System and method for depositing a spacer material

Abstract

One variation of the method includes receiving a portion of a substrate tape including a substrate within a coating zone; depositing a series of droplets of a spacer material on the first substrate, each droplet of the series of droplets of the spacer material including a first solvent, a first polymer, and a second polymer; heating the substrate and a proportion of the spacer material to a first temperature; dissolving the second polymer out of the series of droplets of the spacer material by washing the series of droplets of the spacer material and the substrate with a second solvent to provide an open network of pores; and irradiating the series of droplets of the spacer material to crosslink the first polymer and form a discrete spacer layer having the open network of pores sized to transport ions through the discrete spacer layer.

Description

Cross-references to related applications

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 330,763, filed April 13, 2022, which is incorporated herein by reference in its entirety. Technical Field

[0002] This invention relates generally to the field of battery technology, and more specifically to novel and useful systems and methods for depositing separator materials in the field of battery technology. Brief description of the attached diagram

[0003] Figure 1 It is a flowchart representation of the method;

[0004] Figure 2 It is a flowchart representation of a variation of the method;

[0005] Figure 3 It is a flowchart representation of a variation of the method;

[0006] Figure 4 It is a flowchart representation of a variant of the method; and

[0007] Figure 5 It is a flowchart representation of a variation of the method. Description of the implementation plan

[0008] The following description of embodiments of the present invention is not intended to limit the invention to these embodiments, but rather to enable those skilled in the art to make and use the invention. The variations, configurations, implementations, example implementations, and examples described herein are optional and are not exclusive. The invention described herein may include any and all combinations of these variations, configurations, implementations, example implementations, and examples.

[0009] 1. Method

[0010] like Figures 1-5 As shown, method S100 includes: during a first time period: in block S110, receiving a first substrate in an encapsulation region; in block S120, spraying a series of separator material droplets onto the first substrate, each droplet comprising a first solvent, a first polymer miscible with the first solvent, and a second polymer miscible with the first solvent; and in block S122, reaching a target substrate temperature below the boiling point of the first solvent.

[0011] The method S100 also includes, during a second time period after the first time period: heating, in block S130, the first substrate and the series of separator material droplets to a target substrate temperature to evaporate the first solvent from the series of separator material droplets and to promote phase separation of the second polymer from the first polymer; washing, in block S140, the series of separator material droplets with a second solvent to dissolve the second polymer from the series of separator material droplets and to provide an open-celled network of pores within the series of separator material droplets having the pores; and irradiating, in block S150, the series of separator material droplets and the first substrate to crosslink the first polymer and form a separator membrane on the first substrate, the separator membrane defining the open-celled network of pores having the pores sized to transport ions.

[0012] 1.1 Variant: Separator thickness

[0013] One variation of the method S100 includes: during the first time period: receiving, in block S110, the substrate within the build area; defining, in block S112, a target liquid temperature range for the separator material; heating, in block S114, a nozzle facing the substrate and coupled to a reservoir volume of the separator material in a liquid state toward the target liquid temperature range at the nozzle; detecting, in block S116, a first temperature of the separator material at the nozzle; in response to the first temperature of the separator material falling within the target liquid temperature range, spraying, in block S120, a first volume of the separator material on the substrate via the nozzle, the separator material including a first solvent, a first polymer miscible in the first solvent, and a second polymer miscible in the first solvent; and reaching, in block S122, a target substrate temperature below a boiling point of the first solvent.

[0014] The variation of the method S100 also includes: during a second time period after the first time period: heating, in block S130, the substrate and the first volume of the separator material to a target substrate temperature to evaporate the first solvent from the first volume of the separator material; dissolving, in block S140, the second polymer from the first volume of the separator material to provide the open-celled network of pores having the pores; and irradiating, in block S150, the first volume of the separator material to crosslink the first polymer and form a separator membrane having a separator thickness proximate to the target separator thickness.

[0015] 1.2 Variant: Discrete separators

[0016] One variant of the method S100 includes: during a first time period: receiving, in block S110, a section of a substrate tape including a first substrate within an enclosure; and depositing, in block S120, a series of spacer material droplets on the first substrate, each droplet of the series of spacer material droplets including a first solvent, a first polymer, and a second polymer.

[0017] The variant of the method S100 includes: during a second time period after the first time period: heating, in block S130, the first substrate and the series of spacer material droplets to a first temperature; washing, in block S140, the series of spacer material droplets and the first substrate with a second solvent to dissolve the second polymer out of the series of spacer material droplets and provide an open network of pores within the series of spacer material droplets; and irradiating, in block S150, the series of spacer material droplets to crosslink the first polymer and form a discrete spacer layer having the open network of pores sized to transport ions through the discrete spacer layer.

[0018] 2. Application

[0019] Generally, the substrate supply station, the spray system, the refill station, the washing station, and the irradiation station (hereinafter “system 100”) can cooperate to perform the blocks of the method S100 to deposit a spacer material as an aerosol (or “series” of spacer material droplets, a “mist” or “cloud” of spacer material droplets) on a substrate (e.g., an electrode, a cathode, an anode) and form a thin spacer film (e.g., a discrete spacer layer, a permeable spacer film) of uniform thickness on the substrate.

[0020] More specifically, the spacer material includes a homogeneous polymer-polymer-solvent liquid mixture including: a first solvent; a first polymer miscible in the first solvent; and a second polymer miscible in the first solvent. In one example, the first solvent includes an organic ketone such as butanone; the first polymer includes a copolymer such as poly(vinylidene fluoride-hexafluoropropylene) (or “PVDF-HFP”); and the second polymer includes a polyether such as poly(ethylene oxide) (or “PEO”), poly(oxyethylene) (or “POE”), or polyethylene glycol (or “PEG”). In this example, the first polymer (e.g., PVDF-HFP) and the second polymer (e.g., PEG) are mixed in the first solvent (e.g., butanone) to form a homogeneous polymer-polymer-solvent liquid mixture exhibiting greater than 80% by weight of the first solvent.

[0021] Accordingly, system 100 can execute the blocks of method S100 during a processing cycle to: spray a volume of separator material on a substrate; upon contact with the substrate, heat the substrate to rapidly dry the volume of separator material and evaporate a first solvent (e.g., butanone) from the volume of separator material; dissolve a second polymer (e.g., PEG) from the volume of separator material by washing or rinsing the substrate in a chemical bath of a second solvent comprising an alcohol (e.g., isopropyl alcohol) to provide an open network of pores; and irradiate the volume of separator material with an electron beam to further crosslink the first polymer (e.g., PVDF-HFP) and form a separator film of uniform thickness that defines the network of open pores sized to transport ions (e.g., lithium ions) through the separator film.

[0022] Additionally, system 100 can also monitor the temperature of the separator material in the gaseous environment within the vessel and the temperature of the separator material in a liquid state within the reservoir of the coating supply subsystem to maintain a target vapor pressure and uniform polymer-polymer-solvent liquid mixture within the reservoir. Additionally, system 100 can utilize a target temperature range of the separator material and the target vapor pressure to: achieve a precise and repeatable liquid flow of the separator material through a nozzle of a spray system; and thereby achieve a precise and repeatable thickness of the separator material on a substrate via spraying during a processing cycle. System 100 can also define (or achieve) and implement time and temperature parameters of a drying segment of a processing cycle to evaporate the first solvent (e.g., butanone) from the separator material coating the substrate and control the phase separation of the first polymer (e.g., PVDF-HFP) from the second polymer (e.g., PEG).

[0023] Additionally or alternatively, system 100 can: irradiate the volume of separator material to form a porous electrolyte structure that extends beyond a perimeter of the substrate; and then fill the network of open pores with solvated ions to form an electrolyte. For example, system 100 can execute the blocks of the method to form an electrolyte that carries ions (e.g., carries lithium ions) on a cathode and / or an anode, which can then be assembled into a battery cell of a two-dimensional battery or a three-dimensional battery (e.g., for use in an electric vehicle, a wearable device, a cellular device, or a battery-operated tool). Moreover, the electrolyte can be used as a buffer or electrode separator between an anode and a cathode - assembled into a battery cell - to prevent the flow of electrons between the anode and the cathode within the battery cell and thereby prevent an electrical short within the battery.

[0024] Method S100 is described below as being performed by system 100 to deposit (e.g., spray) separator material on a substrate (e.g., electrode) and to form a thin film, or discrete separator layer, or permeable separator membrane of the separator material on the substrate via a processing cycle. However, method S100 can similarly be implemented to produce a thin film, discrete separator layer, or permeable separator membrane of the separator material directly on a cathode and / or an anode, and / or to produce a separate, continuous non-conductive structure for subsequent assembly with an anode and cathode to form a two-dimensional battery or three-dimensional battery, etc.

[0025] 3. System

[0026] System 100 includes a substrate supply station 105, a spray system 110, a refill station 120, a washing station 130, and an irradiation station 140. Substrate supply station 105 includes a substrate reel (e.g., electrode reel, anode reel, cathode reel) configured to deliver a substrate tape including a series of substrates to spray system 110. Spray system 110 includes a chassis 112, a multi-axis stage 113, a nozzle 114, and a coating supply subsystem 115 configured to selectively supply separator material (e.g., polymer-polymer-solvent liquid mixture) in a liquid state from a reservoir to nozzle 114, a gas regulator 116, a set of heaters 117, and a set of temperature sensors 118. Spray system 110 is configured to spray a volume of separator material onto a substrate.

[0027] Refill station 120 includes a fresh supply of separator material (e.g., polymer-polymer-solvent liquid mixture) and is configured to refill the reservoir of the spray system with the fresh supply of separator material. Washing station 130 includes a chemical bath of a second solvent such as an alcohol (e.g., isopropyl alcohol) and is configured to dissolve the second polymer out of the separator material on the substrate. Irradiation station 140 includes an electron beam configured to transmit electrons toward the substrate to crosslink the first polymer and form a separator film (e.g., discrete separator layer, permeable separator membrane) on the substrate.

[0028] 3.1 Base supply station

[0029] In one implementation, substrate supply station 105 includes a substrate reel (e.g., electrode reel, anode reel, cathode reel) configured to deliver a substrate tape including a series of substrates to spray system 110. In particular, substrate supply station 105 includes a substrate reel configured to deliver a cathode tape including a series of cathodes and / or an anode tape including a series of anodes from the substrate supply station to spray system 110.

[0030] In one variation, the system 100 can trigger the substrate supply station 105 to load a cathode tape onto the substrate spool and to transport a cathode spool including a first cathode of a series of cathodes from the substrate supply station to the coating zone within the spray system 110. The system 100 can then receive, within the coating zone, a first portion of the cathode tape including the first cathode and implement the methods and techniques described below to spray a separator material on the first cathode occupying the coating zone, dry the separator material on the first cathode, wash the first cathode with an alcohol bath, and irradiate the separator material and the first cathode with an electron beam to form a separator film on the first cathode in the first portion of the cathode tape.

[0031] Additionally or alternatively, the system 100 can trigger the substrate supply station 105 to load an anode tape onto the substrate spool and to transport an anode spool including a first anode of a series of anodes from the substrate supply station to the coating zone within the spray system 110. The system 100 can then receive, within the coating zone, a first portion of the anode tape including the first anode and implement the methods and techniques described below to spray a separator material on the first anode occupying the coating zone, dry the separator material on the first anode, wash the first anode with an alcohol bath, and irradiate the separator material and the first anode with an electron beam to form a separator film on the first anode in the first portion of the anode tape.

[0032] The system 100 can repeat these methods and techniques for each other cathode of the series of cathodes, for each other anode of the series of anodes, and for each other portion of the substrate tape (e.g., cathode tape, anode tape) to transport the substrate tape to the spray system 110.

[0033] 3.1 Spray system

[0034] The spray system 110 includes a chassis 112, a multi-axis platform 113, a paint supply subsystem 115, a gas regulator 116, a set of heaters 117, and a set of temperature sensors 118 coupled to the paint supply subsystem 115.

[0035] The chassis 112 bounds the enclosure and is arranged around the spray system 110. The multi-axis platform 113 is configured to support the paint supply subsystem 115. The paint supply subsystem 115 is supported by the multi-axis platform 113 and includes: a container configured to contain a gaseous environment above a reservoir configured to contain a barrier material (e.g., a polymer-polymer-solvent liquid mixture) in a liquid state; a first heater 117 configured to heat the reservoir of barrier material in a liquid state; a nozzle 114 coupled to the reservoir, facing the substrate, and configured to spray a volume of the barrier material from the reservoir on the substrate; a second heater 117 coupled to the nozzle 114 and configured to heat the barrier material prior to spraying the substrate; and a valve between the reservoir and the nozzle 114.

[0036] The gas regulator 116 is coupled to the paint supply subsystem and is configured to regulate the pressure of the gas within the container of the paint supply subsystem 115. In one variation, the gas regulator 116 can increase the pressure of the gas within the container and through the nozzle 114 to remove excess barrier material that can accumulate within the nozzle 114 over a period of time (e.g., a week, three weeks, a month).

[0037] The temperature sensor 118 can include a set of temperature sensors 118 configured to output signals corresponding to the temperature of the barrier material at the reservoir, the temperature of the barrier material at the nozzle 114, and the temperature of the substrate.

[0038] 3.1.1 Chassis + gantry

[0039] Chassis 112: bounds the enclosure and is arranged around the spray system 110. The chassis 112 is configured to support the multi-axis platform and the paint supply subsystem 115.

[0040] The multi-axis platform 113 includes a three-axis gantry (e.g., X-axis, Y-axis, and Z-axis): supported by the chassis 112; arranged on the substrate occupying the enclosure; configured to face one side of the substrate (e.g., arranged on, under, or adjacent to one side of the substrate); and configured to support the paint supply subsystem 115 in a range of vertical, lateral, and longitudinal positions to enable the nozzle 114 to access the edges of the substrate (e.g., electrode) during a processing cycle.

[0041] In one variation, the multi-axis platform includes a five-axis gantry (e.g., X-axis, Y-axis, Z-axis, A-axis, and B-axis): supported by the chassis 112; arranged on the base occupying the footprint; configured to face one side of the base; and configured to support the coating supply subsystem 115 in a range of vertical, lateral, longitudinal, and rotational positions to enable the nozzle 114 to access the edge of the base (e.g., electrode) during a processing cycle.

[0042] 3.1.2 Coating supply subsystem

[0043] The coating supply subsystem 115 is supported by the multi-axis platform 113 and includes: a vessel configured to contain a gaseous environment of the partition material; a reservoir arranged in the vessel and configured to contain the partition material in a liquid state; a nozzle 114 coupled to the reservoir and facing the base; a first heater 117 configured to heat the partition material; a second heater 117 coupled to the nozzle 114 and configured to heat the partition material prior to spraying the base; a first valve between the reservoir and the nozzle 114; and a second valve arranged proximal to the nozzle 114.

[0044] The first valve is operable in an open position to supply the partition material in a liquid state from the reservoir to the nozzle 114 and in a closed position to retain the partition material in a liquid state within the reservoir and to maintain the gaseous environment in the vessel. The second valve is operable in a closed position to prevent an existing volume of the first solvent (e.g., butanone) from entering the nozzle 114 and in an open position to supply the existing volume of the first solvent (e.g., butanone) through the nozzle 114 and thereby enable cleaning of the nozzle 114 without disassembly of the coating supply subsystem 115.

[0045] 3.1.3 Temperature sensor

[0046] In one implementation, the spray system 110 includes a set of temperature sensors 118 (e.g., PID sensors, thermocouples) coupled to the coating supply subsystem 115 and / or the base occupying the footprint. These temperature sensors 118 are configured to output signals corresponding to the temperature of the partition material during a processing cycle.

[0047] In one variation, the system 100 can include: a first temperature sensor 118 coupled to the container and configured to output a signal corresponding to a temperature of the septum material in the gaseous environment; a second temperature sensor 118 coupled to the nozzle 114 and configured to output a signal corresponding to a temperature of the septum material in the liquid state prior to exiting the nozzle 114; and a third temperature sensor 118 coupled to the spray system 110 and configured to output a signal corresponding to a temperature of the substrate. The system 100 can then: interpret the temperature of the septum material and / or the substrate; monitor the temperature; and derive a correlation between the temperature and a vapor pressure of the gaseous environment prior to beginning the overwrap segment of the process cycle, as further described below.

[0048] 4. Separator material: Polymer-polymer-solvent liquid mixture

[0049] Generally, the septum material is a polymer-polymer-solvent liquid mixture and includes: a first solvent; a first polymer miscible in the first solvent; and a second polymer miscible in the first solvent. The polymer-polymer-solvent liquid mixture includes greater than 80% by weight of the first solvent, and includes a low viscosity to enable the nozzle to deposit a series of septum material droplets (e.g., aerosol) on the porous substrate and adhere to a surface of the porous substrate.

[0050] In one implementation, the first solvent includes an organic ketone, such as butanone, characterized by a boiling point of 79.64 degrees Celsius or 175.26 degrees Fahrenheit. The first polymer includes a copolymer, such as poly(vinylidene fluoride-hexafluoropropylene) (or “PVDF-HFP”), and is characterized by a molecular weight of about 400,000 grams / mole. The second polymer includes a polyether, such as poly(ethylene oxide) (or “PEO”), poly(oxyethylene) (or “POE”), or polyethylene glycol (or “PEG”), and is characterized by a molecular weight of about 20,000 grams / mole. In this implementation, the first polymer (e.g., PVDF-HFP) and the second polymer (e.g., PEG) are mixed in the first solvent (e.g., butanone) to form a polymer-polymer-solvent liquid mixture that exhibits a homogenous phase of greater than 80% by weight of the first solvent.

[0051] In one variation, the polymer-polymer-solvent liquid mixture includes a first solvent (e.g., butanone), and a first polymer (e.g., PVDF-HFP) and a second polymer (e.g., PEG) mixed in the first solvent. In this variation, the system 100 can heat the polymer-polymer-solvent liquid mixture toward a target liquid temperature range to maintain the polymer-polymer-solvent liquid mixture as a homogenous mixture within the reservoir and at the nozzle of the coating supply subsystem. Additionally, the first polymer (e.g., PVDF-HFP) is immiscible with the second polymer (e.g., PEG), and vice versa.

[0052] Further, during the processing cycle, the system 100 sprays the polymer-polymer-solvent liquid mixture as an aerosol (or “series” of separator material droplets, a “mist” or “cloud” of separator material droplets) on the substrate occupying the cladding region. For example, the polymer-polymer-solvent liquid mixture can exhibit less than 20% by weight of the first solvent (e.g., between 15% and 20% by weight of butanone). Upon initial contact between the series of separator material droplets and the substrate, the system 100 further causes the series of separator material droplets to rapidly dry, such as with a heater coupled to the substrate, thereby facilitating phase separation of the first polymer (e.g., PVDF-HFP) and the second polymer (e.g., PEG). The system 100 then washes, rinses, or sprays the substrate with a volume of a second solvent, such as with an alcohol (e.g., isopropyl alcohol), dissolving the second polymer (e.g., PVDF-HFP) out of the series of separator material droplets. The resulting series of separator material droplets, with the second polymer removed, can thereby form a continuous film (e.g., aerosol) defining a network of voids distributed throughout its volume.

[0053] The system 100 then selectively irradiates the series of separator material droplets and the substrate via an electron beam to further crosslink molecules of the first polymer (e.g., PVDF-HFP) and form a separator film (e.g., discrete separator layer, permeable separator film) across the substrate. Thus, the separator film defines an open network of pores sized to facilitate uniform and rapid ion transport; prevent formation of defects on the substrate; and thereby prevent electrical shorts between anodes or cathodes in the substrate and battery cell, such as due to dendrites growing from an anode into the separator film, as further described below.

[0054] 5. Processing cycle

[0055] At the start of a processing cycle (e.g., a spray deposition cycle, a spray processing cycle), the system 100 resets the multi-axis platform to a home position facing the coating zone. The substrate supply station then delivers a series of substrates (e.g., anodes, cathodes) to the spray system so that the substrates (e.g., anodes, cathodes) occupy the coating zone. The system 100 then initiates the processing cycle (e.g., a spray deposition cycle, a spray processing cycle).

[0056] The system 100 washes or rinses the substrate with a second solvent to dissolve the second polymer out of the separator material, thereby providing an open network of pores. The system 100 then irradiates the separator material and the substrate with an electron beam to further crosslink the first polymer and form a separator layer. The resulting separator layer is non-conductive and includes an open network of pores sized to transport ions (e.g., lithium ions) through the separator layer and between adjacent anodes and cathodes within an assembled battery cell.

[0057] 5.1 Coating section

[0058] Once the system 100 initiates the processing cycle, the system 100 can trigger the multi-axis platform to position the coating supply subsystem to face the substrate within the coating zone and initiate a first coating segment of the processing cycle.

[0059] Prior to initiating the first coating segment of the processing cycle, the system 100 can achieve a target gas temperature range of the separator material in the gaseous environment in the container, a target liquid temperature range of the separator material at the nozzle in a liquid state, and a target substrate temperature of the substrate for a dry segment of the processing cycle. The system 100 can then deposit (or“spray”) a volume of the separator material (or“a series of separator material droplets”) as an aerosol across all surfaces and / or edges of the substrate (e.g., an anode, a cathode) occupying the coating zone during the first coating segment of the processing cycle via the nozzle.

[0060] In particular, the system 100 can: configure a valve disposed within the coating supply subsystem to an open position to deliver the separator material (e.g., a polymer-polymer-solvent liquid mixture) in a liquid state from the reservoir to the nozzle; and spray a series of separator material droplets on the substrate within the cladding zone such that each droplet in the series of separator material droplets contains molecules of a first polymer (e.g., PVDF-HFP) that define a small cross-sectional width: the small cross-sectional width is greater than a minimum cross-sectional width of the lithium ion; and less than a minimum cross-sectional width of a thickness of the substrate (e.g., 50 microns, 100 microns). Thus, the series of separator material droplets can encapsulate edges of the substrate (e.g., anode, cathode). Further, in block S120, the system 100 can spray a series of separator material droplets on the substrate, each droplet in the series of separator material droplets including a first solvent (e.g., butanone), a first polymer (e.g., PVDF-HFP) miscible in the first solvent, and a second polymer (e.g., PEG) miscible in the first solvent.

[0061] Further, the system 100 can detect a minimum volume of the separator material in a liquid state within the reservoir and track a volume of the separator material exiting the nozzle for each cladding segment of the processing cycle. Then, the system 100 can derive a correlation between the total volume of the separator material exiting the nozzle for each cladding segment and trigger a refill station to refill the reservoir with a new volume of the separator material in response to the total volume of the separator material exceeding the minimum volume of the separator material.

[0062] 5.1.1 Separator material temperature + pressure regulation

[0063] Prior to spraying the separator material on the substrate occupying the cladding zone, the system 100 can define a target gas temperature range of the first solvent of the gaseous environment of the vessel and a target liquid temperature range of the separator material of the reservoir, which yields a target flow rate of the separator material through the nozzle. Then, the system 100 can monitor temperatures of the vessel and the separator material in the reservoir based on signals from a set of temperature sensors coupled to the coating supply subsystem. Further, the system 100 can adjust the temperatures of the gaseous environment and the separator material to the target temperature ranges with heaters coupled to the coating supply subsystem and the nozzle to maintain the target flow rate of the separator material through the nozzle.

[0064] In one implementation, the system 100 can define a target gas temperature range corresponding to a target vapor pressure of the first solvent in the gaseous environment within the vessel. In particular, the system 100 can: achieve the target gas temperature range proportional to a vapor pressure of the separator material (e.g., a polymer-polymer-solvent liquid mixture) in the gaseous environment within the vessel; detect a temperature of the first solvent in the gaseous environment; and initiate a cladding segment of the processing cycle based on the temperature.

[0065] For example, the system 100 can: define a target gas temperature range for the first solvent; at a vessel containing a gaseous environment above a reservoir of the barrier material in a liquid state, heat the gaseous environment toward the target gas temperature range; and interpret a first temperature of the gaseous environment within the vessel based on a first signal from a first temperature sensor coupled to the coating supply subsystem. Then, in response to the first temperature of the gaseous environment falling within the target gas temperature range, the system 100 can initiate a coating segment of the processing cycle and spray a series of droplets of the barrier material through the nozzle and onto the substrate.

[0066] In another implementation, the system 100 can similarly define a target liquid temperature range for the barrier material to maintain a homogeneous polymer-polymer-solvent liquid mixture within the reservoir; detect a temperature of the barrier material in a liquid state at the nozzle; and based on the temperature, initiate a coating segment of the processing cycle. For example, the system 100 can: define a target liquid temperature range for the barrier material; at the nozzle coupled to the reservoir of the barrier material in a liquid state and facing the substrate, heat the nozzle toward the target liquid temperature range; and interpret a first temperature of the barrier material at the nozzle based on a signal from a temperature sensor coupled to the coating supply subsystem. Then, in response to the first temperature of the barrier material falling within the target liquid temperature range, the system 100 can initiate a coating segment of the processing cycle and spray a series of droplets of the barrier material through the nozzle and onto the substrate.

[0067] Additionally, the system 100 can define a target gas temperature range for the first solvent equivalent to a target liquid temperature range for the barrier material, detect a temperature of the barrier material in a liquid state at the nozzle and a temperature in the gaseous environment, and then based on these temperatures of the barrier material in a liquid state and the first solvent in the gaseous environment, initiate a coating segment of the processing cycle. For example, the system 100 can: define a target gas temperature range for the first solvent corresponding to a target vapor pressure for the barrier material in a gaseous state; at a vessel containing a gaseous environment above a reservoir of the barrier material in a liquid state, heat the gaseous environment toward the target gas temperature range; interpret a first temperature of the gaseous environment based on a first signal from a first temperature sensor coupled to the coating supply subsystem; define a target liquid temperature range for the barrier material; at the nozzle coupled to the reservoir of the barrier material in a liquid state and facing the substrate, heat the nozzle toward the target liquid temperature range; and interpret a second temperature of the barrier material in a liquid state at the nozzle based on a second signal from a second temperature sensor coupled to the coating supply subsystem. Then, in response to the first temperature of the gaseous environment falling within the target gas temperature range and in response to the second temperature of the barrier material falling within the target liquid temperature range, the system 100 can spray a series of droplets of the barrier material through the nozzle and onto the substrate.

[0068] Alternatively, in response to the first temperature of the gaseous environment falling outside of the target gas temperature range and in response to the second temperature of the bulkhead material falling outside of the target liquid temperature range, the system 100 can: heat the gaseous environment toward the target gas temperature range via a first heater coupled to the vessel; heat the bulkhead material in the liquid state toward the target liquid temperature range via a second heater coupled to the nozzle; interpret a third temperature of the gaseous environment based on a signal from the first temperature sensor; and interpret a fourth temperature of the bulkhead material in the liquid state at the nozzle based on a signal from the second temperature sensor. Then, in response to the third temperature of the gaseous environment falling within the target gas temperature range and in response to the fourth temperature of the bulkhead material falling within the target liquid temperature range, the system 100 can spray a series of bulkhead material droplets on the substrate via the nozzle.

[0069] Accordingly, the system 100 can monitor the temperature of the gaseous environment and the first solvent in the liquid state to maintain a target vapor pressure and a homogeneous polymer-polymer-solvent liquid mixture within the reservoir. Additionally, the system 100 can utilize the target temperature range and the target vapor pressure to achieve an accurate and repeatable flow of the bulkhead material through the nozzle to spray the bulkhead material on the substrate during the cladding segment of the processing cycle.

[0070] 5.1.2 Separator thickness

[0071] In one implementation, the system 100 can trigger the multi-axis platform to position the nozzle of the spray system at a target offset distance relative to the substrate within the cladding region. More specifically, the system 100 can receive a target bulkhead thickness of a bulkhead film (e.g., a discrete bulkhead layer, a permeable bulkhead film) formed during irradiation of the series of bulkhead material droplets and select a target offset distance between the nozzle and the substrate proportional to the target bulkhead thickness.

[0072] In one variation, the system 100 can set the target offset distance of the nozzle according to a battery specification (e.g., a multi-cell battery for an electric vehicle, a single-cell battery for a wearable device) and corresponding mechanical, electrical, optical, and / or physical properties of the bulkhead film formed on the substrate (e.g., an anode, a cathode).

[0073] For example, a user can require a separator membrane having a target separator thickness for a multi-cell battery for an electric vehicle, and define a battery specification that limits the multi-cell battery to exhibit low resistance, large ion flux, target conductivity, and high mechanical strength to withstand forces exerted during subsequent assembly into a battery cell. System 100 can then: receive a battery specification that limits a target separator thickness (e.g., 10 microns) of the separator membrane; select a target offset distance of the nozzle relative to the substrate based on the target separator thickness; and detect a first distance between the nozzle and the substrate within a coating zone by interpreting a signal from a depth sensor coupled to the coating supply subsystem. System 100 can then, in response to the target offset distance exceeding the first distance between the nozzle and the substrate: trigger the multi-axis platform to adjust the nozzle from the first distance to the target offset distance; and spray a first series of separator material droplets on a first portion of the substrate via the nozzle at the target offset distance. System 100 can then spray a second series of separator material droplets on a second portion of the substrate, and implement the methods and techniques described below to form a separator membrane exhibiting low resistance, large ion flux, and high mechanical strength - with a separator thickness that is close to the target separator thickness (e.g., 10 microns + / - 0.01 microns, 10 microns + / - 0.1 microns).

[0074] Accordingly, system 100 can spray discrete portions or segments of a substrate with separator material via a nozzle positioned at a target offset distance from the substrate in order to form a thin separator membrane having a target separator thickness according to a particular battery specification, such as defined by an operator.

[0075] 5.1.3 Refilling reservoir with separator material

[0076] In one implementation, system 100 can detect a minimum volume of separator material in a liquid state within a reservoir, and track a volume of separator material exiting the nozzle for each coating segment of a processing cycle in order to trigger a refill station to refill the reservoir with a new volume of separator material.

[0077] For example, during a first coating segment of a processing cycle, the system 100 can: detect a minimum volume of the barrier material in a liquid state in the reservoir; receive a first substrate within the coating zone; define a target liquid temperature range of the barrier material in a liquid state in the reservoir; detect a first temperature of the barrier material at the nozzle; and in response to the first temperature of the barrier material falling within the target liquid temperature range, spray a first volume of the barrier material on the first substrate via the nozzle. Then, during a second coating segment of the processing cycle, the system 100 can: receive a second substrate within the coating zone; heat the nozzle towards the target liquid temperature range; detect a second temperature of the barrier material at the nozzle; and in response to the second temperature of the barrier material falling within the target liquid temperature range, spray a second volume of the barrier material on the second substrate via the nozzle. Then, the system 100 can: calculate a total volume of the barrier material on the first substrate and the second substrate based on a combination of the first volume of the barrier material and the second volume of the barrier material; and in response to the minimum volume of the barrier material exceeding the total volume of the barrier material, refill the reservoir with a third volume of the barrier material in a liquid state that is greater than the minimum volume of the barrier material.

[0078] Thus, the system 100 can track the volume of the barrier material that exits the nozzle during each coating segment of a processing cycle, and refill the reservoir with a volume of the barrier material in a liquid state if the minimum volume of the barrier material exceeds the total volume of the barrier material that exits the nozzle.

[0079] 5.2 Drying section: Removal of first solvent + phase separation

[0080] During a second drying segment of the processing cycle, the system 100 can rapidly and simultaneously dry each of a series of droplets of the barrier material after the series of droplets of the barrier material contact the substrate. Further, the system 100 can heat the substrate and the series of droplets of the barrier material to a temperature within a target temperature range proportional to a boiling point of the first solvent over a period of time. During the drying segment, the system 100 can also evaporate the first solvent from each of the series of droplets of the barrier material, and promote phase separation of a second polymer (e.g., PEG) and a first polymer (e.g., PVDF-HFP) on the substrate.

[0081] In one implementation, the system 100 can set a time parameter and a temperature parameter of a drying segment of a processing cycle to control phase separation of a first polymer (e.g., PVDF-HFP) and a second polymer (e.g., PEG). In particular, in block S122, the system 100 can reach a target substrate temperature range that is proportional to a boiling point of a first solvent (e.g., butanone). Then, in block S130, the system 100 can heat the substrate and the series of separator material droplets for a duration (e.g., 10 seconds, 30 seconds) to evaporate the first solvent out of the separator material. More specifically, the system 100 can reach a target substrate temperature range such as between 74 degrees Celsius and 79 degrees Celsius; between 77 degrees Celsius and 79 degrees Celsius; and / or between 78.9 degrees Celsius and 79.4 degrees Celsius, etc. Then, the system 100 can initiate a drying segment of a processing cycle and heat the series of separator material droplets and the substrate to a temperature within the target substrate temperature range.

[0082] For example, the system 100 can spray a series of separator material droplets on a substrate during a coating segment of a processing cycle. In this example, each droplet of the series of separator material droplets includes: a first solvent that includes a first volume of an organic ketone solvent (e.g., butanone); a first polymer that is miscible in the first volume of the organic ketone solvent and includes a second volume of a copolymer (e.g., PVDF-HFP); and a second polymer that is miscible in the first volume of the organic ketone solvent and includes a third volume of a polyether (e.g., PEG). Then, the system 100 can: reach a target substrate temperature that is below a boiling point of the organic ketone solvent (e.g., between 77 degrees Celsius and 79 degrees Celsius); initiate a drying segment of a processing cycle; and heat the substrate and the series of separator material droplets to a temperature within the target substrate temperature range (e.g., 78 degrees Celsius) via a heater coupled to the substrate to evaporate the first volume of the organic ketone solvent (e.g., butanone) out of the series of separator material droplets and to facilitate phase separation of the second polymer (e.g., PEG) from the first polymer (e.g., PVDF-HFP).

[0083] However, the series of separator material droplets and the substrate can be processed for any other duration or at any other temperature during a second drying segment of a processing cycle.

[0084] Then, the system 100 can transport the substrate to a washing assembly to wash or rinse the series of separator material droplets with a second solvent to dissolve the second polymer out of the series of separator material droplets and thereby provide an open network of pores.

[0085] 5.3 Washing section: Removal of second polymer

[0086] During the third wash segment of the processing cycle, the system 100 can dissolve the second polymer (e.g., PEG) out of the series of separator material droplets by washing or rinsing the series of separator material droplets with a chemical bath containing a second solvent (e.g., an alcohol) to provide an open network of pores. Further, in block S140, the system 100 can wash the substrate and the series of separator material droplets with the second solvent to form an open network of pores distributed throughout the series of separator material droplets.

[0087] In one implementation, the system 100 can receive a series of separator material droplets and a substrate from a spray system at a wash station, each droplet containing a first volume of a first polymer (e.g., PVDF-HFP) and a second volume of a second polymer (e.g., PEG). At the wash station, the system 100 can then dissolve the second volume of the second polymer (e.g., PEG) out of the series of separator material droplets by washing the series of separator material droplets with a second solvent including a third volume of an alcohol (e.g., isopropyl alcohol) that can fully swell the substrate, dissolving the second polymer (e.g., PEG) out of the pores in the separator material to provide open channels for transporting ions through the separator material.

[0088] In one variation, the system 100 can perform blocks of the method S100 to rinse the series of separator material droplets and the substrate with a second solvent (e.g., isopropyl alcohol) to provide an open network of pores; and project a stream of air on the series of separator material droplets and the substrate to remove excess isopropyl alcohol from the series of separator material droplets and the substrate that remains from the chemical bath. For example, the substrate can be immersed in a heated bath of the second solvent (e.g., isopropyl alcohol) and agitated for a duration, removed from the bath and dried to remove the second polymer (e.g., PEG) from the separator material.

[0089] Further, the system 100 can then transport the substrate to an irradiation station that irradiates the series of separator material droplets on the substrate, thereby promoting cross-linking of the first polymer (e.g., PVDF-HFP) to form a separator film having an open network of pores.

[0090] 5.4 Irradiation section: Thin film

[0091] During the fourth irradiation segment of the processing cycle, in block S150, system 100 can irradiate the series of separator material droplets and the substrate to crosslink the first polymer and form a separator membrane (e.g., a discrete separator layer, a permeable separator membrane) on the substrate. This separator membrane has a porous open network sized to transport ions through the separator membrane. Specifically, system 100 can selectively expose the substrate to an electron beam to further crosslink the molecules within the first polymer (e.g., PVDF-HFP) and form a separator membrane.

[0092] In one embodiment, the irradiation station includes an electron beam configured to deliver electrons toward the series of separator material droplets and the substrate to crosslink molecules within a first polymer (e.g., PVDF-HFP) to form a polymer matrix, to flash dry any remaining solvent from the substrate, and to form a separator film on the substrate.

[0093] In one variant, system 100 may receive a first substrate including a cathode at an irradiation station, and then receive a second substrate including an anode from a cleaning station at the irradiation station. In this variant, system 100 may receive both the cathode and the anode, wherein a second polymer (e.g., PEG) is removed from the series of separator material droplets; and electrons are transferred toward the cathode and the anode via an electron beam to form a continuous non-conductive structure extending beyond the periphery of the cathode and beyond the periphery of the anode.

[0094] For example, system 100 may receive a first substrate including a cathode at an irradiation station and irradiate the series of separator material droplets and the cathode with an electron beam to crosslink a first polymer (e.g., PVDF-HFP) and form a continuous non-conductive structure: defining a separator film having a porous open network sized to transport ions through the separator film; and extending beyond the periphery of the cathode. Then, system 100 may receive a second substrate including an anode at an irradiation station and irradiate the series of separator material droplets and the anode with an electron beam to crosslink the molecules within the first polymer (e.g., PVDF-HFP) and form a continuous non-conductive structure: defining a separator film having a porous open network sized to transport ions through the separator film; and extending beyond the periphery of the anode. Therefore, after subsequent post-processing of assembling the anode and cathode into a battery cell, the continuous non-conductive structure can prevent electron flow between the anode and cathode, such as preventing electrical short circuits in the battery cell.

[0095] Alternatively or alternatively, the system 100 may irradiate the series of separator material droplets and the cathode and / or anode with an electron beam to crosslink the first polymer and form a separator membrane on the cathode and / or anode, the separator membrane including a permeable separator membrane having a porous open network sized to transport ions through the permeable separator membrane.

[0096] Therefore, the system 100 can irradiate the series of separator material droplets after rapid drying and washing of the substrate to form a rigid, continuous, non-conductive structure of uniform thickness on the substrate, thereby forming a separator material film exhibiting the target mechanical, electrical, optical, and physical properties.

[0097] 6. Post-processing battery assembly: Introduction of solvated ions

[0098] In one variation, the separator membrane can form a porous electrolyte structure extending beyond the periphery of the substrate (e.g., cathode, anode) during the final irradiation segment of a processing cycle. System 100 can then expose the electrolyte structure to a solvent (e.g., an organic solvent) and ions to fill the network of open pores in the electrolyte structure with solvated ions, thereby forming an electrolyte. In this variation, system 100 can introduce solvated ions (e.g., lithium ions) into the electrolyte structure to fill the network of open pores, and thus enable the electrolyte structure to be used as an ion-carrying (e.g., lithium-ion-carrying) electrolyte in a subsequently assembled battery cell for electric vehicles or wearable devices.

[0099] Therefore, system 100 can perform a processing cycle to form a porous electrolyte structure extending beyond the periphery of the anode or cathode, and then fill the open pores with a network of solvated ions to form an electrolyte. Alternatively, the electrolyte can be used as a buffer or electrode separator between the anode and cathode, and subsequently assembled into a battery cell to prevent the flow of electrons between the anode and cathode within the battery cell (i.e., to prevent electrical short circuits).

[0100] 7. Variant: Parallel nozzles

[0101] In one variant, the paint supply subsystem may include a set of nozzles connected in parallel via valves, such that each nozzle in the set can simultaneously spray septum material onto a substrate to obtain a septum film exhibiting a uniform target thickness across the substrate. In this variant, the valves may include chemically resistant solenoid valves that are resistant to a first solvent (e.g., methyl ethyl ketone) in the polymer-polymer-solvent liquid mixture, operable in open and closed positions to maintain the vapor pressure of the polymer-polymer-solvent liquid mixture within each nozzle of the paint supply subsystem.

[0102] For example, a paint supply subsystem may include a set (e.g., three) of nozzles: connected in parallel via solenoid valves; defining a coating area; and configured to simultaneously spray separator material onto a substrate within the coating area. At a first moment, system 100 may: receive a first portion of a substrate strip comprising a first substrate within the coating area; spray a first series of separator material droplets onto the first portion of the first substrate via a first nozzle; spray a second series of separator material droplets onto a second portion of the first substrate via a second nozzle; and spray a third series of separator material droplets onto a third portion of the first substrate via a third nozzle, the third portion being located between the first and second portions of the first substrate.

[0103] At a second time following the first time, system 100 may implement the methods and techniques described above to: heat the first substrate to a target substrate temperature to simultaneously and rapidly dry a first series of separator material droplets, a second series of separator material droplets, and a third series of separator material droplets on the first substrate, to evaporate a first solvent (e.g., methyl ethyl ketone) from the first series of separator material droplets, the second series of separator material droplets, and the third series of separator material droplets; and wash the first series of separator material droplets and the second series of separator material droplets with a second solvent (e.g., isopropanol). The system comprises three series of separator material droplets and a substrate, which are used to dissolve a second polymer (e.g., PEG) from the first, second, and third series of separator material droplets to provide an open-cell network with pores; and to irradiate the first, second, and third series of separator material droplets with an electron beam to crosslink the first polymer (e.g., PVDF-HFP) to form a separator material film extending beyond the periphery of the first substrate (e.g., encapsulating all sides of the first substrate). Therefore, each nozzle in the coating supply subsystem can spray a corresponding portion of the substrate to obtain a separator film of uniform target thickness.

[0104] Alternatively or concurrently, the paint supply subsystem may include a set (e.g., three) of nozzles: connected in parallel via solenoid valves; defining a set (e.g., three) of coating zones; and configured to spray diaphragm material onto a corresponding substrate in a series of substrates within each coating zone. In this variant, system 100 can process a series of substrates simultaneously in batches during a processing cycle.

[0105] For example, at a first time, system 100 may: receive a first portion of the substrate including a first substrate in a first encapsulation region; receive a second portion of the substrate including a second substrate in a second encapsulation region; and receive a third portion of the substrate including a third substrate in a third encapsulation region. At approximately a first time, system 100 may: spray a first series of separator material droplets onto the first substrate via a first nozzle; spray a second series of separator material droplets onto the second substrate via a second nozzle; and spray a third series of separator material droplets onto the third substrate via a third nozzle. In a second time following the first time, system 100 may implement the methods and techniques described above to: heat the first substrate, the second substrate, and the third substrate to a target substrate temperature to simultaneously and rapidly dry the first series of separator material droplets, the second series of separator material droplets, and the third series of separator material droplets on the first substrate, the second substrate, and the third substrate, to evaporate a first solvent (e.g., methyl ethyl ketone) from the first series of separator material droplets, the second series of separator material droplets, and the third series of separator material droplets; wash the first series of separator material droplets, the second series of separator material droplets, and the third series of separator material droplets, as well as the first substrate, the second substrate, and the third substrate, with a second solvent (e.g., isopropanol). The system comprises three substrates: a first series of separator material droplets, a second series of separator material droplets, and a third series of separator material droplets, from which a second polymer (e.g., PEG) is dissolved to provide a porous open network on the first, second, and third substrates; and an electron beam is used to irradiate the first, second, and third series of separator material droplets to crosslink the first polymer (e.g., PVDF-HFP) to form a first separator material film extending beyond the periphery of the first substrate (e.g., encapsulating all sides of the first substrate), a second separator material film extending beyond the periphery of the second substrate, and a third separator material film extending beyond the periphery of the third substrate. Therefore, each nozzle in the coating supply subsystem can spray a corresponding substrate from a series of substrates to obtain separator material films of uniform target thickness on a series of substrates in a batch coating process.

[0106] 8. Other separator material applications

[0107] Typically, the above description outlines a method S100 for manufacturing a conformal rigid separator membrane within a 2D or 3D lithium-ion battery for electric vehicles, such as by fabricating a separator membrane of uniform thickness on a planar anode and then assembling a planar cathode on the separator membrane. However, similar methods and techniques can be implemented to produce conformal rigid separator membranes in the case of fabricating 3D batteries on silicon wafers. Similarly, these methods, techniques, and materials can be implemented to produce 2D or 3D hydrogen fuel cells comprising a separator membrane that defines a controlled density and distribution of relatively large pores, which improves hydrogen ion conduction through the fuel cell. Furthermore, these methods, techniques, and materials can be implemented to produce 2D or 3D nickel-metal hydride batteries comprising a separator membrane that defines a controlled density and distribution of relatively large pores, which improves hydrogen ion conduction through the nickel-metal hydride battery.

[0108] However, the separator material can be applied and processed in any other way to form a conformal rigid separator membrane. Similarly, method S100 can be implemented in any other way to manufacture a conformal rigid separator membrane, such as manufacturing a conformal rigid separator membrane directly on the electrode or manufacturing a conformal rigid separator membrane separately from the electrode.

[0109] The system 100 and methods described herein can be at least partially embodied and / or implemented as a machine configured to receive a computer-readable medium storing computer-readable instructions. The instructions can be executed by a computer-executable component integrated with hardware / firmware / software elements of an application, applet, host, server, network, website, communication service, communication interface, user computer, or mobile device, wristband, smartphone, or any suitable combination thereof. Other embodiments of the system 100 and methods can be at least partially embodied and / or implemented as a machine configured to receive a computer-readable medium storing computer-readable instructions. The instructions can be executed by a computer-executable component integrated with a computer-executable component integrated with devices and networks of the types described above. The computer-readable medium can be stored on any suitable computer-readable medium, such as RAM, ROM, flash memory, EEPROM, optical devices (CD or DVD), hard disk drives, floppy disk drives, or any suitable device. The computer-executable component can be a processor, but any suitable dedicated hardware device can (optionally or additionally) execute the instructions.

[0110] As will be appreciated by those skilled in the art from the foregoing detailed description and from the drawings and claims, modifications and alterations may be made to embodiments of the invention without departing from the scope of the invention as defined in the appended claims.

Claims

1. A method for depositing a separator material, comprising: during a first time period: receiving a first substrate in a coating zone; spraying a series of separator material droplets on the first substrate, each droplet in the series of separator material droplets comprising a first solvent, a first polymer miscible in the first solvent, and a second polymer miscible in the first solvent; and achieving a target substrate temperature below a boiling point of the first solvent; and during a second time period after the first time period: heating the first substrate and the series of separator material droplets to the target substrate temperature to evaporate the first solvent out of the series of separator material droplets and to promote phase separation of the second polymer from the first polymer; washing the series of separator material droplets with a second solvent to dissolve the second polymer out of the series of separator material droplets and to provide an open pore network having pores within the series of separator material droplets; and irradiating the series of separator material droplets and the first substrate to crosslink the first polymer and form a separator film on the first substrate, the separator film defining the open pore network having pores sized to transport ions.

2. The method of claim 1: further comprising, during the first time period: defining a target gas temperature range for the first solvent, the target gas temperature range corresponding to a target vapor pressure of a separator material in a gaseous environment; at a vessel containing a gaseous environment of the first solvent above a reservoir of separator material in a liquid state, heating the gaseous environment toward the target gas temperature range; and detecting a second temperature of the gaseous environment; and wherein spraying the series of separator material droplets on the first substrate comprises spraying the series of separator material droplets on the first substrate in response to the second temperature of the separator material falling within the target gas temperature range.

3. The method of claim 1: further comprising, during the first time period: defining a target liquid temperature range for a separator material; at a nozzle coupled to a reservoir of separator material in a liquid state and facing the first substrate, heating the nozzle toward the target liquid temperature range; and detecting a second temperature of separator material at the nozzle; and wherein spraying the series of separator material droplets on the first substrate comprises spraying the series of separator material droplets on the first substrate via the nozzle in response to the second temperature falling within the target liquid temperature range.

4. The method of claim 3: further comprising, during the first time period: receiving a target separator thickness for the separator film; selecting a target offset distance between the nozzle and the first substrate based on the target separator thickness; and detecting a first distance between the nozzle and the first substrate within the coating zone; in response to the target offset distance exceeding the first distance between the nozzle and the first substrate, adjusting the first distance to the target offset distance between the nozzle and the first substrate; ​ wherein jetting the series of separator material droplets on the first substrate includes jetting the series of separator material droplets on the first substrate at the target offset distance via the nozzle; and wherein irradiating the series of separator material droplets and the first substrate includes irradiating the series of separator material droplets and the first substrate to crosslink the first polymer and form a separator membrane exhibiting a separator thickness proximate to the target separator thickness.

5. The method of claim 1 : wherein receiving the first substrate includes receiving the first substrate including a cathode within the envelope region; wherein jetting the series of separator material droplets on the first substrate includes jetting the series of separator material droplets on the cathode; and wherein irradiating the series of separator material droplets and the first substrate includes irradiating the series of separator material droplets and the cathode with an electron beam to crosslink the first polymer and form a continuous non-conductive structure: the continuous non-conductive structure defines the separator membrane having the open network of pores sized to transport ions through the separator membrane; and the continuous non-conductive structure extends beyond a perimeter of the cathode.

6. The method of claim 1 : wherein receiving the first substrate includes receiving the first substrate including an anode within the envelope region; wherein jetting the series of separator material droplets on the first substrate includes jetting the series of separator material droplets on the anode; and wherein irradiating the series of separator material droplets and the first substrate includes irradiating the series of separator material droplets and the anode with an electron beam to crosslink the first polymer and form a continuous non-conductive structure: the continuous non-conductive structure defines the separator membrane having the open network of pores sized to transport ions through the separator membrane; and the continuous non-conductive structure extends beyond a perimeter of the anode.

7. The method of claim 1 : further comprising, during the first time period, defining a target separator thickness corresponding to a target electrical conductivity of the separator membrane; and wherein irradiating the series of separator material droplets and the first substrate to crosslink the first polymer and form the separator membrane includes irradiating the series of separator material droplets and the first substrate to crosslink the first polymer and form the separator membrane having a separator thickness proximate to the target separator thickness.

8. The method of claim 1 : further comprising, during the first time period, receiving a target separator thickness of the separator membrane; wherein jetting the series of separator material droplets includes: jetting the series of separator material droplets on the first substrate at a first nozzle coupled to a reservoir of separator material in a liquid state and facing the first substrate; Also including, during the second time period, spraying a second series of separator material droplets on the first substrate at a second nozzle coupled to a reservoir of the separator material, each droplet of the second series of separator material droplets including the first solvent, the first polymer, and the second polymer; and wherein irradiating the series of separator material droplets and the first substrate to crosslink the first polymer and form the separator membrane includes irradiating the series of separator material droplets, the second series of separator material droplets, and the first substrate to crosslink the first polymer and form the separator membrane having a separator thickness that is close to the target separator thickness.

9. The method of claim 1: wherein spraying the series of separator material droplets on the first substrate includes spraying the series of separator material droplets on the first substrate, each droplet of the series of separator material droplets including: the first solvent, the first solvent including a first volume of an organic ketone solvent; the first polymer, the first polymer being miscible in the first volume of the organic ketone solvent and including a second volume of a copolymer; and the second polymer, the second polymer being miscible in the first volume of the organic ketone solvent and including a third volume of a polyether; wherein reaching the target substrate temperature includes reaching the target substrate temperature that is below a boiling point of the organic ketone solvent; and wherein heating the first substrate and the series of separator material droplets to the target substrate temperature to evaporate the first solvent includes heating the first substrate and the series of separator material droplets to the target substrate temperature to evaporate the first volume of the organic ketone solvent out of the series of separator material droplets and to promote phase separation of the second polymer from the first polymer.

10. The method of claim 9, wherein washing the series of separator material droplets with the second solvent includes washing the series of separator material droplets with the second solvent including a fourth volume of an alcohol to dissolve the third volume of the polyether out of the series of separator material droplets and to provide the open network of pores within the series of separator material droplets.

11. The method of claim 1, wherein spraying the series of separator material droplets on the first substrate includes spraying the series of separator material droplets on the first substrate, each droplet of the series of separator material droplets including molecules of the first polymer that define a small cross-sectional width: the small cross-sectional width being greater than a minimum cross-sectional width of a lithium ion; and the small cross-sectional width being less than a minimum cross-sectional width of a substrate thickness.

12. The method of claim 1: wherein receiving the first substrate within the cladding zone includes receiving a first portion of a substrate tape including the first substrate within the cladding zone; also including, during a third time period that is after the first time period: receiving a second portion of the substrate ribbon comprising a second substrate within the coating zone; and spraying a second series of droplets of separator material on the second substrate, each droplet of the second series of droplets of separator material including the first solvent, the first polymer miscible in the first solvent, and the second polymer miscible in the first solvent; and further comprising, during a fourth time period after the third time period: heating the second substrate and the second series of droplets of separator material to the target substrate temperature to evaporate the first solvent from the second series of droplets of separator material and to promote phase separation of the second polymer from the first polymer; washing the second series of droplets of separator material with a second solvent to dissolve the second polymer from the second series of droplets of separator material and to provide the open network of pores within the second series of droplets of separator material; and irradiating the second series of droplets of separator material and the second substrate to crosslink the first polymer and form a second separator film on the second substrate having a separator thickness proximate to a target separator thickness.

13. The method of claim 1, wherein irradiating the series of droplets of separator material and the first substrate includes irradiating the series of droplets of separator material and the first substrate via an electron beam to crosslink the first polymer and form the separator film on the first substrate, the separator film including a permeable separator film having the open network of pores sized to transport ions through the permeable separator film.

14. The method of claim 1, wherein dissolving the second polymer from the series of droplets of separator material includes: flushing the series of droplets of separator material and the first substrate with the second solvent to provide the open network of pores having pores; and projecting an air stream on the series of droplets of separator material and the first substrate to remove the second solvent from the series of droplets of separator material and the first substrate.

15. The method of claim 1, wherein spraying the series of droplets of separator material on the first substrate includes spraying the series of droplets of separator material on the first substrate, each droplet of the series of droplets of separator material including between 15% and 20% by weight of the first solvent including an organic ketone.

16. A method for depositing a separator material, comprising: during a first time period: receiving a first substrate within a cladding zone; defining a target liquid temperature range for a separator material; heating a nozzle facing the first substrate and coupled to a reservoir of separator material in a liquid state toward the target liquid temperature range; detecting a first temperature of separator material at the nozzle; in response to the first temperature of the separator material falling within the target liquid temperature range, spraying a first volume of separator material on the first substrate via the nozzle, the separator material including a first solvent, a first polymer miscible in the first solvent, and a second polymer miscible in the first solvent; and attain a target substrate temperature that is below a boiling point of the first solvent; and during a second time period that is after the first time period: heat the first substrate and the first volume of the separator material to the target substrate temperature to evaporate the first solvent out of the first volume of separator material; dissolve the second polymer out of the first volume of separator material to provide an open network of pores; and irradiate the first volume of separator material to crosslink the first polymer and form a separator membrane having a separator thickness that is close to a target separator thickness.

17. The method of claim 16: further comprising, during the first time period: defining a target gas temperature range for the separator material, the target gas temperature corresponding to a target vapor pressure for the separator material in a gaseous state; heating the gaseous environment toward the target gas temperature range at a vessel containing the gaseous environment above a reservoir of separator material in a liquid state; and detecting a second temperature of the gaseous environment; and wherein spraying the first volume of separator material on the first substrate comprises, in response to the first temperature of the separator material falling within the target liquid temperature range and in response to the second temperature of the separator material falling within the target gas temperature range, spraying the first volume of separator material on the first substrate via the nozzle.

18. The method of claim 16, further comprising: during the first time period, detecting a minimum volume of separator material in a liquid state in the reservoir; and during a third time period that is after the second time period: receiving a second substrate within the enclosure; heating the nozzle toward the target liquid temperature range; detecting a second temperature of the separator material at the nozzle; in response to the second temperature of the separator material falling within the target liquid temperature range, spraying a second volume of separator material on the second substrate via the nozzle, the separator material including the first solvent, the first polymer, and the second polymer; based on a combination of the first volume of separator material and the second volume of separator material, calculating a total volume of separator material on the first substrate and the second substrate; and in response to the total volume of separator material exceeding the minimum volume of separator material, refilling the reservoir with a third volume of separator material in a liquid state that is greater than the minimum volume of separator material.

19. A method for depositing separator material, comprising: during a first time period: receiving a portion of a substrate tape including a first substrate within an enclosure; and depositing a series of droplets of separator material on the first substrate, each droplet in the series of droplets of separator material including a first solvent, a first polymer, and a second polymer; and during a second time period that is after the first time period: heating the first substrate and the series of droplets of separator material to a first temperature; washing the series of droplets of separator material and the first substrate with a second solvent to dissolve the second polymer out of the series of droplets of separator material and provide an open network of pores within the series of droplets of separator material; and irradiating the series of separator material droplets to crosslink the first polymer and form a discrete separator layer on the first substrate, the discrete separator layer defining the open network of pores sized to transport ions through the discrete separator layer.

20. The method of claim 19, wherein depositing the series of separator material droplets on the first substrate comprises spray coating a series of monodisperse separator material droplets on the first substrate, each droplet in the series of separator material droplets sized to prevent formation of defects in the discrete separator layer on the first substrate.

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