onto the masking materials on the current collector 310, and a second inner frame 320b can be deployed onto the first inner frame 320a.

[0084] Method 30 also includes depositing the semi-solid electrode material into the cavity at 32, and optionally, spreading the semi-solid electrode material evenly over the current collector foil. In some embodiments, depositing the semi-solid electrode material onto the current collector 310 can form a semi-solid electrode material 330a having a first composition. In some embodiments, dispensing the semi-solid electrode material can include drop-casting the semi-solid electrode material onto a moving current collector to form or substantially form an intermediate electrode. In some embodiments, dispensing the semi-solid electrode material can include extruding the semi-solid electrode material from a moving extrusion nozzle or the like onto a stationary current collector 310. In some embodiments, the semi-solid electrode material can be dispensed onto a stationary current collector 310 via a stationary dispensing mechanism, for example in discrete portions, and then the discrete portions of semi-solid electrode material can be spread over the surface of the current collector 310 by any suitable method to form or substantially form an intermediate electrode. In some embodiments, the current collector material can be apportioned into a plurality of current collectors 310 such that each of the plurality of current collectors 310 is separated from the others. Discrete portions of semi-solid electrode material can then be deployed onto the surface of each individualized current collector 310 to form or substantially form an intermediate electrode. In some embodiments, the intermediate electrode formed according to step 32 of method 30 includes an intermediate electrode material, for example 330a, such that the intermediate electrode is operable in an electrochemical cell, but it has a lower than desired active solid loading for a finished electrode. The intermediate electrode formed can be a positive electrode, anode, negative electrode, cathode, or any other electrode or component of an electrochemical cell. As described herein, the electrode can be a semi-solid electrode including at least an active material and / or an electrically conductive material in a liquid electrolyte.

[0085] In some embodiments, the semi-solid electrode material can be smoothed or spread along the surface of the exposed portion of the current collector 310. In some embodiments, a doctor blade (also referred to herein as a "doctor's blade") or other straight-bladed device can be used to spread the semi-solid electrode material. In some embodiments, the doctor blade and / or inner frame can be operably coupled to a vibration source to vibrate the doctor blade or inner frame during deposition or smoothing of the semi-solid electrode material. The vibration can facilitate dispersion of the semi-solid electrode material during or after the semi-solid electrode material deposition step.

[0086] Method 30 also includes removing the template to define the electrode and form the edges of the electrode at 33. In some embodiments, step 33 can include removing the inner frame, the masking material, or both. In some embodiments, removing the template material can result in the intermediate electrode having cleaner edges with less, substantially no, or no edge chipping. In some embodiments, a portion of the template can be removed, for example the top layer or upper half of the template, and the bottom layer or lower half can remain in place on the current collector 310.

[0087] In some embodiments, once the template or a portion thereof has been removed, the intermediate electrode can be weighed and / or the thickness of the intermediate electrode can be measured. In some embodiments, the weight of the intermediate electrode can be compared to a predetermined weight that the intermediate electrode is expected to have. In some embodiments, the thickness (e.g., in the z-direction) of the intermediate electrode can be compared to a predetermined thickness that the intermediate electrode is expected to have. In some embodiments, the predetermined weight and / or the predetermined thickness can be the first weight or the first thickness.

[0088] Method 30 also includes applying a compressive force F to extract a portion of the electrolyte from the semi-solid electrode material at 34. In some embodiments, the compressive force can be applied to the semi-solid electrode material via a roller or the like. As shown, the roller is rotated along a direction R. In some embodiments, the roller can be moved across the surface of the stationary intermediate electrode to apply the compressive force F. In some embodiments, the intermediate electrode can be positioned on a base (not shown) and the roller can be moved over the surface of the stationary intermediate electrode. In some embodiments, the intermediate electrode can be moved through, past, or under the roller such that the roller can apply the compressive force F. In some embodiments, the intermediate electrode can be conveyed along a conveyor beneath the roller. In some embodiments, the intermediate electrode can be moved through a plurality of rollers such that the rollers apply the compressive force F. In some embodiments, once a portion of the electrolyte has been removed via mechanical compression of the intermediate electrode, the electrode can include a semi-solid electrode material 330b having a second composition, where the ratio of active material to electrolyte is higher than when the semi-solid electrode material 330a has the first composition.

[0089] In some embodiments, the base, the roller, one of the plurality of rollers, and / or each of the plurality of rollers can include a cavity such that electrolyte removed or a portion thereof can be held within or conveyed through the cavity during mechanical compression of the intermediate electrode. In some embodiments, electrolyte removed or a portion thereof can be conveyed from the semi-solid electrode material, through the porous current collector, and into or through the cavity during mechanical compression of the intermediate electrode. In some embodiments, electrolyte removed or a portion thereof can be conveyed from the semi-solid electrode material, around an end or edge of the current collector, between the substrate and the roller or plurality of rollers. In some embodiments, electrolyte removed or a portion thereof can be conveyed from the semi-solid electrode material in a direction opposite the current collector 310 and into or through the cavity. In some embodiments, electrolyte removed or a portion thereof can be conveyed from the semi-solid electrode material 330a via more than one of the pathways described herein. In some embodiments, the cavity can be fluidly coupled to a drain such that electrolyte removed conveyed into or through the cavity can be removed from the mechanical press via the drain. In some embodiments, the cavity can be fluidly coupled to a reservoir such that electrolyte removed conveyed into or through the cavity can be removed from the mechanical press via the reservoir. In some embodiments, electrolyte removed held in the reservoir can be reusable and / or recyclable for other semi-solid electrodes or elsewhere.

[0090] In some embodiments, a semi-permeable membrane (not shown) can be disposed on or around the semi-solid electrode material such that during mechanical compression of the intermediate electrode, the semi-permeable membrane allows electrolyte to be conveyed from the semi-solid electrode material while not allowing active material, conductive material, etc. to be conveyed from the semi-solid electrode material. In some embodiments, the semi-permeable membrane can be a sheet or other planar structure that is configured to be removed before or after the intermediate electrode is removed from the mechanical press and when the mechanically compressed electrode is incorporated into an electrochemical cell or the like. In some embodiments, the semi-permeable membrane can be a conventional separator material configured to allow at least some liquid electrolyte to flow therethrough. In some embodiments, the semi-permeable membrane can be any material that allows at least some liquid electrolyte to flow therethrough while being fully or substantially chemically inert to the composition of the semi-solid electrode material and / or the current collector 310. In some embodiments, the semi-permeable membrane can be held on or around the semi-solid electrode material throughout the mechanical compression and construction of the electrochemical cell such that the semi-permeable membrane is included in the finished electrochemical cell.

[0091] In some embodiments, the absorbent material 340 can be disposed between a portion of the intermediate electrode and at least one of the base, roller, or plurality of rollers prior to mechanically pressing the intermediate electrode, e.g., at 34. In some embodiments, the absorbent material 340 can be disposed between the intermediate electrode and the roller to absorb at least a portion of the electrolyte removed from the intermediate electrode. In some embodiments, the absorbent material 340 can include any of the following: fibrous material, cotton fibers, rice husks, superhydrophobic sawdust, cellulose-based material, superabsorbent polymer, zeolite material, aerogel, nanocellulose aerogel, hydrogel, polyurethane, polypropylene, polyethylene, and cross-linked polymer, nanoparticle, carbon nanotube, polydimethylsiloxane, sepiolite, talc, montmorillonite, a mixture of the following three: sphagnum moss, charcoal, and sawdust, combinations thereof, and the like.

[0092] In some embodiments, in addition to the base having one or more cavities, the roller, and / or the plurality of rollers, an absorbent material 340 can be used. In some embodiments, the absorbent material 340 can be used in place of the base having one or more cavities, the roller, and / or the plurality of rollers. In some embodiments, the absorbent material 340 can circulate via the plurality of rollers. In other words, two or more rollers (or a roller and a pivot point) can hold a flat side of the absorbent material 340 in contact with the semi-solid electrode material 330a. In some embodiments, the absorbent material 340 can remove electrolyte from the semi-solid electrode material 330a in a continuous or semi-continuous operation. In some embodiments, the absorbent material 340 can circulate and can have electrolyte removed from the absorbent material 340 at a location spaced apart from the semi-solid electrode material 330a. In other words, the absorbent material 340 can be “regenerated” and recycled back to contact the semi-solid electrode material 330a. In some embodiments, the cavities can be at least partially filled with the absorbent material such that when extracted electrolyte is conveyed into the cavities, the absorbent material 340 can capture all, substantially all, a majority, some, or a portion of the extracted electrolyte to prevent at least that portion from reabsorbing back into the semi-solid electrode material 330b. In some embodiments, the absorbent material 340 can be positioned such that when extracted electrolyte or a portion thereof is conveyed through the cavities, for example, through the cavities and into a reservoir or drain fluidly coupled thereto, the absorbent material 340 can capture all, substantially all, a majority, some, or a portion of the extracted electrolyte to prevent at least that portion from being conveyed back to the cavities and / or at least that portion from reabsorbing back into the semi-solid electrode material 330b. In some embodiments, the absorbent material 340 can be positioned around the edges of the base, the roller, or the plurality of rollers, and / or the intermediate electrode such that any portion of electrolyte removed from the semi-solid electrode material 330a via the edges of the intermediate electrode can be captured, substantially captured, or at least partially captured by the absorbent material 340. In some embodiments, the absorbent material 340 can be interposed between the roller or the base and the semi-permeable membrane. In some embodiments, the absorbent material 340 can be interposed between the porous current collector 310 and the base or the roller. In some embodiments, the absorbent material 340 can be positioned in more than one of the configurations described herein, for example, the absorbent material 340 can be placed between the base and the current collector 310, between the roller or one or more rollers and the semi-permeable membrane positioned on the exposed surface of the semi-solid electrode material 330a, and around the edges of the intermediate electrode such that all or substantially all of the removed excess electrolyte can be captured by the absorbent material 340.

[0093] Method 30 also includes removing the roller or removing the pressed electrode from the roller assembly and removing the absorbent material 340, the semi-permeable membrane, and / or any remaining template material (e.g., the first inner frame 320a) to form a finished semi-solid electrode having a higher active solid loading. In some embodiments, removing the portion of electrolyte from the intermediate electrode forms a finished electrode having a higher active solid loading than the previously described semi-solid electrode material and electrodes composed thereof. Without wishing to be bound by any particular theory, removing a portion of the electrolyte (e.g., an excess portion of the liquid electrolyte) can reduce the volume of the semi-solid electrode material on the current collector without a corresponding reduction in electrical conductivity across the semi-solid electrode material by removing the electrolyte and by compression through voids and porosity. In some embodiments, the reduction in porosity can include a reduction in porosity from between about 20% and about 50% to between about 5% and about 30%, including all values and ranges therebetween.

[0094] In some embodiments, the first composition of the semi-solid electrode material 330a can include about 20% to about 80% active material by volume. In some embodiments, the first composition of the semi-solid electrode material 330a can include about 40% to about 80% active material by volume, or 50% to about 80% active material by volume. In some embodiments, the first composition of the semi-solid electrode material 330a can include at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, or at least about 75% active material by volume. In some embodiments, the first composition of the semi-solid electrode material 330a can include no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, or no more than about 25% active material by volume. Combinations of the above-mentioned volume percentages of active material in the first composition of the semi-solid electrode material 330a are also possible (e.g., at least about 20% by volume and no more than about 80% by volume or at least about 30% by volume and no more than about 60% by volume), including all values and ranges therebetween. In some embodiments, the first composition of the semi-solid electrode material 330a can include about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, or about 80% active material by volume.

[0095] In some embodiments, the first composition of the semi-solid electrode material 330a can include about 0.5% to about 25% by volume of the electrically conductive material. In some embodiments, the first composition of the semi-solid electrode material 330a can include about 1.0% to about 6% by volume of the electrically conductive material. In some embodiments, the first composition of the semi-solid electrode material 330a can include at least about 0.5%, at least about 1%, at least about 1.5%, at least about 2%, at least about 2.5%, at least about 3%, at least about 3.5%, at least about 4%, at least about 4.5%, at least about 5%, at least about 5.5%, at least about 6%, at least about 6.5%, at least about 7%, at least about 7.5%, at least about 8%, at least about 8.5%, at least about 9%, at least about 9.5%, at least about 10%, at least about 15%, or at least about 20% by volume of the electrically conductive material. In some embodiments, the first composition of the semi-solid electrode material 330a can include no more than about 25%, no more than about 20%, no more than about 15%, no more than about 10%, no more than about 9.5%, no more than about 9%, no more than about 8.5%, no more than about 8%, no more than about 7.5%, no more than about 7%, no more than about 6.5%, no more than about 6%, no more than about 5.5%, no more than about 5%, no more than about 4.5%, no more than about 4%, no more than about 3.5%, no more than about 3%, no more than about 2.5%, no more than about 2%, no more than about 1.5%, or no more than about 1% by volume of the electrically conductive material. Combinations of the above-mentioned volume percentages of the electrically conductive material in the first composition of the semi-solid electrode material 330a are also possible (e.g., at least about 0.5% by volume and no more than about 25% by volume or at least about 3% by volume and no more than about 10% by volume), including all values and ranges therein. In some embodiments, the first composition of the semi-solid electrode material 330a can include about 0.5%, about 1%, about 1.5%, about 2%, about 2.5%, about 3%, about 3.5%, about 4%, about 4.5%, about 5%, about 5.5%, about 6%, about 6.5%, about 7%, about 7.5%, about 8%, about 8.5%, about 9%, about 9.5%, about 10%, about 15%, about 20%, or about 25% by volume of the electrically conductive material.

[0096] In some embodiments, the first composition of the semi-solid electrode material 330a can include about 25% to about 70% electrolyte by volume. In some embodiments, the first composition of the semi-solid electrode material 330a can include about 30% to about 50%, or about 20% to about 40% electrolyte by volume. In some embodiments, the first composition of the semi-solid electrode material 330a can include at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, or at least about 65% electrolyte by volume. In some embodiments, the first composition of the semi-solid electrode material 330a can include no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, or no more than about 30% electrolyte by volume. Combinations of the above-mentioned volume percentages of electrolyte in the first composition of the semi-solid electrode material 330a are also possible (e.g., at least about 25% and no more than about 70% or at least about 30% and no more than about 50%), including all values and ranges therebetween. In some embodiments, the first composition of the semi-solid electrode material 330a can include about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, or about 70% electrolyte by volume.

[0097] In some embodiments, the second composition of the semi-solid electrode material 330b can include about 30% to about 85% active material by volume. In some embodiments, the second composition of the semi-solid electrode material 330b can include about 50% to about 85% active material by volume, or 60% to about 85% active material by volume. In some embodiments, the second composition of the semi-solid electrode material 330b can include at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80% active material by volume. In some embodiments, the second composition of the semi-solid electrode material 330b can include no more than about 85%, no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, or no more than about 35% active material by volume. Combinations of the above-mentioned volume percentages of active material in the second composition of the semi-solid electrode material 330b are also possible (e.g., at least about 30% by volume and no more than about 85% by volume, or at least about 40% by volume and no more than about 70% by volume), including all values and ranges therebetween. In some embodiments, the second composition of the semi-solid electrode material 330b can include about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, or about 85% active material by volume.

[0098] In some embodiments, the second composition of the semi-solid electrode material 330b can include from about 0.5% to about 30% by volume of the electrically conductive material. In some embodiments, the second composition of the semi-solid electrode material 330b can include from about 1.0% to about 6% by volume of the electrically conductive material. In some embodiments, the second composition of the semi-solid electrode material 330b can include at least about 0.5%, at least about 1%, at least about 1.5%, at least about 2%, at least about 2.5%, at least about 3%, at least about 3.5%, at least about 4%, at least about 4.5%, at least about 5%, at least about 5.5%, at least about 6%, at least about 6.5%, at least about 7%, at least about 7.5%, at least about 8%, at least about 8.5%, at least about 9%, at least about 9.5%, at least about 10%, at least about 15%, at least about 20%, or at least about 25% by volume of the electrically conductive material. In some embodiments, the second composition of the semi-solid electrode material 330b can include no more than about 30%, no more than about 25%, no more than about 20%, no more than about 15%, no more than about 10%, no more than about 9.5%, no more than about 9%, no more than about 8.5%, no more than about 8%, no more than about 7.5%, no more than about 7%, no more than about 6.5%, no more than about 6%, no more than about 5.5%, no more than about 5%, no more than about 4.5%, no more than about 4%, no more than about 3.5%, no more than about 3%, no more than about 2.5%, no more than about 2%, no more than about 1.5%, or no more than about 1% by volume of the electrically conductive material. Combinations of the above-mentioned volume percentages of the electrically conductive material in the second composition of the semi-solid electrode material 330b are also possible (e.g., at least about 0.5% by volume and no more than about 30% by volume or at least about 5% by volume and no more than about 10% by volume), including all values and ranges therein. In some embodiments, the second composition of the semi-solid electrode material 330b can include about 0.5%, about 1%, about 1.5%, about 2%, about 2.5%, about 3%, about 3.5%, about 4%, about 4.5%, about 5%, about 5.5%, about 6%, about 6.5%, about 7%, about 7.5%, about 8%, about 8.5%, about 9%, about 9.5%, about 10%, about 15%, about 20%, about 25%, or about 30% by volume of the electrically conductive material.

[0099] In some embodiments, the second composition of the semi-solid electrode material 330b can include about 15% to about 60% electrolyte by volume. In some embodiments, the second composition of the semi-solid electrode material 330b can include about 20% to about 40%, or about 10% to about 30% electrolyte by volume. In some embodiments, the second composition of the semi-solid electrode material 330b can include at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, or at least about 55% electrolyte by volume. In some embodiments, the second composition of the semi-solid electrode material 330b can include no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, no more than about 25%, or no more than about 20% electrolyte by volume. Combinations of the above-mentioned volume percentages of electrolyte in the second composition of the semi-solid electrode material 330b are also possible (e.g., at least about 15% and no more than about 60% or at least about 20% and no more than greater than about 40%), including all values and ranges therebetween. In some embodiments, the second composition of the semi-solid electrode material 330b can include about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, or about 60% electrolyte by volume.

[0100] In some embodiments, the second composition of the semi-solid electrode material 330b can have a ratio of electrolyte to active material that is less than the first composition of the semi-solid electrode material 330a. In some embodiments, the second composition of the semi-solid electrode material 330b can have a ratio of electrolyte to active material between about 5: 1 and about 1 :3, between about 4: 1 and about 1 :2, between about 3: 1 and about 1 : 1, between about 5: 1 and about 1 :2, between about 5: 1 and about 1 : 1, between about 5: 1 and about 2: 1, between about 5: 1 and about 3: 1, between about 5: 1 and about 4: 1, between about 4: 1 and about 1 :3, between about 3: 1 and about 1 :3, between about 2: 1 and about 1 :3, between about 1 : 1 and about 1 :3, or between about 1 :2 and about 1 :3, including all values and ranges therebetween.

[0101] In some embodiments, the weight and / or thickness of the semi-solid electrode can be measured at various points throughout the process of mechanically pressing the intermediate electrode to form a finished electrode. For example, in some embodiments, the weight of the finished electrode can be a second weight and can be compared to the first weight to determine the mass of electrolyte removed during mechanical pressing. In some embodiments, the thickness of the finished electrode can be a second thickness and can be compared to the first thickness to determine the volume of electrolyte removed during mechanical pressing. In some embodiments, if the difference between the first and second weight or the first and second thickness of the semi-solid electrode material 330b is insufficient, then the absorbent material 340 and / or the semi-permeable membrane can be placed back on the semi-solid electrode material and the intermediate electrode can be further mechanically compressed to remove a second portion of electrolyte from the semi-solid electrode material 330b. In some embodiments, the volume or mass of electrolyte removed during mechanical pressing can be used to determine the relative volume or mass percentages of active material, conductive material, and electrolyte in the semi-solid electrode material 330b.

[0102] In some embodiments, once the composition of the semi-solid electrode material 330b matches or substantially matches the desired composition of the semi-solid electrode material 330b in the finished electrode, the electrode can be removed from the mechanical press. In some embodiments, the electrode can be weighed before being mechanically pressed, then can be mechanically pressed for a first period of time to remove a first portion of electrolyte, then weighed again, the difference between the first weight and the second weight can be used to determine the mass of electrolyte removed. If the mass of electrolyte removed substantially corresponds to the desired volume or mass of electrolyte to be removed, then the electrode can be considered a finished electrode and ready for further processing or incorporation into an electrochemical cell (not shown). If the mass of electrolyte removed does not substantially correspond to the desired volume or mass of electrolyte to be removed, then the electrode can be mechanically pressed for a second period of time to remove a second portion of electrolyte, then weighed a third time, the difference between the second weight and the third weight can be used to determine the mass of electrolyte removed during the second period of time. If the mass of electrolyte removed during the first period of time plus the mass of electrolyte removed during the second period of time equals or substantially equals the desired mass of electrolyte to be removed from the semi-solid electrode material, then the electrode can be considered a finished electrode. The mechanical compression of the intermediate electrode can continue in this iterative manner until the total volume or mass of electrolyte removed equals or substantially equals the desired volume or mass of electrolyte to be removed.

[0103] In some embodiments, the finished electrode can include an electrode tab that is electrically connected to the current collector and configured to transport electrons into or out of the electrode. In some embodiments, the electrode tab can extend beyond the current collector and / or the insulating material. In some embodiments, the electrode tab can be electrically coupled to the current collector prior to deploying the semi-solid electrode material onto the current collector. In some embodiments, the battery can include an integrated electrical tab, which can eliminate the need for (i) a separate tab component (e.g., an electrical lead), (ii) connecting a dedicated tab to the current collector, and (iii) a dedicated tab sealing operation. Instead, in some embodiments, an electrical terminal or lead can be provided as an extension of the current collector integral with the current collector. In some embodiments, the tab or lead can be defined by removing material from a larger area of current collector material, thereby defining the current collector and the tab or lead.

[0104] Method 30 optionally includes coupling the finished electrode (e.g., cathode) with a second finished electrode (e.g., anode) with a separator interposed to form a finished electrochemical cell. In other words, once the finished electrode has been singulated and excess electrolyte has been removed, the finished electrode can be assembled into an electrochemical cell with a second finished electrode that exhibits an opposite redox reaction. In other words, a cathode and an anode can be coupled together with a separator disposed therebetween.

[0105] In some embodiments, a separator can be disposed between the anode and the cathode. In some embodiments, the separator can be coupled to at least one of the anode and the cathode with an adhesive. In some embodiments, one anode, one cathode, and one separator can be stacked together to form a unit cell assembly. Each unit cell assembly can also include a conductive tab (also referred to as a lead) to couple the electrodes to an external circuit. Multiple unit cell assemblies are then stacked or arrayed together to form a battery cell. In some embodiments, the number of unit cell assemblies in the battery cell can vary depending on, for example, the desired capacity and / or thickness of the resulting battery cell. These stacked unit cell assemblies are electrically connected in parallel, and the respective tabs in each unit cell assembly are typically welded together via a welding process such as resistance welding, laser and ultrasonic welding, seam welding, electron beam welding, and the like.

[0106] In some embodiments, the prepared electrochemical cell can be vacuum sealed in a prismatic pouch that can provide airtight isolation of the electrochemical cell materials from the environment. Thus, the pouch can serve to avoid leakage of harmful materials, such as electrolyte solvents and / or corrosive salts, into the surrounding environment, and can prevent water and / or oxygen from permeating into the cell. Other functions of the pouch can include, for example, compression packaging of the inner layers, voltage isolation for safety and handling, and mechanical protection of the cell components. In some embodiments, during the vacuum pouch sealing, electrolyte can be injected into the stacked cell assembly, and then the cell assembly and electrolyte can be sealed into the pouch. In some embodiments, if the semi-solid electrode material can already contain the full desired amount of electrolyte, no electrolyte can be added during the pouch sealing step.

[0107] In some embodiments, the sealed cell unit can then be subjected to a formation process, in which an initial charging operation can be performed to create a stable SEI layer that can passivate the electrode-electrolyte interface and prevent side reactions. In some embodiments, several charge and discharge cycles can be performed to ensure that the capacity of the battery meets the required specifications. In some embodiments, a degassing step can be performed to release gases introduced or generated during the initial charging phase or in the electrochemical reactions in the cell formation step. The presence of entrained gases in the electrodes generally reduces the electrical conductivity and density of the electrodes, and limits the amount of active electrochemical material that can be placed in the battery cell, and can cause dendrite growth that can corrode the battery performance of lithium batteries. In some embodiments, dendrite formation can result in a reduction in cycle life and a reduction in overall safety performance. In some embodiments after the release of entrained gases, a resealing step can be taken to reseal the battery cell.

[0108] Figures 4A-4E A method 40 of forming a semi-solid electrode material with a higher active material concentration and higher energy density is illustrated, without requiring an electrolyte priming step and / or a drying step. The method 40 includes loading a semi-solid electrode material 430a having a first composition into a press 435 at 41. In some embodiments, the press 435 can include a base 436 and a frame 438, where the base 436 and the frame 438 form a cavity 439. In some embodiments, the base 436 can include a water-tight seal around its edges, such that substantially no semi-solid electrolyte material 430a leaks through the boundary between the base 436 and the frame 438. In some embodiments, reference is made to FIG. 3, where the semi-solid electrode material 430a can have the same or substantially similar properties as the semi-solid electrode material 330a. Figures 3A-3E As described above, the semi-solid electrode material 430a can have the same or substantially similar properties as the semi-solid electrode material 330a.

[0109] In some embodiments, a semi-permeable membrane (not shown) can be disposed on or around the semi-solid electrode material such that, during mechanical compression of the intermediate electrode, the semi-permeable membrane allows electrolyte to be transported out of the semi-solid electrode material while not allowing active material, conductive material, etc. to be transported out of the semi-solid electrode material. In some embodiments, the semi-permeable membrane can be a sheet or other planar structure that is configured to be removed from on or around the semi-solid electrode material before or after the intermediate electrode is removed from the mechanical press and when the mechanically compressed electrode is incorporated into an electrochemical cell or the like. In some embodiments, the semi-permeable membrane can be a conventional separator material configured to allow at least some liquid electrolyte to flow therethrough. In some embodiments, the semi-permeable membrane can be any material that allows at least some liquid electrolyte to flow therethrough while being fully or substantially chemically inert to the composition of the semi-solid electrode material 430a and / or the current collector 410. In some embodiments, the semi-permeable membrane can remain on or around the semi-solid electrode material throughout the mechanical compression and construction of the electrochemical cell such that the semi-permeable membrane is included in the finished electrochemical cell.

[0110] At 42, the semi-solid electrode material 430a is uniformly disposed in the cavity 439 of the press 435 to become flush or approximately flush with the top edge of the frame 438. The absorbent material 440 is then placed on the top edge of the frame 438. In some embodiments, the absorbent material 440 can be the same as or substantially similar to the absorbent material 340, as described above with reference to FIG. 3. Figures 3A-3E

[0111] At 43, a force F is applied to the underside of the base 436 to collapse the cavity 439 and extract a portion of electrolyte from the semi-solid electrode material 430a into the absorbent material 440. At 44, once the portion of electrolyte has been removed by mechanical compression of the semi-solid electrode material 430a, the semi-solid electrode material 430a can become a semi-solid electrode wafer 430b having a second composition. The semi-solid electrode wafer 430b has a higher ratio of active material to electrolyte than the semi-solid electrode material 430a. In some embodiments, the cavity 439 can be fluidly coupled to a drain (not shown) such that the removed electrolyte transported into or through the cavity can be removed from the mechanical press via the drain. In some embodiments, the cavity can be fluidly coupled to a reservoir (not shown) such that the removed electrolyte transported into or through the cavity can be removed from the mechanical press via the reservoir. In some embodiments, the removed electrolyte held in the reservoir can be reusable and / or recyclable for other semi-solid electrodes or elsewhere.

[0112] ​At 45, the semi-solid electrode wafer 430b is removed from the press 435, where it can be used to construct an electrochemical cell or further processed. Removing the semi-solid electrode wafer 430b from the press 435 can also include removing the absorbent material in contact with the semi-solid electrode wafer 430b. The semi-solid electrode wafer 430b is a versatile, standalone material that can be applied to a variety of different applications. In some embodiments, the semi-solid electrode wafer 430b can have the same or substantially similar compositional properties as the semi-solid electrode material 330b described above with reference to Figures 3A-3E In some embodiments, the method 40 can include densifying the semi-solid electrode material 430a using a roller, as described above with reference to Figures 3A-3E

[0113] In some embodiments, the first composition of the semi-solid electrode material 430a can include about 20% to about 80% active material by volume. In some embodiments, the first composition of the semi-solid electrode material 430a can include about 40% to about 80%, or 50% to about 80% active material by volume. In some embodiments, the first composition of the semi-solid electrode material 430a can include at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, or at least about 75% active material by volume. In some embodiments, the first composition of the semi-solid electrode material 430a can include no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, or no more than about 25% active material by volume. Combinations of the above-mentioned volume percentages of active material in the first composition of the semi-solid electrode material 430a are also possible (e.g., at least about 20% by volume and no more than about 80% by volume, or at least about 30% by volume and no more than about 60% by volume), including all values and ranges therebetween. In some embodiments, the first composition of the semi-solid electrode material 430a can include about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, or about 80% active material by volume.

[0114] ​In some embodiments, the first composition of the semi-solid electrode material 430a can include about 0.5% to about 25% by volume of the electrically conductive material. In some embodiments, the first composition of the semi-solid electrode material 430a can include about 1.0% to about 6% by volume of the electrically conductive material. In some embodiments, the first composition of the semi-solid electrode material 430a can include at least about 0.5%, at least about 1%, at least about 1.5%, at least about 2%, at least about 2.5%, at least about 3%, at least about 3.5%, at least about 4%, at least about 4.5%, at least about 5%, at least about 5.5%, at least about 6%, at least about 6.5%, at least about 7%, at least about 7.5%, at least about 8%, at least about 8.5%, at least about 9%, at least about 9.5%, at least about 10%, at least about 15%, or at least about 20% by volume of the electrically conductive material. In some embodiments, the first composition of the semi-solid electrode material 430a can include no more than about 25%, no more than about 20%, no more than about 15%, no more than about 10%, no more than about 9.5%, no more than about 9%, no more than about 8.5%, no more than about 8%, no more than about 7.5%, no more than about 7%, no more than about 6.5%, no more than about 6%, no more than about 5.5%, no more than about 5%, no more than about 4.5%, no more than about 4%, no more than about 3.5%, no more than about 3%, no more than about 2.5%, no more than about 2%, no more than about 1.5%, or no more than about 1% by volume of the electrically conductive material. Combinations of the above-mentioned volume percentages of the electrically conductive material in the first composition of the semi-solid electrode material 430a are also possible (e.g., at least about 0.5% by volume and no more than about 25% by volume or at least about 3% by volume and no more than about 10% by volume), including all values and ranges therein. In some embodiments, the first composition of the semi-solid electrode material 430a can include about 0.5%, about 1%, about 1.5%, about 2%, about 2.5%, about 3%, about 3.5%, about 4%, about 4.5%, about 5%, about 5.5%, about 6%, about 6.5%, about 7%, about 7.5%, about 8%, about 8.5%, about 9%, about 9.5%, about 10%, about 15%, about 20%, or about 25% by volume of the electrically conductive material.

[0115] In some embodiments, the first composition of the semi-solid electrode material 430a can include about 25% to about 70% electrolyte by volume. In some embodiments, the first composition of the semi-solid electrode material 430a can include about 30% to about 50%, or about 20% to about 40% electrolyte by volume. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80% active material by volume. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include no more than about 85%, no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, or no more than about 35% active material by volume. Combinations of the above-mentioned volume percentages of active material in the second composition of the semi-solid electrode wafer 430b are also possible (e.g., at least about 30% by volume and no more than about 85% by volume, or at least about 40% by volume and no more than about 70% by volume), including all values and ranges therebetween. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, or about 85% active material by volume.

[0116] In some embodiments, the second composition of the semi-solid electrode wafer 430b can include about 30% to about 85% active material by volume. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include about 50% to about 85% active material by volume, or 60% to about 85% active material by volume. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80% active material by volume. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include no more than about 85%, no more than about 80%, no more than about 75%, no more than about 70%, no more than about 65%, no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, or no more than about 35% active material by volume. Combinations of the above-mentioned volume percent of active material in the second composition of the semi-solid electrode wafer 430b are also possible (e.g., at least about 30% by volume and no more than about 85% by volume, or at least about 40% by volume and no more than about 70% by volume), including all values and ranges therebetween. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, or about 85% active material by volume.

[0117] In some embodiments, the second composition of the semi-solid electrode wafer 430b can include about 0.5% to about 30% by volume of the electrically conductive material. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include about 1.0% to about 6% by volume of the electrically conductive material. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include at least about 0.5%, at least about 1%, at least about 1.5%, at least about 2%, at least about 2.5%, at least about 3%, at least about 3.5%, at least about 4%, at least about 4.5%, at least about 5%, at least about 5.5%, at least about 6%, at least about 6.5%, at least about 7%, at least about 7.5%, at least about 8%, at least about 8.5%, at least about 9%, at least about 9.5%, at least about 10%, at least about 15%, at least about 20%, or at least about 25% by volume of the electrically conductive material. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include no more than about 30%, no more than about 25%, no more than about 20%, no more than about 15%, no more than about 10%, no more than about 9.5%, no more than about 9%, no more than about 8.5%, no more than about 8%, no more than about 7.5%, no more than about 7%, no more than about 6.5%, no more than about 6%, no more than about 5.5%, no more than about 5%, no more than about 4.5%, no more than about 4%, no more than about 3.5%, no more than about 3%, no more than about 2.5%, no more than about 2%, no more than about 1.5%, or no more than about 1% by volume of the electrically conductive material. Combinations of the above-mentioned volume percentages of the electrically conductive material in the second composition of the semi-solid electrode wafer 430b are also possible (e.g., at least about 0.5% by volume and no more than about 30% by volume or at least about 5% by volume and no more than about 10% by volume), including all values and ranges therein. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include about 0.5%, about 1%, about 1.5%, about 2%, about 2.5%, about 3%, about 3.5%, about 4%, about 4.5%, about 5%, about 5.5%, about 6%, about 6.5%, about 7%, about 7.5%, about 8%, about 8.5%, about 9%, about 9.5%, about 10%, about 15%, about 20%, about 25%, or about 30% by volume of the electrically conductive material.

[0118] In some embodiments, the second composition of the semi-solid electrode wafer 430b can include about 15% to about 60% electrolyte by volume. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include about 20% to about 40%, or about 10% to about 30% electrolyte by volume. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, or at least about 55% electrolyte by volume. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include no more than about 60%, no more than about 55%, no more than about 50%, no more than about 45%, no more than about 40%, no more than about 35%, no more than about 30%, no more than about 25%, or no more than about 20% electrolyte by volume. Combinations of the above-mentioned volume percentages of electrolyte in the second composition of the semi-solid electrode wafer 430b are also possible (e.g., at least about 15% and no more than about 60% or at least about 20% and no more than greater than about 40%), including all values and ranges therein. In some embodiments, the second composition of the semi-solid electrode wafer 430b can include about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, or about 60% electrolyte by volume.

[0119] In some embodiments, the second composition of the semi-solid electrode material 330b can have a ratio of electrolyte to active material that is less than the first composition of the semi-solid electrode material 430a. In some embodiments, the second composition of the semi-solid electrode wafer 430b can have a ratio of electrolyte to active material between about 5: 1 and about 1 :3, between about 4: 1 and about 1 :2, between about 3: 1 and about 1 : 1, between about 5: 1 and about 1 :2, between about 5: 1 and about 1 : 1, between about 5: 1 and about 2: 1, between about 5: 1 and about 3: 1, between about 5: 1 and about 4: 1, between about 4: 1 and about 1 :3, between about 3: 1 and about 1 :3, between about 2: 1 and about 1 :3, between about 1 : 1 and about 1 :3, or between about 1 :2 and about 1 :3, including all values and ranges therein.

[0120] Figure 4Fis a top view of the semi-solid electrode wafer 430b. As shown, the semi-solid electrode wafer 430b has a rectangular shape when viewed from the top. In some embodiments, the semi-solid electrode wafer 430b can have a circular shape, an L-shape, a square shape, or any other shape suitable for incorporation into an electrochemical cell when viewed from the side. As such, in some embodiments, the cavity 439 can have a rectangular shape, a circular shape, an L-shape, a square shape, or any other suitable shape for producing an electrode when viewed from the top.

[0121] In some embodiments, the weight and / or thickness of the semi-solid electrode can be measured at various points throughout the process of mechanically compressing the intermediate electrode to form the finished electrode. For example, in some embodiments, the weight of the finished electrode can be a second weight and can be compared to the first weight to determine the mass of electrolyte removed during mechanical compression. In some embodiments, the thickness of the finished electrode can be a second thickness and can be compared to the first thickness to determine the volume of electrolyte removed during mechanical compression. In some embodiments, if the difference between the first and second weight or the first and second thickness of the semi-solid electrode wafer 430b is not sufficient, the absorbent material 440 and / or the semi-permeable membrane can be placed back on the semi-solid electrode wafer and the intermediate electrode can be further mechanically compressed to remove a second portion of electrolyte from the semi-solid electrode wafer 430b. In some embodiments, the volume or mass of electrolyte removed during mechanical compression can be used to determine the relative volume or mass percentages of active material, conductive material, and electrolyte in the semi-solid electrode wafer 430b.

[0122] In some embodiments, once the composition of the semi-solid electrode wafer 430b matches or substantially matches the desired composition of the semi-solid electrode wafer 430b in the finished electrode, the electrode can be removed from the mechanical press. In some embodiments, the electrode can be weighed before being mechanically pressed, and then can be mechanically pressed for a first period of time to remove a first portion of electrolyte, then weighed again, the difference between the first weight and the second weight can be used to determine the mass of electrolyte removed. If the mass of electrolyte removed substantially corresponds to the desired volume or mass of electrolyte to be removed, then the electrode can be considered a finished electrode and ready for further processing or incorporation into an electrochemical cell (not shown). If the mass of electrolyte removed does not substantially correspond to the desired volume or mass of electrolyte to be removed, then the electrode can be mechanically pressed for a second period of time to remove a second portion of electrolyte, then weighed a third time, the difference between the second weight and the third weight can be used to determine the mass of electrolyte removed during the second period of time. If the mass of electrolyte removed during the first period of time plus the mass of electrolyte removed during the second period of time equals or substantially equals the desired mass of electrolyte to be removed from the semi-solid electrode material, then the electrode can be considered a finished electrode. Mechanical compression of the intermediate electrode can continue in this iterative manner until the total volume or mass of electrolyte removed equals or substantially equals the desired volume or mass of electrolyte to be removed.

[0123] Figure 5A and 5B A method 50 of additional use of the above-mentioned semi-solid electrode wafer 430b according to embodiments is illustrated. In some embodiments, the semi-solid electrode wafer 430b can be used to form an electrochemical cell including a second electrode 470, a current collector 472, and a separator 474. As shown at 51, the second electrode 470 is disposed on the current collector 472, and the separator 474 is disposed on the second electrode 470. In some embodiments, an electrolyte droplet 476 can be placed on the separator 474 to wet the surface of the separator 474. At 52, the semi-solid electrode wafer 430b is disposed on the separator 474. Wetting the surface of the separator 474 can prevent interstitial spaces along the interface between the semi-solid electrode wafer 430b and the separator 474. The interstitial spaces are filled with the electrolyte droplet 476 and substantially free of areas that prevent ion movement at the interface between the semi-solid electrode wafer 430b and the separator 474.

[0124] In some embodiments, the semi-solid electrode wafer 430b can be easily transported. In some embodiments, multiple semi-solid electrode wafers 430b can be stacked together. In some embodiments, the semi-solid electrode wafer 430b can be stacked on other electrodes. In some embodiments, multiple semi-solid electrode wafers 430b with different battery chemistries can be stacked together. In other words, a first semi-solid electrode wafer can have a first battery chemistry and a second semi-solid electrode wafer can have a second battery chemistry, where the second battery chemistry is different from the first battery chemistry. In some embodiments, additional semi-solid electrode wafers can have additional chemistries. In some embodiments, the semi-solid electrode wafer 430b can be included into a dual battery or electrochemical cell system with multiple battery chemistries.

[0125] Various concepts can be implemented as one or more methods, of which an example has been provided. The acts performed as part of the method can be ordered in any suitable way. Accordingly, embodiments can be constructed in which acts are performed in an order different than illustrated, which can include performing some acts simultaneously, even though shown as serial acts in illustrative embodiments. In other words, it will be understood that such features are not necessarily limited to a particular order of execution, but can be executed in any number of threads, processes, services, servers, etc., serially, asynchronously, concurrently, in parallel, simultaneously, synchronically, etc., in a manner consistent with the present disclosure. As such, some of these features can be mutually contradictory, in that they cannot be simultaneously present in a single embodiment. Similarly, some features are applicable to one aspect of the innovation, and inapplicable to others.

[0126] Furthermore, the present disclosure can include other innovations presently unforeseeable. Applicants reserve the right to claim such innovations, including ones to continue, to proceed with the applications, to proceed with a continuation-in-part, to abandon, and / or to otherwise assign such applications. As such, it is understood that the advantages, embodiments, examples, functions, features, logic, operations, organization, structures, topologies, and / or other aspects of the disclosure defined herein are by way of illustration only and not by way of limitation. Various embodiments of the technology disclosed herein can be implemented in a manner that enables a great deal of flexibility and customization, depending on the particular desires and / or characteristics of the individual and / or enterprise user, database configuration and / or relational model, data types, data transmission and / or network framework, syntactical structure, and / or the like.

[0127] As defined and used herein, all definitions should be understood as controlling the meaning of the terms defined and / or the ordinary meaning of the terms defined.

[0128] As used herein in the specification and embodiments, the terms “about” or “approximately” when used before a value indicates a range of that value plus or minus 10%. Where a range of values is provided, it is understood that every intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the disclosure. The upper and lower limits of these smaller ranges can independently be included in the smaller ranges, and are also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure.

[0129] As used herein in the specification and embodiments, the indefinite articles “a” and “an” should be understood to mean “at least one” unless the context clearly dictates otherwise.

[0130] As used herein in the specification and embodiments, the phrase “and / or” should be understood to mean “one or the other” or both of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and / or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements can optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and / or B” when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including additional elements); etc.

[0131] As used herein in the specification and embodiments, “or” should be understood to have the same meaning as “and / or” as defined above. For example, when used in the context of items linked with “or” or “and / or” such as in a list of items joined by “or” or “and / or,” such as when used, for example, in the phrase “A, B or C,” “A, B, and / or C” or “at least one of A and B” or “A or B or C,” or “at least one of A, B, and C” the “or” or “and / or” is to be interpreted as inclusive or, i.e., the inclusion of at least one, but also including more than one, of a plurality or list of elements, options or labels. Only terms that are clearly intended to be exclusive, such as “either A or B, and not both” or, when used in the embodiments, “consisting of,” will refer to the exclusion of either or both of the elements or labels that such terminology directly references. In general, the term “or” as used herein, when used in the context of exclusivity (e.g., the phrases “either A or B” or “only A or B”), shall be interpreted as having the same meaning as “only one of A or B.” “Consisting essentially of’ when used in the embodiments shall have the same meaning as used in the patent law.

[0132] As used herein in the specification and embodiments, the phrase "at least one," in reference to a list of one or more elements, should be understood to mean at least one element selected from among the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that the

[0133] In the embodiments and above specification, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," "holding," "composed of," and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases "consisting of" and "consisting essentially of shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.

[0134] While particular embodiments of the present disclosure have been illustrated and described above, it would be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope of the present disclosure. It is therefore intended that the embodiments described herein be considered in all respects as illustrative only and not restrictive. Various changes and modifications can be made to the method and steps described above without departing from the spirit and scope of the disclosure. Where certain steps in the above-described method indicate that certain events occur, it will be understood that the ordering of certain steps can be modified and that such modification are in accordance with the variations of the application. Additionally, certain steps can be performed concurrently in a parallel process, and described above in a serial manner. Embodiments have been specifically illustrated and described herein, but it will be appreciated that various modifications can be made to the form and details herein without departing from the underlying principles.

Claims

1. A method of forming a dense semi-solid electrode, the method comprising: mixing an active material and a conductive material with a liquid electrolyte to form a semi-solid electrode material, the liquid electrolyte comprising between 50 wt% and 80 wt% of the semi-solid electrode material; disposing the semi-solid electrode material onto a current collector; disposing a semi-permeable membrane onto an exposed surface of the semi-solid electrode material; and compressing the semi-solid electrode material between the current collector and the semi-permeable membrane to extract a portion of the liquid electrolyte and form a dense semi-solid electrode, wherein the dense semi-solid electrode comprises between 60% and 85% by volume of the active material, and the liquid electrolyte comprises between 10 wt% and 45 wt% of the dense semi-solid electrode.

2. The method of claim 1, wherein the semi-permeable membrane is configured to absorb the portion of the liquid electrolyte extracted during compression.

3. The method of claim 1, further comprising: disposing an absorbent material onto an exposed surface of the semi-permeable membrane, the absorbent material configured to absorb the portion of the liquid electrolyte extracted during compression.

4. The method of claim 1, wherein mechanically compressing the semi-solid electrode material comprises compressing the semi-solid material between a compression mold and a substrate.

5. The method of claim 1, wherein the compressed semi-solid electrode material comprises greater than 70 wt% of the active material.

6. The method of claim 1, wherein the semi-solid electrode material after mixing has a first ratio of liquid electrolyte to active material between 10: 1 and 1: 1; and wherein the semi-solid electrode material after compression has a second ratio of liquid electrolyte to active material between 5: 1 and 1:

3.

7. The method of claim 1, wherein the semi-solid electrode material after mixing has a first active material molarity between 5M and 15M; and wherein the semi-solid electrode material after compression has a second active material molarity between 16M and 24M.

8. The method of claim 1, wherein the semi-solid electrode material after mixing has a first energy density between 3 mAh / g and 5 mAh / g; and wherein the semi-solid electrode material after compression has a second energy density between 6 mAh / g and 14 mAh / g.

9. The method of claim 1, wherein the conductive material comprises conductive particles.

10. The method of claim 1, wherein the dense semi-solid electrode is a first electrode and the current collector is a first current collector, the method further comprising: removing the semi-permeable membrane from the first electrode; placing a second electrode on a second current collector; placing a separator on the second electrode such that a first surface of the separator contacts the second electrode and a second surface of the separator is exposed, the second surface opposite the first surface; placing an electrolyte droplet on the second surface of the separator; and placing the first electrode on the separator to form an electrochemical cell.

11. A method of forming a semi-solid electrode, comprising: ​ mixing the active material and the conductive material with a liquid electrolyte to form a semi-solid electrode material having a first volume, the first volume of the semi-solid electrode material having between 50 wt% and 80 wt% of the liquid electrolyte of the semi-solid electrode material; inserting the semi-solid electrode material between a current collector and a semi-permeable membrane; and applying a compressive force to the semi-solid electrode material via a roller such that the semi-solid electrode material has a second volume that is less than the first volume, the second volume of the semi-solid electrode material having between 10 wt% and 45 wt% of the liquid electrolyte of the semi-solid electrode material.

12. The method of claim 11, further comprising: exposing the semi-solid electrode material to an absorbent material such that a portion of the liquid electrolyte migrates from the semi-solid electrode material to the absorbent material.

13. The method of claim 12, wherein the absorbent material is transported by one or more rollers.

14. The method of claim 13, wherein a flat portion of the absorbent material is in contact with the semi-solid electrode material.

15. The method of claim 11, wherein the second volume is between 50% and 95% of the first volume.

16. The method of claim 15, wherein the second volume is between 50% and 80% of the first volume.

17. The method of claim 15, wherein the second volume is between 70% and 95% of the first volume.

18. A method of forming a semi-solid electrode, comprising: mixing an active material and a conductive material with a liquid electrolyte to form a semi-solid electrode material having a first thickness, the liquid electrolyte being between 50 wt% and 80 wt% of the semi-solid electrode material; inserting the semi-solid electrode material between a current collector and a semi-permeable membrane; and applying a compressive force to the semi-solid electrode material via a roller such that the semi-solid electrode material has a second thickness that is less than the first thickness and has between 10 wt% and 45 wt% of the liquid electrolyte of the semi-solid electrode material.

19. The method of claim 18, wherein the first thickness is between 100 pm and 2,000 pm.

20. The method of claim 18, wherein the second thickness is between 5 pm and 50 pm.

21. The method of claim 18, wherein the mechanical compression is achieved by mechanically compressing the semi-solid electrode material between a base and a die of a mechanical press.

22. A method of forming a semi-solid electrode, comprising: mixing an active material and a conductive material with a liquid electrolyte to form a first semi-solid electrode material, the first semi-solid electrode material having a first composition comprising between 50 wt% and 80 wt% of the liquid electrolyte; inserting the first semi-solid electrode material between a current collector and a semi-permeable membrane; and mechanically compressing the first semi-solid electrode material to form a second semi-solid electrode material, the second semi-solid electrode material having a second composition comprising between 10 wt% and 45 wt% of the liquid electrolyte.

23. A method of forming a semi-solid electrode, comprising: mixing the active material and the conductive material with a liquid electrolyte to form a first semi-solid electrode material having a first density, the liquid electrolyte comprising between 50 wt% and 80 wt% of the semi-solid electrode material; inserting the first semi-solid electrode material between a current collector and a semi-permeable membrane; and mechanically compressing the first semi-solid electrode material to form a second semi-solid electrode material having a second density greater than the first density, the second semi-solid electrode material comprising between 60% and 85% by volume of the active material and between 10 wt% and 45 wt% of the liquid electrolyte.

24. The method of claim 23, wherein the first density is less than 2 g / cm3 3 .

25. The method of claim 24, wherein the second density is between 2.1 g / cm 3 and 4 g / cm 3 .

26. The method of claim 25, wherein the energy density of the second semi-solid electrode material is greater than 7 mAh / g.

27. The method of claim 26, wherein the energy density of the second semi-solid electrode material is greater than 8 mAh / g.

28. The method of claim 27, wherein the energy density of the second semi-solid electrode material is greater than 9 mAh / g.

29. The method of claim 28, wherein the energy density of the second semi-solid electrode material is greater than 10 mAh / g.

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