Continuous and semi-continuous process for electrode and electrochemical cell production

Abstract

Embodiments described herein generally relate to systems and methods for continuous and / or semi-continuous fabrication of electrochemical cells having semi-solid electrodes. In some embodiments, a method may include mixing an active material, a conductive material, and an electrolyte to form a semi-solid electrode material. The method further includes evacuating the semi-solid electrode material, compressing the semi-solid electrode material to form an electrode tile, and dispensing a portion of the electrode tile onto a current collector via a dispensing device to form an electrode. In some embodiments, the current collector is disposed on a pouch material. In some embodiments, the dispensing device includes a top blade for top edge control and two side plates for side edge control. In some embodiments, the method may further include transporting the electrode through the top blade and the two side plates to shape the electrode.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 329,994, filed on April 12, 2022, entitled “Continuous and Semi-Continuous Methods of Electrode and Electrochemical Cell Production,” and U.S. Provisional Application No. 63 / 343,339, filed on May 18, 2022, entitled “Continuous and Semi-Continuous Methods of Electrode and Electrochemical Cell Production,” the contents of each of which are incorporated herein by reference in their entirety. Technical Field

[0003] Embodiments described herein relate to systems and methods for producing an electrochemical cell having at least one semi-solid electrode. Background Art

[0004] The embodiments described herein generally relate to systems and methods for continuous and / or semi-continuous manufacture of electrochemical cells with semi-solid electrodes. The battery manufacturing method generally includes coating a conductive substrate (i.e., a current collector) with a slurry including an active material dissolved or dispersed in a solvent, a conductive additive, and a binder. After the slurry is applied to the metal substrate, the slurry is dried (e.g., by evaporating the solvent) and calendered to a specified thickness. The manufacture of battery electrodes may also generally include material mixing, casting, calendering, drying, cutting, and processing (bending, rolling, etc.) according to the constructed battery architecture. Since the electrodes are manipulated during assembly, and in order to ensure that the conductive network is in place, all components are compressed into a cohesive assembly, for example by using a binder. However, the binder itself takes up space, can increase processing complexity, and can hinder ionic and electronic conductivity. The production of semi-solid electrodes with little or no binder can solve some of these problems. However, several problems may arise during the production of semi-solid electrodes

[0005] First, edge control of semi-solid electrodes may be difficult. Templates and masks often shape the edges of semi-solid electrodes. Templates and masks are often inefficient and may result in less clear edges (i.e., edge fragmentation). Loss of electrolyte and / or electrolyte solvent via evaporation may occur during processing, resulting in poor battery performance. Small batch processing of electrode production may result in various concentration gradients or lack of uniformity in the electrode. In addition, cutting the current collector via mechanical means may also result in inefficiency because worn tools must be replaced frequently. Summary of the invention

[0006] Embodiments described herein generally relate to systems and methods for continuous and / or semi-continuous manufacture of electrochemical cells with semi-solid electrodes. In some embodiments, the method may include mixing an active material, a conductive material, and an electrolyte to form a semi-solid electrode material. The method further includes evacuating the semi-solid electrode material, compressing the semi-solid electrode material to form an electrode brick, and distributing a portion of the electrode brick to a current collector via a dispensing device to form an electrode. In some embodiments, the current collector is disposed on a bag material. In some embodiments, the dispensing device includes a top blade for thickness control and two side plates for side edge control. In some embodiments, the method may further include conveying the electrode through the top blade and the two side plates to shape the electrode. In some embodiments, the dispensing device may apply a downward force to the bag so that the two side plates form a seal with the bag. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is a schematic diagram of a method for semi-continuous or continuous manufacturing of a semi-solid electrode according to an embodiment.

[0008] Figure 2 is a schematic diagram of a system for semi-continuous or continuous manufacturing of a semi-solid electrode according to an embodiment.

[0009] Figure 3 is a diagram of a gravity dryer according to an embodiment.

[0010] Figure 4 is a diagram of a compressor according to an embodiment.

[0011] Figure 5 is an illustration of a cartridge with a forming device according to an embodiment.

[0012] Figure 6 is a diagram of a laser cutting apparatus according to an embodiment.

[0013] Figure 7 is a diagram of a wetting device and a tunnel according to an embodiment.

[0014] FIG. 8A to FIG. 8B is a diagram of a sealing device according to an embodiment.

[0015] Fig. 9 is a diagram of a gravity dryer according to an embodiment.

[0016] FIG. 10A to FIG. 10B is an illustration of components of a brick forming system according to an embodiment.

[0017] FIG. 11A to FIG. 11F is a diagram of a compressor according to an embodiment.

[0018] FIG. 12A to FIG. 12E is a diagram of an extrusion system according to an embodiment.

[0019] Fig.13 An adjoining system having a set of rotating drums for assembling electrochemical cells is shown according to an embodiment.

[0020] FIG. 14A to FIG. 14C A cartridge and its various components according to an embodiment are shown.

[0021] Fig.15 is a diagram of a densification station according to an embodiment.

[0022] FIG. 16A to FIG. 16C is an illustration of a conveyor having a web steering system incorporated therein, according to an embodiment.

[0023] FIG. 17A to FIG. 17D is an illustration of a bag sealer according to an embodiment.

[0024] Fig.18 is an illustration of a web diverting apparatus according to an embodiment.

[0025] Fig.19 is an illustration of a system for continuous or semi-continuous manufacturing of an electrochemical cell including a semi-solid electrode, according to an embodiment.

[0026] Fig. 20 According to the embodiment Fig.19 The system is composed of Fig.19 The diagram includes a portion of a cathode casting station indicated by arrow A.

[0027] Fig.21 It is shown that according to the embodiment, the Fig.19 Illustration of a top view of a web alignment assembly in a system of FIG.

[0028] Fig. 22 yes Fig.21 Another view of the web alignment assembly.

[0029] Fig.23 yes Fig.21 Side view of the web alignment assembly.

[0030] Fig.24 yes Fig.23 The web alignment assembly consists of Fig.23 A side view of the portion indicated by arrow B.

[0031] Fig.25 It is along Fig.24 A side cross-sectional view of a portion of the web alignment assembly taken along line CC in FIG. DETAILED DESCRIPTION

[0032] The embodiments described herein generally relate to systems and methods for continuously and / or semi-continuously manufacturing electrochemical cells with semi-solid electrodes. In some embodiments, the electrode brick can be formed of an active material, a conductive material, and an electrolyte. In some embodiments, the brick can be quite large so that more than about 100 semi-solid electrodes can be formed from the material of a single electrode brick. In some embodiments, the brick can be formed from densified semi-solid electrode materials. Examples of densified semi-solid electrodes and methods for manufacturing densified semi-solid electrodes are described in U.S. Patent Publication No. 2021 / 0226192 ('192 Publication), entitled "Apparatuses and Processes for Forming a Semi-Solid Electrode Having High Active Solids Loading and Electrochemical Cells Including the Same", filed on January 21, 2020, and the entire disclosure of the patent disclosure is hereby incorporated by reference. In some embodiments, the electrode brick can be injected with an electrolyte. Examples of infusion processes are described in U.S. Patent No. 11,005,087 (the '087 patent), filed on January 17, 2017, entitled "Systems and Methods for Infusion Mixing a Slurry-Based Electrode," the entire disclosure of which is hereby incorporated by reference. In some embodiments, the production processes described herein may include any of the process steps described in U.S. Patent Publication No. 2022 / 0115710 (the '710 publication), filed on December 12, 2021, entitled "Methods of Continuous and Semi-Continuous Production of Electrochemical Cells," the disclosure of which is hereby incorporated by reference in its entirety.

[0033] In some embodiments, pretreatment processing (e.g., drying) may be applied to the active material and the conductive material. After forming the electrode brick, the electrode brick may be set in a barrel. In some embodiments, the brick may have a high level of uniformity. A portion of the electrode brick is distributed from the barrel onto the current collector to form a semi-solid electrode. In some embodiments, the semi-solid electrode may then be formed by both the top blade and the side plate. In some embodiments, the electrode may be wetted by a solvent (e.g., an electrolyte or an electrolyte solvent). In some embodiments, the electrode may be a first electrode and may be adjacent to a second electrode with a separator disposed therebetween to form an electrochemical cell. In some embodiments, the bag material located on the outside of the electrochemical cell may be sealed in a single step. Other possible processing steps are described in U.S. Patent Publication No. 2020 / 0014025 ('025 Publication), entitled "Continuous and Semi-Continuous Methods of Semi-Solid Electrode and Battery Manufacturing", filed on July 9, 2019, the entire disclosure of which is hereby incorporated by reference.

[0034] 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 "member" is intended to mean a single member or a combination of members, and "material" is intended to mean one or more materials, or a combination thereof.

[0035] When used in conjunction with "cylindrical," "linear," and / or other geometric relationships, the term "substantially" is intended to convey that the structure so defined is nominally cylindrical, linear, etc. As an example, a portion of a support member described as "substantially linear" is intended to convey that while linearity of the portion is desired, some nonlinearity may occur in the "substantially linear" portion. Such nonlinearity may result from manufacturing tolerances or other practical considerations (such as, for example, pressure or forces applied to the support member). Thus, a geometric configuration modified by the term "substantially" includes such geometric properties within a tolerance range of plus or minus 5% of the geometric configuration. For example, a "substantially linear" portion is a portion that defines an axis or centerline whose linearity error is within plus or minus 5%.

[0036] As used herein, the terms "group" and "plurality" can refer to multiple features or a single feature with multiple parts. For example, when referring to a group of electrodes, the group of electrodes can be considered to be an electrode with multiple parts, or the group of electrodes can be considered to be a plurality of different electrodes. In addition, for example, when referring to a plurality of electrochemical cells, the plurality of electrochemical cells can be considered to be a plurality of different electrochemical cells, or an electrochemical cell with multiple parts. Therefore, a group of parts or a plurality of parts can include a plurality of parts that are continuous or discontinuous with each other. A variety of particles or a variety of materials can also be manufactured by a plurality of articles that are produced separately and then combined together (for example, via mixing, adhesives or any suitable method).

[0037] As used herein, the term "z-direction" generally refers to the third direction, where the longitudinal and transverse directions are the first and second directions, unless otherwise indicated. In other words, the z-direction refers to the depth or thickness of a feature, rather than the length and width.

[0038] As used herein, the terms "about" and "approximately" generally mean plus or minus 10% of the stated value, for example, about 250 μm would include 225 μm to 275 μm, and about 1,000 μm would include 900 μm to 1,100 μm.

[0039] As used herein, the term "semisolid" refers to a material that is a mixture of a liquid phase and a solid phase, such as, for example, a particle suspension, a colloidal suspension, an emulsion, a gel, or a micelle.

[0040] As used herein, the terms "activated carbon network" and "networked carbon" refer to the general qualitative state of an electrode. For example, an electrode having an activated carbon network (or networked carbon) causes the carbon particles within the electrode to present individual particle morphology and arrangement relative to each other, which promotes electrical contact and conductivity between particles. In contrast, the terms "unactivated carbon network" and "unnetworked carbon" refer to electrodes in which carbon particles exist as individual particle islands or multi-particle aggregate islands, which may not be sufficiently connected to provide sufficient electrical conduction through the electrode.

[0041] Figure 1is a schematic diagram of a method 10 for semi-continuously or continuously manufacturing a semi-solid electrode according to an embodiment. As shown, method 10 optionally includes gravity drying the active material and the conductive material at step 11. Then, method 10 includes mixing the active material, the conductive material and the electrolyte to form a semi-solid electrode material at step 12. Method 10 optionally includes evacuating the semi-solid electrode material at step 13. Method 10 further includes compressing the semi-solid electrode material to form a semi-solid electrode brick at step 14, and distributing a portion of the semi-solid electrode brick to a collector to form a semi-solid electrode at step 16. Then, method 10 optionally includes conveying the electrode through a former at step 17, wetting the semi-solid electrode with a solvent at step 18, conveying the semi-solid electrode through a tunnel at step 19, abutting the semi-solid electrode to another electrode interposed by a separator at step 21 to form an electrochemical cell, and sealing the electrochemical cell in a bag at step 23.

[0042] At step 11, a drying step may be employed to remove excess moisture from any of the materials used to make the semi-solid electrode. In some embodiments, the powder is subjected to a drying step. In some embodiments, the powder may include an active material. In some embodiments, the powder may include a conductive material. In some embodiments, the powder may include both an active material and a conductive material. In some embodiments, step 11 may include a gravity drying step. In some embodiments, gravity drying may include allowing the powder to fall through a drying vessel (i.e., via gravity). In some embodiments, a drying gas may flow through the drying vessel while the powder falls vertically through the drying vessel. Using a gravity drying process is more effective and efficient than a simple oven or an oven with a conveyor. As an advantage, the powder can move in three dimensions as it falls through the vessel. In other words, the powder moves downward with gravity, can be spread from front to back, and can be spread from left to right. This is in contrast to a simple oven in which the powder does not move and an oven in which the powder moves only in one dimension along the conveyor. This freedom of movement can help the powder spread out, and more surface area can be exposed to the drying gas. Moreover, using gravity to move the powder is more energy-efficient than using pneumatic flow. In addition, the drying gas can flow perpendicularly or countercurrently to the movement of the powder, thereby improving the heat exchange efficiency (i.e., countercurrent heat exchange is more effective than parallel flow heat exchange). In some embodiments, the drying gas can include air, argon, helium, nitrogen, or any non-reactive gas, or a combination thereof. In some embodiments, the moisture content of the drying gas can be less than about 1 ppm, less than about 0.9 ppm, less than about 0.8 ppm, less than about 0.7 ppm, less than about 0.6 ppm, less than about 0.5 ppm, less than about 0.4 ppm, less than about 0.3 ppm, less than about 0.2 ppm, less than about 0.1 ppm, less than about 0.09 ppm, less than about 0.08 ppm, less than about 0.07 ppm, less than about 0.06 ppm, less than about 0.05 ppm, less than about 0.04 ppm, less than about 0.03 ppm, less than about 0.02 ppm, or less than about 0.01 ppm, including all values ​​and ranges therebetween.

[0043] In some embodiments, step 11 can be performed at ambient temperature. In some embodiments, step 11 can include applying heat. In some embodiments, the temperature at which the drying vessel in step 11 is maintained can be at least about 25°C, at least about 30°C, at least about 35°C, at least about 40°C, at least about 45°C, at least about 50°C, at least about 55°C, at least about 60°C, at least about 65°C, at least about 70°C, at least about 75°C, at least about 80°C, at least about 85°C, at least about 90°C, or at least about 95°C. In some embodiments, the temperature at which the drying vessel in step 11 is maintained can be no more than about 100°C, no more than about 95°C, no more than about 90°C, no more than about 85°C, more than about 80°C, no more than about 75°C, no more than about 70°C, no more than about 65°C, no more than about 60°C, no more than about 55°C, no more than about 50°C, no more than about 45°C, no more than about 40°C, no more than about 35°C, or no more than about 30°C. Combinations of the above-mentioned temperatures of the drying vessel in step 11 are also possible (e.g., at least about 25°C and no more than about 100°C, or at least about 50°C and no more than about 75°C), including all values ​​and ranges therebetween. In some embodiments, the temperature at which the drying vessel in step 11 is maintained may be about 25°C, about 30°C, about 35°C, about 40°C, about 45°C, about 50°C, about 55°C, about 60°C, about 65°C, about 70°C, about 75°C, about 80°C, about 85°C, about 90°C, about 95°C, or about 100°C.

[0044] In some embodiments, after step 11, the moisture content of the powder can be less than about 10 ppm, less than about 9 ppm, less than about 8 ppm, less than about 7 ppm, less than about 6 ppm, less than about 5 ppm, less than about 4 ppm, less than about 3 ppm, less than about 2 ppm, less than about 1 ppm, less than about 0.9 ppm, less than about 0.8 ppm, less than about 0.7 ppm, less than about 0.6 ppm, less than about 0.5 ppm, less than about 0.4 ppm, less than about 0.3 ppm, less than about 0.2 ppm or less than about 0.1 ppm by weight, including all values ​​and ranges therebetween.

[0045] At step 12, the active material, the conductive material, and the electrolyte are mixed together to form a semi-solid electrode material. In some embodiments, the active material, the conductive material, and the electrolyte are mixed in the absence of a binder. In some embodiments, the semi-solid electrode material can be binder-free or substantially binder-free. In some embodiments, the mixing can be via a continuous process. In some embodiments, the mixing can be in a continuous mixer. In some embodiments, the mixing can be in a twin-screw extruder. Further examples of mixing methods and compositions are described in U.S. Patent No. 9,484,569 (the '569 patent), entitled "Electrochemical Slurry Compositions and Methods for Preparing the Same," filed on March 15, 2013, the entire disclosure of which is hereby incorporated by reference in its entirety. In some embodiments, the electrolyte can be incorporated into the active material and the conductive material via an injection process. In some embodiments, the injection process can include evacuation. In some embodiments, the semi-solid electrode can be substantially mixed so that the semi-solid electrode material has a high level of uniformity. Further examples of injection processes are described in the '087 patent. In some embodiments, the electrochemical cell described herein can include a separator having a separator seal. Further examples of separators with separator seals are described in more detail in International Patent Application No. PCT / US2020 / 058564 (the '564 Application), filed on November 2, 2020, entitled “Electrochemical Cells with Separator Seals, and Methods of Manufacturing the Same,” the entire disclosure of which is hereby incorporated by reference in its entirety.

[0046] In some embodiments, the amount of semisolid electrode material mixed together can be sufficient to form a large number of semisolid electrodes. Mixing a large number of materials together can facilitate a more continuous production process because the semisolid electrode material does not have to be refilled frequently. In some embodiments, the amount of semisolid electrode material mixed together can be sufficient to form at least about 50 semisolid electrodes, at least about 60 semisolid electrodes, at least about 70 semisolid electrodes, at least about 80 semisolid electrodes, at least about 90 semisolid electrodes, at least about 100 semisolid electrodes, at least about 150 semisolid electrodes, at least about 200 semisolid electrodes, at least about 250 semisolid electrodes, at least about 300 semisolid electrodes, at least about 350 semisolid electrodes, at least about 400 semisolid electrodes, at least about 500 semisolid electrodes, at least about 600 semisolid electrodes, at least about 700 semisolid electrodes, at least about 800 semisolid electrodes, at least about 900 semisolid electrodes, at least about 1000 semisolid electrodes, at least about 1500 semisolid electrodes, at least about 2000 semisolid electrodes, at least about 2500 semisolid electrodes, at least about 3000 semisolid electrodes, at least about 3500 semisolid electrodes, at least about 4000 semisolid electrodes, at least about 5 ... solid electrodes, at least about 450 semi-solid electrodes, at least about 500 semi-solid electrodes, at least about 550 semi-solid electrodes, at least about 600 semi-solid electrodes, at least about 650 semi-solid electrodes, at least about 700 semi-solid electrodes, at least about 750 semi-solid electrodes, at least about 800 semi-solid electrodes, at least about 850 semi-solid electrodes, at least about 900 semi-solid electrodes, at least about 950 semi-solid electrodes, or at least about 1,000 semi-solid electrodes, including all values ​​and ranges therebetween.

[0047] In optional step 13, vacuum can be applied to the semi-solid electrode material to degas the semi-solid electrode material. In some embodiments, vacuum can be applied before adding electrolyte. In some embodiments, vacuum can be applied after adding electrolyte. In some embodiments, vacuum can be applied concurrently with mixing (i.e., at step 12). In some embodiments, vacuum can be carried out in the same vessel as mixing. In some embodiments, vacuum can be carried out in a vessel different from a mixer. In some embodiments, the vacuum can reduce the pressure in the vessel containing the semi-solid electrode material by at least about 0.05 bar, at least about 0.1 bar, at least about 0.15 bar, at least about 0.2 bar, at least about 0.25 bar, at least about 0.3 bar, at least about 0.35 bar, at least about 0.4 bar, at least about 0.45 bar, at least about 0.5 bar, at least about 0.55 bar, at least about 0.6 bar, at least about 0.65 bar, at least about 0.7 bar, at least about 0.75 bar, at least about 0.80 bar, at least about 0.85 bar, at least about 0.90 bar, at least about 0.95 bar, or at least about 1 bar, including all values ​​and ranges therebetween.

[0048] At step 14, the semi-solid electrode material is compressed to form a semi-solid electrode brick. In some embodiments, the compression can be performed in the same vessel as the mixing (i.e., step 12). In some embodiments, the compression can be performed in the same vessel as the vacuum (i.e., step 13). In some embodiments, the compression can be performed in a different vessel than the mixing. In some embodiments, the compression can be performed in a different vessel than the vacuum. In some embodiments, the compression can increase the density of the semi-solid electrode material by at least about 1 times, at least about 1.1 times, at least about 1.2 times, at least about 1.3 times, at least about 1.4 times, at least about 1.5 times, at least about 1.6 times, at least about 1.7 times, at least about 1.8 times, at least about 1.9 or at least about 2 times, including all values ​​and ranges therebetween. In some embodiments, compression can reduce the electrolyte content in the semi-solid electrode material by at least about 1, at least about 1.1, at least about 1.2, at least about 1.3, at least about 1.4, at least about 1.5, at least about 1.6, at least about 1.7, at least about 1.8, at least about 1.9, or at least about 2, including all values ​​and ranges therebetween. In some embodiments, compression can include any of the methods described in the '192 publication.

[0049] In some embodiments, the semi-solid electrode brick formed in step 14 may include sufficient semi-solid electrode material to form at least about 50 semi-solid electrodes, at least about 60 semi-solid electrodes, at least about 70 semi-solid electrodes, at least about 80 semi-solid electrodes, at least about 90 semi-solid electrodes, at least about 100 semi-solid electrodes, at least about 150 semi-solid electrodes, at least about 200 semi-solid electrodes, at least about 250 semi-solid electrodes, at least about 300 semi-solid electrodes, at least about 350 semi-solid electrodes, at least about 400 semi-solid electrodes, at least about 4 ... About 400 semisolid electrodes, at least about 450 semisolid electrodes, at least about 500 semisolid electrodes, at least about 550 semisolid electrodes, at least about 600 semisolid electrodes, at least about 650 semisolid electrodes, at least about 700 semisolid electrodes, at least about 750 semisolid electrodes, at least about 800 semisolid electrodes, at least about 850 semisolid electrodes, at least about 900 semisolid electrodes, at least about 950 semisolid electrodes, or at least about 1,000 semisolid electrodes, including all values ​​and ranges therebetween.

[0050] In some embodiments, the electrode brick can stand independently without breaking. In other words, the electrode brick can have enough cohesive properties and / or structural stability so that it stands on the surface without support and without breaking. In some embodiments, the electrode brick can stand vertically with its longest dimension without support and without breaking. In some embodiments, the length of the electrode brick can be at least about 10cm, at least about 15cm, at least about 20cm, at least about 25cm, at least about 30cm, at least about 35cm, at least about 40cm, at least about 45cm, at least about 50cm, at least about 55cm, at least about 60cm, at least about 65cm, at least about 70cm, at least about 75cm or at least about 80cm. In some embodiments, the width of the electrode brick can be at least about 5cm, at least about 10cm, at least about 15cm, at least about 20cm, at least about 25cm, at least about 30cm, at least about 35cm, at least about 40cm, at least about 45cm, at least about 50cm, at least about 55cm or at least about 60cm. In some embodiments, the thickness of the electrode brick can be at least about 0.5 cm, at least about 1 cm, at least about 1.5 cm, at least about 2 cm, at least about 2.5 cm, at least about 3 cm, at least about 3.5 cm, at least about 4 cm, at least about 4.5 cm, or at least about 5 cm.

[0051] In some embodiments, the density of the electrode brick may be at least about 1 g / cm 3 , at least about 1.5 g / cm 3 , at least about 2g / cm 3 , at least about 2.5g / cm 3 , at least about 3g / cm 3 , at least about 3.5g / cm 3 , at least about 4g / cm 3 or at least about 4.5 g / cm 3 In some embodiments, the density of the electrode brick may be no more than about 5 g / cm 3 , not more than about 4.5g / cm 3 , not more than about 4g / cm 3 , not more than about 3.5g / cm 3 , not more than about 3g / cm 3 , not more than about 2.5g / cm 3 , not more than about 2g / cm 3 or not more than about 1.5g / cm 3 Combinations of the above-mentioned densities of the electrode bricks are also possible (e.g., at least about 1 g / cm 3 And not more than about 5g / cm 3 , or at least about 2 g / cm 3 And not more than about 4g / cm 3), including all values ​​and ranges therebetween. In some embodiments, the density of the electrode brick can be at least about 1 g / cm 3 , at least about 1.5 g / cm 3 , at least about 2g / cm 3 , at least about 2.5g / cm 3 , at least about 3g / cm 3 , at least about 3.5g / cm 3 , at least about 4g / cm 3 , at least about 4.5g / cm 3 or about 5g / cm 3 .

[0052] Method 10 optionally includes step 15, laser cutting metal foil to form a current collector. In some embodiments, step 15 is performed as part of a process different from steps 12, 13 and 14. In some embodiments, step 15 is performed on a conveyor or conveying system different from the other steps of method 10. Laser cutting is a beneficial method for the formation of a current collector because blades and rotating tools may often wear out over time. In step 15, the foil is applied to a bag material or a film material. The laser cutting process is then applied to the foil to form a current collector. In some embodiments, the laser cutting process may include a kiss-cutting process. In some embodiments, the accuracy of the laser cutting process can minimize any cutting of the bag material. In other words, the error margin of the laser cutting process can be small enough so that the foil is completely cut without any significant cutting of the bag material. In some embodiments, the accuracy (i.e., margin of error) of laser cutting can be less than about 500 nm, less than about 450 nm, less than about 400 nm, less than about 350 nm, less than about 300 nm, less than about 250 nm, less than about 200 nm, less than about 150 nm, less than about 100 nm, less than about 90 nm, less than about 80 nm, less than about 70 nm, less than about 60 nm, less than about 50 nm, less than about 40 nm, less than about 30 nm, less than about 20 nm, or less than about 10 nm.

[0053] In some embodiments, the thickness of the foil (and subsequent current collector) can be at least about 500 nm, at least about 1 μm, at least about 1.5 μm, at least about 2 μm, at least about 2.5 μm, at least about 3 μm, at least about 3.5 μm, at least about 4 μm, at least about 4.5 μm, at least about 5 μm, at least about 5.5 μm, at least about 6 μm, at least about 6.5 μm, at least about 7 μm, at least about 7.5 μm, at least about 8 μm, at least about 8.5 μm, at least about 9 μm, or at least about 9.5 μm. In some embodiments, the thickness of the foil can be no more than about 10 μm, no more than about 9.5 μm, no more than about 9 μm, no more than about 8.5 μm, no more than about 8 μm, no more than about 7.5 μm, no more than about 7 μm, no more than about 6.5 μm, no more than about 6 μm, no more than about 5.5 μm, no more than about 5 μm, no more than about 4.5 μm, no more than about 4 μm, no more than about 3.5 μm, no more than about 3 μm, no more than about 2.5 μm, no more than about 2 μm, no more than about 1.5 μm, or no more than about 1 μm. Combinations of the above referenced ranges for foil thickness are also possible (e.g., at least about 500 nm and no more than about 10 μm, or at least about 1 μm and no more than about 5 μm), including all values ​​and ranges therebetween. In some embodiments, the thickness of the foil may be about 500 nm, about 1 μm, about 1.5 μm, about 2 μm, about 2.5 μm, about 3 μm, about 3.5 μm, about 4 μm, about 4.5 μm, about 5 μm, about 5.5 μm, about 6 μm, about 6.5 μm, about 7 μm, about 7.5 μm, about 8 μm, about 8.5 μm, about 9 μm, about 9.5 μm, or about 10 μm.

[0054] At step 16, a portion of the semisolid electrode brick is dispensed onto a current collector to form a semisolid electrode. In some embodiments, the dispensing of a portion of the semisolid electrode brick can be performed from the same vessel where compression (i.e., step 14) occurs. In some embodiments, the dispensing can be performed from a vessel different from the vessel where compression occurs. In some embodiments, the dispensing can be performed from a barrel having a nozzle. In some embodiments, the dispensing can be performed onto a conveyor or conveying system.

[0055] At step 17, the semi-solid electrode is conveyed (e.g., via a conveyor belt) through the former. In some embodiments, the former may be fixed to the same device that performs the distribution at step 16. In some embodiments, the former may include a top blade that controls the thickness of the semi-solid electrode. In some embodiments, the former may include one or more side plates to control the width of the semi-solid electrode. Strict control of the edge of the semi-solid electrode can improve edge integrity and reduce crushing. In some embodiments, the side plates can form a seal with the conveyor, bag material, or collector so that no semi-solid electrode material leaks out or is pushed out through the bottom area of ​​the semi-solid electrode. In some embodiments, the lateral edges of the semi-solid electrode can be controlled by squeezing the bag material between adjacent plates on the conveyor. In some embodiments, step 17 may include high-speed micron-level adjustment of the top blade in the z direction (i.e., toward and away from the conveyor). In some embodiments, an x-ray gauge and / or a beta gauge can be used to monitor the electrode thickness for consistency. In some embodiments, a closed-loop algorithm can be used with an x-ray gauge and / or a beta gauge to reduce the error margin of the semi-solid electrode thickness from one semi-solid electrode to the next. In other words, the error margin of the electrode thickness can be reduced in situ. In some embodiments, the algorithm can be applied to smooth the movement of the top blade in the z-direction (ie, making adjustments gradually to avoid uneven surfaces on the semi-solid electrode).

[0056] Method 10 optionally includes wetting the semisolid electrode with a solvent at step 18. The solvent (i.e., the electrolyte solvent) may evaporate during any portion of method 10. This may reduce the movement of the electroactive material through the semisolid electrode and the subsequent electrochemical cell. Therefore, replacing the solvent may help reduce the probability of such a situation occurring. In some embodiments, wetting at step 18 may include spraying. In some embodiments, step 18 may include spraying the solvent. In some embodiments, step 18 may include spraying the electrolyte. In some embodiments, step 18 may include spraying the solvent and spraying the electrolyte. In some embodiments, step 18 may include spraying the solvent onto the semisolid electrode. In some embodiments, step 18 may include spraying the electrolyte onto the semisolid electrode. In some embodiments, step 18 may include spraying both the solvent and the electrolyte onto the semisolid electrode. In some embodiments, step 18 may include inkjet printing the solvent for high precision application. Inkjet printing may limit or completely eliminate overspraying. In some embodiments, a separator may be set to the semisolid electrode before step 18, and spraying may be performed on the separator. In some embodiments, step 18 may include spraying the solvent onto the separator. In some embodiments, step 18 may include spraying the electrolyte onto the separator. In some embodiments, step 18 may include spraying both the solvent and the electrolyte onto the separator. In some embodiments, step 18 may include inkjet printing the solvent for high precision application.

[0057] In some embodiments, step 18 may include spraying hard carbon. In some embodiments, step 18 may include spraying a hard carbon suspension. In some embodiments, step 18 may include applying a hard carbon suspension to a semi-solid electrode. In some embodiments, step 18 may include spraying a hard carbon suspension onto a semi-solid electrode. In some embodiments, step 18 may include applying a hard carbon suspension onto a separator. In some embodiments, step 18 may include spraying a hard carbon suspension onto a separator. Examples of electrodes, separators, and electrochemical cells incorporating hard carbon are described in International Patent Application No. PCT / US2021 / 038921 ('921 Application), filed on June 24, 2021, entitled "Electrochemical Cells with Multi-Layered Electrodes and Coated Separatorsand Methods of Making the Same," the entire disclosure of which is incorporated by reference in its entirety. In some embodiments, spraying the separator with a solvent may make it easier for the solvent to adhere to the semi-solid electrode. In some embodiments, the spraying may be performed onto the semi-solid electrode. In some embodiments, the solvent may include an electrolyte salt. In some embodiments, the solvent may be free of an electrolyte salt. In some embodiments, a solvent and electrolyte salt may be added (e.g., via spraying) to a conventional electrode (i.e., a solid electrode). Wetting a large conventional electrode may be difficult. Wetting a large area of ​​a conventional electrode with electrolyte and / or solvent prior to assembly may be beneficial in conventional electrochemical cell manufacturing (e.g., conventional lithium ion electrochemical cell manufacturing).

[0058] At step 19, the semi-solid electrode may optionally be conveyed through a tunnel. The tunnel may help prevent evaporation of the solvent. In other words, the tunnel may reduce the effects of exhaust gas that exposes the semi-solid electrode to the surrounding environment. Any portion of the conveyor or conveying system may include a tunnel roof. In other words, the tunnel may be deployed during any portion of method 10 (e.g., before step 18).

[0059] At step 21, the semi-solid electrode may optionally be adjacent to another electrode (i.e., an adjacent electrode) interposed by a separator to form an electrochemical cell. In some embodiments, the adjacent electrode may be from a conveyor or delivery system different from the semi-solid electrode. In some embodiments, the adjacent electrode may be placed on top of the semi-solid electrode from above. In some embodiments, the adjacent electrode may be a conventional electrode. In some embodiments, the adjacent electrode may be another semi-solid electrode. Further examples of adjacent methods and adjacent systems are described in the '025 disclosure.

[0060] At step 23, the electrochemical cell may optionally be sealed in a bag. In some embodiments, the sealing of the bag may be performed via pulse heating. Bag sealing methods often use a sealing device that applies constant heat to the sealing device. In the presence of such heat, the bag material may deform and wrinkle. In addition, the electrolyte from the semi-solid electrode may evaporate under such heat. By using pulse heating, the application of heat is very fast so that the temperature of the surrounding environment does not increase significantly. In addition, the sealing at step 23 may be performed via a single sealing device. In other words, a single device may seal the entire perimeter of the bag in one motion, rather than sealing only one side at a time via multiple passes or multiple sealing devices.

[0061] Figure 2 1 is a schematic diagram of a system 100 for semi-continuous or continuous manufacturing of a semi-solid electrode according to an embodiment. As shown, the system 100 includes a compressor 120, a barrel 130, a conveyor 148, and a forming device 150. In some embodiments, the system 100 may include a gravity dryer 110, a mixer 118, a laser cutting device 140, a wetting device 160, a tunnel 168, an abutment system 170, and a bag sealer 180. In some embodiments, the system 100 may be used to implement the above reference Figure 1 The method 10.

[0062] In some embodiments, gravity dryer 110 may include a vessel through which powder may be conveyed by gravity. In some embodiments, gravity dryer may include a gas inlet and a gas outlet for drying gas. In some embodiments, the moisture content maintained by gravity dryer 110 may be less than about 1 pm, less than about 0.9 ppm, less than about 0.8 ppm, less than about 0.7 ppm, less than about 0.6 ppm, less than about 0.5 ppm, less than about 0.4 ppm, less than about 0.3 ppm, less than about 0.2 ppm, less than about 0.1 ppm, less than about 0.09 ppm, less than about 0.08 ppm, less than about 0.07 ppm, less than about 0.06 ppm, less than about 0.05 ppm, less than about 0.04 ppm, less than about 0.03 ppm, less than about 0.02 ppm or less than about 0.01 ppm, including all values ​​and ranges therebetween.

[0063] The mixer 118 mixes the active material, the conductive material, and the electrolyte to form a semi-solid electrode material. In some embodiments, the mixer 118 may include a twin-screw extruder. In some embodiments, the mixer 118 may include a twin-screw kneader. In some embodiments, the mixer may include any of the mixers mentioned in the '569 patent. In some embodiments, the mixer 118 may be fluidly coupled to the gravity dryer 110 so that the material can flow continuously from the gravity dryer 110 to the mixer 118.

[0064] The compressor 120 forms the semi-solid electrode material into a semi-solid electrode brick. In some embodiments, the compressor 120 can be fluidly coupled to the mixer 118 so that the semi-solid electrode material can flow continuously from the mixer 118 to the compressor 120. In some embodiments, the compressor 120 can be fluidly coupled to a vacuum. In some embodiments, the compressor 120 can include a piston for compression. In some embodiments, the compressor 120 can be part of the same device as the mixer 118. In other words, the same device can both mix and compress the electrode material.

[0065] The cartridge 130 contains the semi-solid electrode brick and distributes the portion of the semi-solid electrode brick onto the current collector to form a semi-solid electrode. In some embodiments, the cartridge 130 may include a nozzle for dispensing. In some embodiments, the cartridge 130 may be a part of the same structure or device as the compressor 120 and / or the mixer 118.

[0066] The laser cutting device 140 cuts the foil to form the current collector. In some embodiments, the laser cutting device 140 can perform half-cutting. In some embodiments, the accuracy (i.e., the margin of error) of the laser cutting device 140 can reach less than about 500nm, less than about 450nm, less than about 400nm, less than about 350nm, less than about 300nm, less than about 250nm, less than about 200nm, less than about 150nm, less than about 100nm, less than about 90nm, less than about 80nm, less than about 70nm, less than about 60nm, less than about 50nm, less than about 40nm, less than about 30nm, less than about 20nm or less than about 10nm.

[0067] Conveyor 148 moves the semi-solid electrode through additional processing units of system 100. In some embodiments, the system may include multiple conveyors (not shown). In some embodiments, multiple conveyors may be used to place multiple electrodes together as described in the '025 publication.

[0068] The forming device 150 shapes the edge of the semi-solid electrode. In other words, the forming device 150 controls the edge of the semi-solid electrode. In some embodiments, the forming device 150 may include a single frame for shaping the outer edge of the semi-solid electrode. In some embodiments, the forming device 150 may include a top blade for controlling the thickness of the semi-solid electrode and a side plate for controlling the width of the semi-solid electrode. In some embodiments, the forming device 150 can be adjusted with micron-level accuracy. In some embodiments, the forming device 150 can be learned in a closed-loop processing algorithm. In some embodiments, the forming device 150 can be part of the same structure as the barrel 130. In other words, the top blade and the side plate can be attached to the barrel 130.

[0069] The wetting device 160 wets the semi-solid electrode with an electrolyte solvent to replace the electrolyte solvent lost during production. In some embodiments, the wetting device may include an ejector. In some embodiments, a tunnel 168 may be disposed throughout the conveyor 148. In some embodiments, the tunnel 168 may be disposed adjacent to the wetting device 160 to reduce evaporation of electrolyte from the semi-solid electrode.

[0070] In some embodiments, the adjoining system 170 can bring an additional electrode together with the semi-solid electrode to form an electrochemical cell. In some embodiments, the adjoining system 170 can include a second conveyor. Further examples of adjoining systems are described in the '025 publication.

[0071] In some embodiments, bag sealer 180 seals the bag around the outside edge of the electrochemical cell. In some embodiments, bag sealer 180 can include a pulse heater. In some embodiments, bag sealer 180 can have a shape so that it can seal around the outside edge of the electrochemical cell in a single step.

[0072] In some embodiments, the system 100 may be enclosed in a main cover that controls the environment in which each of the electrodes is produced and the electrochemical cell is assembled. In some embodiments, the system 100 may include a plurality of conveyors 148. In some embodiments, the system 100 may include an anode casting station and a cathode casting station. In some embodiments, the anode casting station may include a first conveyor, and the cathode casting station may include a second conveyor. In some embodiments, the anode casting station and / or the cathode casting station may include a barrel that distributes the material to the lateral turning platform. In some embodiments, the barrel at the anode casting station distributes the anode material, and the barrel at the cathode casting station distributes the cathode material. In some embodiments, the barrel may distribute portions of semi-solid electrode bricks. In some embodiments, each of the anode casting station and the cathode casting station may include an optical measuring device and an x-ray. The optical measuring device and the x-ray may be used for quality control to confirm the thickness of the semi-solid electrode after formation. In some embodiments, the anode may be formed at the anode casting station, wherein the anode material is disposed on the collector and / or the bag material. In some embodiments, the cathode may be formed at the cathode casting station, wherein the cathode material is disposed on the collector and / or the bag material.

[0073] After being formed at the cathode forming station, the cathode material can pass through the spray hood. In some embodiments, the wetting device 160 and / or the tunnel 168 can be located inside the spray hood. In some embodiments, the solvent can be sprayed onto the anode material and / or cathode material in the spray hood. In some embodiments, the solvent sprayed on the cathode material can be flammable. The use of a spray hood can help prevent ignition by keeping the concentration level of the flammable material outside the flammable range. In some embodiments, the spray hood includes an exhaust device to ventilate the spray hood to the surrounding environment and keep the concentration of the flammable material below the flammable limit. In some embodiments, the spray hood can be explosion-proof. In some embodiments, the cathode material can pass through the spray hood. In some embodiments, the anode material can pass through the spray hood. In some embodiments, the anode material can pass through the first spray hood and the cathode material can pass through the second spray hood. In some embodiments, the anode material and the cathode material can pass through the same spray hood.

[0074] In some embodiments, the spray hood can be purged of oxygen to reduce the risk of ignition inside the hood. In some embodiments, the oxygen purging can be performed by evacuating the spray hood. In some embodiments, the oxygen purging can be performed by flowing an inert gas (e.g., nitrogen, argon) into the spray hood. In some embodiments, the oxygen purging can be performed by evacuating the spray hood and flowing an inert gas into the spray hood.

[0075] In some embodiments, the formed anode material, the formed cathode material and the separator material can be fed to a vacuum drum (not shown), wherein the anode material, the cathode material and the separator are merged together. In some embodiments, each of the anode material, the cathode material and the separator can wrap the vacuum drum at different points along the vacuum drum to form the layer of the electrochemical cell. In some embodiments, the vacuum drum can apply force to the electrode to increase their density. In some embodiments, the vacuum drum can apply downward force on the electrode so that the pressure experienced by the electrode is at least about 1MPa, at least about 2MPa, at least about 3MPa, at least about 4MPa, at least about 5MPa, at least about 6MPa, at least about 7MPa, at least about 8MPa or at least about 9MPa. In some embodiments, the vacuum drum can apply downward force on the electrode so that the pressure experienced by the electrode is no more than about 10MPa, no more than about 9MPA, no more than about 8MPA, no more than about 7MPA, no more than about 6MPA, no more than about 5MPA, no more than about 4MPA, no more than about 3MPA or no more than about 2MPA. Combinations of the above-mentioned pressures experienced by the electrode due to the downward force of the vacuum drum are also possible (e.g., at least about 1 MPa and no more than about 10 MPa, or at least about 3 MPa and no more than about 7 MPa), including all values ​​and ranges therebetween. In some embodiments, the vacuum drum can exert a downward force on the electrode such that the pressure experienced by the electrode is about 1 MPa, about 2 MPa, about 3 MPa, about 4 MPa, about 5 MPa, about 6 MPa, about 7 MPa, about 8 MPa, about 9 MPa, or about 10 MPa.

[0076] In some embodiments, the diameter of the vacuum drum can be at least about 1 cm, at least about 5 cm, at least about 10 cm, at least about 20 cm, at least about 30 cm, at least about 40 cm, at least about 50 cm, at least about 60 cm, at least about 70 cm, at least about 80 cm, or at least about 90 cm. In some embodiments, the diameter of the vacuum drum can be no more than about 1 m, no more than about 90 cm, no more than about 80 cm, no more than about 70 cm, no more than about 60 cm, no more than about 50 cm, no more than about 40 cm, no more than about 30 cm, no more than about 20 cm, no more than about 10 cm, or no more than about 5 cm. Combinations of the above-mentioned diameters of the vacuum drum are also possible (e.g., at least about 1 cm and no more than about 1 m, or at least about 10 cm and no more than about 50 cm), including all values ​​and ranges therebetween. In some embodiments, the vacuum drum may have a diameter of about 1 cm, about 5 cm, about 10 cm, about 20 cm, about 30 cm, about 40 cm, about 50 cm, about 60 cm, about 70 cm, about 80 cm, about 90 cm, or about 1 m.

[0077] In some embodiments, the vacuum drum can be held in place with tacks. In some embodiments, the vacuum drum can include a plurality of components arranged around the periphery of the vacuum drum. In some embodiments, the components can include a tray. In some embodiments, the vacuum drum can include a central duct with a vacuum for removing liquid from the material outside the vacuum drum. After merging together, a laser cutter can cut the anode material, cathode material, and separator to form a separate electrochemical cell. As shown, a separate electrochemical cell can be transported across a vacuum conveyor. In some embodiments, a vacuum conveyor can remove stray particles from the electrochemical cell. The separate electrochemical cell can be measured via optical measurement for quality control. Then, the separate electrochemical cells can selectively slide off the vacuum conveyor, depending on whether they pass the quality control test.

[0078] In some embodiments, the system 100 may include a first vacuum drum receiving a feed of cathode material and separator material and a second vacuum drum receiving a feed of anode material. In some embodiments, the first vacuum drum presses the separator material and cathode material onto a conveyor, and then the second vacuum drum presses the anode material onto the cathode material and separator.

[0079] In some embodiments, the anode casting station and / or the cathode casting station may include a densification station (not shown). In some embodiments, the densification station may employ any of the electrode densification methods described in the '192 publication.

[0080] In some embodiments, system 100 can produce at least about 100, at least about 150, at least about 200, at least about 250, at least about 300, at least about 350, at least about 400, at least about 450, at least about 500, at least about 550, at least about 600, at least about 650, at least about 700, at least about 750, at least about 800, at least about 850, at least about 900, at least about 950, or at least about 1,000 electrodes per minute, including all values ​​and ranges therebetween. In some embodiments, system 100 can produce at least about 100, at least about 150, at least about 200, at least about 250, at least about 300, at least about 350, at least about 400, at least about 450, at least about 500, at least about 550, at least about 600, at least about 650, at least about 700, at least about 750, at least about 800, at least about 850, at least about 900, at least about 950, or at least about 1,000 electrochemical cells per minute, including all values ​​and ranges therebetween.

[0081] Figure 3A gravity dryer 210 according to an embodiment is shown. In some embodiments, the gravity dryer 210 can be used as described above with reference to Figure 2 The gravity dryer 110 described above is the same or substantially similar. Therefore, certain aspects of the gravity dryer 210 are not described in more detail herein. As shown, the gravity dryer 210 includes a powder loading port 212, a powder discharge port 213, a gas inlet 214, and a gas outlet 215. As shown, the powder includes an active material AM and a conductive material CM that are fed into the gravity dryer 210. The powder falls through the gravity dryer 210 while the gas G is fed through the gravity dryer 210.

[0082] In some embodiments, the powder loading port 212 may include a screen to filter out larger particles. In some embodiments, the powder loading port 212 may include a funnel-shaped opening to facilitate pouring. The exit port 213 discharges powder from the gravity dryer. In some embodiments, the exit port 213 may be fluidically coupled to another processing unit (e.g., a mixer). Gas G is fed into the gravity dryer 210 via a gas inlet. In some embodiments, gas G may be fed under positive pressure. In some embodiments, the pressure at which gas G may be fed is at least about 1 bar, at least about 1.5 bar, at least about 2 bar, at least about 2.5 bar, at least about 3 bar, at least about 3.5 bar, at least about 4 bar, at least about 4.5 bar, at least about 5 bar, at least about 5.5 bar, at least about 6 bar, at least about 6.5 bar, at least about 7 bar, at least about 7.5 bar, at least about 8 bar, at least about 8.5 bar, at least about 9 bar or at least about 9.5 bar. In some embodiments, the pressure at which the gas G can be fed is no more than about 10 bar, no more than about 9.5 bar, no more than about 9 bar, no more than about 8.5 bar, no more than about 8 bar, no more than about 7.5 bar, no more than about 7 bar, no more than about 6.5 bar, no more than about 6 bar, no more than about 5.5 bar, no more than about 5 bar, no more than about 4.5 bar, no more than about 4 bar, no more than about 3.5 bar, no more than about 3 bar, no more than about 2.5 bar, no more than about 2 bar, or no more than about 1.5 bar. Combinations of the above-mentioned pressures of the gas G fed to the gravity dryer 210 are also possible (e.g., at least about 1 bar and no more than about 10 bar, or at least about 2 bar and no more than about 5 bar), including all values ​​and ranges therebetween. In some embodiments, the gas G may be fed at a pressure of about 1 bar, about 1.5 bar, about 2 bar, about 2.5 bar, about 3 bar, about 3.5 bar, about 4 bar, about 4.5 bar, about 5 bar, about 5.5 bar, about 6 bar, about 6.5 bar, about 7 bar, about 7.5 bar, about 8 bar, about 8.5 bar, about 9 bar, about 9.5 bar, or about 10 bar.

[0083] As shown, gravity dryer 210 includes a single gas inlet 214 and a single gas outlet 215. In some embodiments, gravity dryer 210 may include multiple gas inlets 214 and / or gas outlets 215. In some embodiments, gravity dryer 210 may include at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9 or at least about 10 gas inlets 214 and / or gas outlets 215. As shown, gas G flows perpendicularly to the flow of powder. In some embodiments, gas G may flow countercurrently to the flow of powder. In some embodiments, gas G may flow parallel to the flow of powder.

[0084] Figure 4 2 is a diagram of a compressor 220 according to an embodiment. In some embodiments, the compressor 220 may be similar to the compressor 220 described above with reference to FIG. Figure 2 The compressor 120 described above is the same or substantially similar. Therefore, certain aspects of the compressor 220 are not described in more detail herein. The compressor 220 forms the semi-solid electrode material into a semi-solid electrode brick. As shown, the compressor 220 includes a container 222, a piston 224, and a pump 226. The compressed conductive material CM and active material AM are shown. In some embodiments, an electrolyte may be included in the compressed material (i.e., the material in the compressor 220 may be a semi-solid electrode). In some embodiments, an electrolyte may be added to the compressor 220. In some embodiments, the electrolyte may be injected into the compressor 220. The method and apparatus for injection are described in more detail in the '087 patent.

[0085] The container 222 holds the semi-solid electrode material in place during compression. In some embodiments, the container 222 can have a cylindrical shape, a cubic shape, a rectangular prism shape, or any other suitable shape. In some embodiments, the volume of the container 222 can be at least about 0.1 L, at least about 0.5 L, at least about 1 L, at least about 5 L, at least about 10 L, at least about 50 L, at least about 100 L, at least about 500 L, at least about 1 m 3 or at least about 5m 3 In some embodiments, the volume of the container 222 may be no more than 10m 3 , not more than 5m 3 , not more than 1m 3 , no more than 500 L, no more than 100 L, no more than about 50 L, no more than about 10 L, no more than about 5 L, no more than about 1 L, or no more than about 0.5 L. Combinations of the above-mentioned volumes of container 222 are also possible (e.g., at least about 0.1 L and no more than about 10 m 3, or at least about 5 L and no more than about 10 L), including all values ​​and ranges therebetween. In some embodiments, the volume of container 222 can be about 0.1 L, about 0.5 L, about 1 L, about 5 L, about 10 L, about 50 L, about 100 L, about 500 L, about 1 m 3 , about 5m 3 or about 10m 3 .

[0086] Piston 224 compresses the semi-solid electrode material (i.e., by moving along line AA) to form a semi-solid electrode brick. In some embodiments, piston 224 may include a gasket around the edge to form a seal with container 222. In some embodiments, vacuum pump 226 can remove gas and / or electrolyte from the semi-solid electrode material in container 222. In some embodiments, the vacuum pump can extract a vacuum of at least about 0.1 bar, at least about 0.2 bar, at least about 0.3 bar, at least about 0.4 bar, at least about 0.5 bar, at least about 0.6 bar, at least about 0.7 bar, at least about 0.8 bar, or at least about 0.9 bar, including all values ​​and ranges therebetween.

[0087] Figure 5 2 is a diagram of a cartridge 230 with a forming device 250 according to an embodiment. In some embodiments, the cartridge 230 and the forming device 250 may be used as described above with reference to Figure 2 The cartridge 130 and forming device 150 are the same or substantially similar. Therefore, certain aspects of the cartridge 230 and forming device 250 are not described in further detail herein. In some embodiments, the cartridge 230 may be the same as described above with reference to Figure 4 230. In other words, a single device can perform all of the functions of the compressor 230 and the barrel 230. As shown, the barrel 230 includes a container 232, a piston 234 and a nozzle opening 237, and the forming device 250 (attached to the barrel 230) includes a top blade 252 and side plates 254a, 254b (collectively referred to as side plates 254). As shown, the nozzle opening 237 is a wide opening blocked by the top blade 252 and therefore depicted by a dotted line. The barrel 230 can distribute portions of the semi-solid electrode brick SSEB onto the conveyor 248a.

[0088] The container 232 contains the semi-solid electrode brick SSEB. In some embodiments, the container 232 may have a cylindrical shape, a cubic shape, a rectangular prism shape, or any other suitable shape. In some embodiments, the volume of the container 232 may be at least about 0.1 L, at least about 0.5 L, at least about 1 L, at least about 5 L, at least about 10 L, at least about 50 L, at least about 100 L, at least about 500 L, at least about 1 m 3 or at least about 5m 3In some embodiments, the volume of the container 232 may be no more than 10 m 3 , not more than 5m 3 , not more than 1m 3 , no more than 500 L, no more than 100 L, no more than about 50 L, no more than about 10 L, no more than about 5 L, no more than about 1 L, or no more than about 0.5 L. Combinations of the above-mentioned volumes of container 232 are also possible (e.g., at least about 0.1 L and no more than about 10 m 3 , or at least about 5 L and no more than about 10 L), including all values ​​and ranges therebetween. In some embodiments, the volume of container 232 can be about 0.1 L, about 0.5 L, about 1 L, about 5 L, about 10 L, about 50 L, about 100 L, about 500 L, about 1 m 3 , about 5m 3 or about 10m 3 The piston 234 pushes the semi-solid electrode brick SSEB so that a portion of the semi-solid electrode brick SSEB leaves the cartridge 230 through the nozzle opening 237 .

[0089] As shown, the top blade 252 controls the thickness of the semi-solid electrode, and the side plate 254 controls the width of the semi-solid electrode. In some embodiments, the top blade 252 and / or the side plate 254 can be adjusted with micron-level precision. In some embodiments, the top blade 252 and / or the side plate 254 can be controlled by an algorithm that can be learned in a closed-loop process algorithm. In some embodiments, the side plate 254 can establish a seal with the conveyor 248a to prevent the part of the semi-solid electrode from flowing out of the nozzle to the side. In some embodiments, the side plate 254 can be clamped to the barrel 230 via a clamping plate. In some embodiments, the side plate can be made of polyethylene terephthalate (PET). In some embodiments, the thickness of the side plate can be about 0.15mm, about 0.2mm or about 0.25mm, including all values ​​and ranges therebetween.

[0090] In some embodiments, a support may be placed below the conveyor 248a to prevent the conveyor 248a from deflecting due to the force applied by casting the semi-solid electrode bricks SSEB onto the conveyor 248a. In some embodiments, the conveyor 248a may be supported from above (e.g., via a beam suspended from a ceiling) to prevent the conveyor 248a from deflecting due to the force applied by casting the semi-solid electrode bricks SSEB onto the conveyor 248a.

[0091] Figure 6 240 according to an embodiment is shown. The laser cutter 240 cuts the collector material CCM conveyed along the conveyor 248b. In some embodiments, the laser cutter 240 can be used with the laser cutter 240 as described above. Figure 2The laser cutter 140 described is the same or substantially similar. Therefore, certain aspects of the laser cutter 240 are not described in more detail herein. The collector material CCM is applied to the bag material PM and cut via the laser cutter 240. In some embodiments, the portion of the collector material CCM is removed to establish the area of ​​the bag material PM around the edge of the collector material CCM for sealing. In some embodiments, the accuracy (i.e., margin of error) of the laser cutter 240 can be less than about 500nm, less than about 450nm, less than about 400nm, less than about 350nm, less than about 300nm, less than about 250nm, less than about 200nm, less than about 150nm, less than about 100nm, less than about 90nm, less than about 80nm, less than about 70nm, less than about 60nm, less than about 50nm, less than about 40nm, less than about 30nm, less than about 20nm or less than about 10nm.

[0092] In some embodiments, the conveyor 248a can advance horizontally. In some embodiments, the conveyor 248a may include a plurality of members or trays (not shown) arranged side by side and advancing in a horizontal direction. In some embodiments, a rotating wheel or drum on either side of the conveyor 248a may facilitate the movement of the conveyor 248a. In some embodiments, one or more inserting fingers may be accommodated in the inner side of the conveyor 248a to insert the portion of the collector material CCM into the gap between the trays. In some embodiments, the inserting fingers accommodated in the inner side of the conveyor 248a may include a vacuum therein so that the inserting fingers may contact the collector material CCM (or the conveyor belt on which the collector material CCM is located) and pull the collector material CCM into the gap between the trays. In some embodiments, the trays may be gathered together to squeeze the inserting portion of the collector material CCM. The portion of the inserting / squeezing the collector material CCM before the electrode material is cast on the conveyor 248a may help to create space between the electrode materials when the trays are later released and spaced apart from each other again. The electrode material may be separated into discrete electrodes.

[0093] Figure 7 is a diagram of a wetting device 260 and a tunnel 268 according to an embodiment. In some embodiments, the wetting device 260 and the tunnel 268 can be the same as described above with reference to Figure 2The wetting device 160 and tunnel 168 are identical or substantially similar. Therefore, certain aspects of the wetting device 160 and tunnel 168 are not described in more detail herein. As shown, the wetting device 260 is an ejector. In some embodiments, other wetting devices, such as a hose or an inkjet device, can be used. The wetting device 260 can distribute electrolyte or electrolyte solvent to the semi-solid electrode transported along the conveyor 248a. In some embodiments, the electrolyte or electrolyte solvent sprayed can replace the solvent lost during other parts of the manufacturing process. Wetting with electrolyte or electrolyte solvent can improve the electrochemical properties of the semi-solid electrode SSE and / or the diffusivity within the SSE. Tunnel 268 can reduce solvent evaporation by limiting exposure to the external atmosphere.

[0094] In some embodiments, the rate at which the wetting device 260 applies liquid to the semi-solid electrode and / or separator may be at least about 0.5 mg / cm 2 , at least about 1 mg / cm 2 , at least about 1.5 mg / cm 2 , at least about 2 mg / cm 2 or at least about 2.5 mg / cm 2 In some embodiments, the rate at which the wetting device applies liquid to the semi-solid electrode and / or separator may be no more than about 3 mg / cm 2 , not more than about 2.5mg / cm 2 , not more than about 2mg / cm 2 , not more than about 1.5mg / cm 2 or not more than about 1 mg / cm 2 Combinations of the above-mentioned amounts of liquid applied to the electrodes and / or separators are also possible (e.g., at least about 0.5 mg / cm 2 And not more than about 3mg / cm 2 , or at least about 1 mg / cm 2 and not more than about 2 mg / cm 2 ), including all values ​​and ranges therebetween. In some embodiments, the rate at which the wetting device 260 applies liquid to the semi-solid electrode and / or separator may be about 0.5 mg / cm 2 , about 1mg / cm 2 , about 1.5mg / cm 2 , about 2mg / cm 2 , about 2.5mg / cm 2 or about 3 mg / cm 2 .

[0095] In some embodiments, the rate at which wetting device 260 applies liquid to the semi-solid electrode and / or separator may be at least about 0.5 μL / cm 2 , at least about 1 μL / cm2 , at least about 1.5 μL / cm 2 , at least about 2 μL / cm 2 or at least about 2.5 μL / cm 2 In some embodiments, the rate at which the wetting device applies liquid to the semi-solid electrode and / or separator may be no more than about 3 μL / cm 2 , not more than about 2.5; L / cm 2 , not more than about 2μL / cm 2 , not more than about 1.5μL / cm 2 or no more than about 1 μL / cm 2 Combinations of the above-mentioned amounts of liquid applied to the electrodes and / or separator are also possible (eg, at least about 0.5 μL / cm 2 and no more than about 3 μL / cm 2 , or at least about 1 μL / cm 2 and no more than about 2 μL / cm 2 ), including all values ​​and ranges therebetween. In some embodiments, the rate at which the wetting device 260 applies liquid to the semi-solid electrode and / or separator may be about 0.5 μL / cm 2 , about 1μL / cm 2 , about 1.5μL / cm 2 , about 2μL / cm 2 , about 2.5μL / cm 2 or about 3 μL / cm 2 .

[0096] FIG. 8A to FIG. 8B A bag sealer 280 is shown according to an embodiment. Fig. 8A A profile view of the bag sealer 280 is shown, and Figure 8B 280. In some embodiments, the bag sealer 280 may be used in conjunction with the bag sealer 280 as described above with reference to FIG. Figure 2 The bag sealer 180 described is the same or substantially similar. Therefore, certain aspects of the bag sealer 280 are not described in more detail herein. As shown, the bag sealer 280 includes a base 282, a heater frame 284, and a wire material barrel 285. In use, the base 282 moves toward the electrochemical cell EC while the electrochemical cell EC is conveyed along the conveyor 248a. The heater frame 284 contacts the outer edge of the bag material of the electrochemical cell EC when heated by a pulse heater. This heat application seals the outer edge of the bag material in a single step. The base 282 is then raised, and the heater frame 284 is removed from contact with the electrochemical cell EC. The design of the heater frame 284 extending around the periphery of the electrochemical cell EC allows heat sealing of the bag material to be performed in a single step.

[0097] The heater frame 284 includes a heating wire that is lined on the outer periphery of the heater frame 284. After a large number of heating cycles, the wire may become fatigued and unusable. The wire drum 285 allows the deployment of new wire to replace the worn wire. Once the wire becomes fatigued, the wire drum can dispense a section of new wire from the first portion of the wire drum 285 (e.g., via one or more wheels that contact the new wire), and the worn wire can be fed back into the wire drum at the second portion of the wire drum 285. This mechanism is similar to an automatic plastic toilet seat changer.

[0098] Pulse heating of the wires of the heater frame 284 can cause the heater frame 284 to expand and / or move. In some embodiments, restraints 286 can be placed at various locations around the heater frame 284 to minimize movement of the heater frame 284 during pulse heating. In some embodiments, the restraints 286 can include pins welded to the heater frame 284 and / or the base 282.

[0099] Fig. 9 310 is a diagram of a gravity dryer 310 according to an embodiment. As shown, the gravity dryer 310 includes a container 311, a powder loading port 312, a powder discharge port 313, a gas inlet 314, a gas outlet 315, a vertical plate 316, a feeder plate 317, and a gas permeable bottom plate 318. In some embodiments, the powder loading port 312, the powder discharge port 313, the gas inlet 314, and the gas outlet 315 can be the same as described above with reference to Figure 3 The powder loading port 212, powder discharge port 231, gas inlet 214, and gas outlet 215 are the same or substantially similar. Therefore, certain aspects of the powder loading port 312, powder discharge port 313, gas inlet 314, and gas outlet 315 are not described in more detail herein. Active material AM and conductive material CM, as well as gas G, are shown passing through the gravity dryer 310.

[0100] In some embodiments, the container 311 can have a cylindrical shape. The cylindrical shape and / or the inclusion of vertical plates 316 can maintain a low but non-zero vertical solid stress on the powder inside the gravity dryer 310. Maintaining a low, non-zero vertical solid stress on the powder inside the gravity dryer 310 can prevent gas G from flowing. In other words, gas G can begin to flow around the powder and does not contribute to drying the powder clusters. The cylindrical shape of the container 311 and / or the inclusion of vertical plates 316 in the container 311 can contribute to the dispersion of the flow of gas G to prevent gas G from flowing and powder from clustering.

[0101] The feeder disk 317 may be porous so that the gas G flows through many holes on the feeder disk 317 into the container 311, rather than through a single orifice. The combination of the feeder disk 317 and the gas permeable bottom plate 318 may help disperse the gas G throughout the container 311. In some embodiments, the feeder disk 317 may have a circular shape.

[0102] FIG. 10A to FIG. 10B is an illustration of components of a brick forming system according to an embodiment. Fig. 10A is a side view, and Fig. 10B is a top view of the components. As shown, the active material AM, the conductive material CM and the electrolyte (not shown) are transferred from the mixer 318 to the hopper 317 after being mixed. In some embodiments, the mixer 318 may include a twin-screw extruder. In some embodiments, the mixer 318 may include a twin-screw kneader. The active material AM, the conductive material CM and the electrolyte (the active material AM, the conductive material CM and the electrolyte are collectively referred to as "semi-solid electrode materials" herein) are transferred from the hopper 317 to the compressor 320a and / or the compressor 320b (collectively referred to as the compressor 320) through the feeder 319a and / or the feeder 319b (collectively referred to as the feeder 319). In some embodiments, the compressor 320 can be a brick forming chamber, in which the semi-solid electrode material can be pressed to form a semi-solid electrode brick. Once the semi-solid electrode material is in the compressor 320, the brick forming presses 324a, 324b (collectively referred to as the brick forming press 324) are formed. As shown, feeder 319 is adjustable and can be moved along line P to align feeder 319a or feeder 319b with hopper 317. Semi-solid electrode material flows to compressor 320a via feeder 319a and / or flows to compressor 320b via feeder 319b. In some embodiments, the semi-solid electrode material in compressor 320a can be pressed by brick forming press 324a. In some embodiments, the semi-solid electrode material in compressor 320b can be pressed by brick forming press 324b.

[0103] In some embodiments, the semi-solid electrode material can be subjected to a conductivity test at conductivity testing stations 325a, 325b (collectively referred to as conductivity testing stations 325). In some embodiments, the conductivity test can be performed with the semi-solid electrode material in compressor 320. In some embodiments, the semi-solid electrode material can be removed from compressor 320 prior to the conductivity test. After being subjected to the conductivity test, the semi-solid electrode material can be fed into cartridges 330a, 330b (collectively referred to as cartridges 330). In some embodiments, cartridges 330 can be used as described above with reference to Figure 5 The cartridge 230 described above is the same or substantially similar. Therefore, certain aspects of the cartridge 330 are not described in further detail herein.

[0104] FIG. 11A to FIG. 11F is a diagram of a compressor 420 according to an embodiment. Figure 1 lA to Fig.11F Each of the figures shows a different part of the brick forming process. As shown, the compressor 420 includes a container base 421, a container jacket 422, a sliding platform 423 and a piston 424. In some embodiments, the container jacket 422 and the piston 424 can be as described above with reference to Figure 4 The container 222 and piston 224 are identical or substantially similar. Therefore, certain aspects of the container sheath 422 and piston 424 are not described in more detail herein.

[0105] In use, such as Fig.11A As shown, the container jacket 422 is lifted. The container base 421 and the container jacket 422 are moved to a forward position along the sliding platform 423. When the container base 421 and the container jacket 422 are in the forward position, the semi-solid electrode material can be loaded into the container jacket 422. In some embodiments, the forward position can be away from the piston 424 so that the piston 424 does not interfere with the loading of the semi-solid electrode material. The semi-solid electrode material is then loaded into the container jacket 422. After the semi-solid electrode material is loaded into the container jacket 422, the container base 421 and the container jacket 422 slide along the sliding platform 423 to a retracted position, as shown. Fig. 11B In some embodiments, the retracted position can place the container base 421 and the container sleeve 422 so that they are directly below the piston 424. After the container base 421 and the container sleeve 422 are placed under the piston 424, the piston 424 is lowered, as shown in FIG. Fig. 11C The piston 424 compresses the semi-solid electrode material to form a semi-solid electrode brick SSEB.

[0106] After the piston 424 has compressed the semi-solid electrode material to form a semi-solid electrode brick SSEB, the piston 424 is raised. Fig.11D After the piston 424 is raised, the container base 421 and the container jacket 422 move to the forward position along the sliding platform 423, as shown in FIG. Fig.11E Then the container jacket 422 is lowered along the outer periphery of the container base 421 to expose the semi-solid electrode brick SSEB, as shown. Fig.11F The semi-solid electrode brick SSEB may then be removed from the compressor 420 and placed into a cartridge (not shown).

[0107] FIG. 12A to FIG. 12E4 is a diagram of an extrusion system 430 according to an embodiment. As shown, the extrusion system 430 includes a distributor 436 (e.g., a nozzle) and a rotating drum 441. The rotating drum 441 includes a plurality of trays 442. The trays 442 are coupled to a flat cam 443 via a cam rod 445. In some embodiments, the flat cam 443 and the cam rod 445 rotate around a static anvil drum. The static anvil drum can be located at or near the center of the rotating drum 441. The conveyor 448 is shown as being in contact with one or more of the trays 442. Fig. 12A The tray 442 is shown adjacent the dispenser 436 in an open position, and Fig. 12B A tray 442 is shown near the dispenser 436 in a closed position. In use, a film and / or a current collector material (not shown) may be placed on a conveyor 448 and advanced along the tray 442 via the drum 441. In some embodiments, the film and / or the current collector material may act as the conveyor 448. In other words, the film and / or the current collector material may move around the outer edge of the drum 441 without a conveyor belt or other conveying device being present below the film and / or the current collector. In some embodiments, the film may be conveyed around the outer edge of the drum 441. In some embodiments, the current collector material may be conveyed around the outer edge of the drum 441. In some embodiments, the film and the current collector material may be conveyed around the outer edge of the drum 441. By adjusting the tray 442 from an open position to a closed position, the current collector may be squeezed so that a portion of the film and / or the current collector material is squeezed between the trays 442. Semi-solid electrode material (not shown) may be dispensed from the dispenser 436 onto the current collector material. When advancing through the drum 441, the trays 442 can separate again, leaving the collector material with semi-solid electrodes separated from each other. In some embodiments, the trays 442 can be attached or bonded together to absorb torque. In other words, the trays 442 can absorb shock together, rather than one tray absorbing shock. In some embodiments, the outer surface of the tray 442 can be cylindrically precision ground.

[0108] In some embodiments, cam rod 445 can control the positioning and timing of tray 442. In some embodiments, tray vacuum and / or chilled water can be fed through a multi-channel rotary joint inside drum 441. In some embodiments, tray 442 can be ground on drum 441 to ensure high accuracy. In some embodiments, the position of each of trays 442 can be controlled by flat cam 445 and cam rod 443 to eliminate cumulative stacking errors. In some embodiments, a membrane insertion mechanism can be included to synchronously insert collector material and / or membrane between trays 442. In some embodiments, cylindrical supports provide rigidity to tray 442.

[0109] The size and amplitude of rotary drum 441 can make rotary drum 441 stronger than linear conveyor (for example, flat belt) and resist movement and deflection from external force (for example, from casting or densification instrument). In addition, the arched shape formed by adjacent trays 442 can produce the structural stability that can resist deflection in rotary drum 441. The anvil drum at the center of rotary drum 441 can have a cylindrical shape, providing additional resistance to external force. The casting carried out from distributor 436 can apply considerable force (for example, about 10kN, about 20kN, about 30kN, about 40kN, about 50kN, about 60kN, about 70kN, about 80kN, about 90kN or about 100kN, including all values ​​and scopes therebetween), and the conveyor with wide base can withstand huge force. In some embodiments, the diameter of the drum 441 can be at least about 5 cm, at least about 10 cm, at least about 15 cm, at least about 20 cm, at least about 25 cm, at least about 30 cm, at least about 35 cm, at least about 40 cm, at least about 45 cm, at least about 50 cm, at least about 55 cm, at least about 60 cm, at least about 65 cm, at least about 70 cm, at least about 75 cm, at least about 80 cm, at least about 85 cm, at least about 90 cm, at least about 95 cm, at least about 1 m, at least about 2 m, at least about 3 m, at least about 4 m, at least about 5 m, at least about 6 m, at least about 7 m, at least about 8 m, or at least about 9 m. In some embodiments, the diameter of the drum 441 can be no more than about 10m, no more than about 9m, no more than about 8m, no more than about 7m, no more than about 6m, no more than about 5m, no more than about 4m, no more than about 3m, no more than about 2m, no more than about 1m, no more than about 95cm, no more than about 90cm, no more than about 85cm, no more than about 80cm, no more than about 75cm, no more than about 70cm, no more than about 65cm, no more than about 60cm, no more than about 55cm, no more than about 50cm, no more than about 45cm, no more than about 40cm, no more than about 35cm, no more than about 30cm, no more than about 25cm, no more than about 20cm, no more than about 15cm or no more than about 10cm.

[0110] Combinations of the above-mentioned diameters of the drum 441 are also possible (e.g., at least about 5 cm and no more than about 10 m, or at least about 20 cm and no more than about 40 cm), including all values ​​and ranges therebetween. In some embodiments, the diameter of the drum 441 can be about 5 cm, about 10 cm, about 15 cm, about 20 cm, about 25 cm, about 30 cm, about 35 cm, about 40 cm, about 45 cm, about 50 cm, about 55 cm, about 60 cm, about 65 cm, about 70 cm, about 75 cm, about 80 cm, about 85 cm, about 90 cm, about 95 cm, about 1 m, about 2 m, about 3 m, about 4 m, about 5 m, about 6 m, about 7 m, about 8 m, about 9 m, or about 10 m.

[0111] The robustness of the drum 441 can help improve the uniformity between the electrodes produced. More specifically, the drum 441 resists movement from the casting force. When the electrode material is cast onto the conveyor 448, this resistance to movement can reduce the error margin of the thickness of the electrode material. In other words, the deviation of the thickness from one electrode to the next electrode can be minimized. In some embodiments, the robustness of the drum 441 and the uniformity of the electrode thickness provided by the drum 441 can save the thickness inspection method (e.g., X-ray inspection) during the electrode production process. Bonding or connecting the tray 442 together can also improve this robustness. In some embodiments, the tray 442 can be cylindrically ground to form the drum 441. During manufacture, the tray 442 may have a slight deviation from one tray to another in size. The tray 442 can be placed on the flat cam 445, and then the drum 441 can be cylindrically ground to make the outer surface of the tray 442 smooth. The smoothness of the outer surface of the tray 442 can further improve the uniformity of the electrode cast onto the conveyor 448.

[0112] As shown, the gap G between the edges of adjacent trays 442 can be measured. In some embodiments, when adjacent trays 442 are not pressed together, the gap G can be at least about 10 μm, at least about 20 μm, at least about 30 μm, at least about 40 μm, at least about 50 μm, at least about 60 μm, at least about 70 μm, at least about 80 μm, at least about 90 μm, at least about 100 μm, at least about 150 μm, at least about 200 μm, at least about 250 μm, at least about 300 μm, at least about 350 μm, at least about 400 μm, or at least about 500 μm. m, at least about 450 μm, at least about 500 μm, at least about 550 μm, at least about 600 μm, at least about 650 μm, at least about 700 μm, at least about 750 μm, at least about 800 μm, at least about 850 μm, at least about 900 μm, at least about 950 μm, at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm or at least about 9 mm. In some embodiments, when adjacent trays 442 are not pressed together, the gap G may be no more than about 1 cm, no more than about 9 mm, no more than about 8 mm, no more than about 7 mm, no more than about 6 mm, no more than about 5 mm, no more than about 4 mm, no more than about 3 mm, no more than about 2 mm, no more than about 1 mm, no more than about 950 μm, no more than about 900 μm, no more than about 850 μm, no more than about 800 μm, no more than about 750 μm, no more than about 700 μm, no more than about 650 μm, or no more than about 100 μm. No more than about 600 μm, no more than about 550 μm, no more than about 500 μm, no more than about 450 μm, no more than about 400 μm, no more than about 350 μm, no more than about 300 μm, no more than about 250 μm, no more than about 200 μm, no more than about 150 μm, no more than about 100 μm, no more than about 90 μm, no more than about 80 μm, no more than about 70 μm, no more than about 60 μm, no more than about 50 μm, no more than about 40 μm, no more than about 30 μm or no more than about 20 μm. When adjacent trays 442 are not pressed together, combinations of the above-mentioned values ​​of the gap G are also possible (e.g., at least about 10 μm and no more than about 1 cm, or at least about 100 μm and no more than about 1 mm), including all values ​​and ranges therebetween.In some embodiments, when adjacent trays 442 are not pressed together, the gap G can be about 10μm, about 20μm, about 30μm, about 40μm, about 50μm, about 60μm, about 70μm, about 80μm, about 90μm, about 100μm, about 150μm, about 200μm, about 250μm, about 300μm, about 350μm, about 400μm, about 450μm, about 500μm, about 550μm, about 600μm, about 650μm, about 700μm, about 750μm, about 800μm, about 850μm, about 900μm, about 950μm, about 1mm, about 2mm, about 3mm, about 4mm, about 5mm, about 6mm, about 7mm, about 8mm, about 9mm or about 1cm.

[0113] In some embodiments, when adjacent trays 442 are not pressed together, the gap G may be no more than about 2 mm, no more than about 1 mm, no more than about 950 μm, no more than about 900 μm, no more than about 850 μm, no more than about 800 μm, no more than about 750 μm, no more than about 700 μm, no more than about 650 μm, no more than about 600 μm, no more than about 550 μm, no more than about 500 μm, no more than about 450 μm, no more than about 400 μm, no more than about 350 μm, no more than about 300 μm, no more than about 150 μm, no more than about 200 μm, no more than about 300 μm, no more than about 350 μm, no more than about 30 ...50 μm, no more than about 300 μm, no more than about 300 μm, no more than about 300 μm, no more than about 300 μm, no more than about 300 μm, About 250μm, no more than about 200μm, no more than about 150μm, no more than about 100μm, no more than about 90μm, no more than about 80μm, no more than about 70μm, no more than about 60μm, no more than about 50μm, no more than about 40μm, no more than about 30μm, no more than about 20μm, no more than about 10μm, no more than about 9μm, no more than about 8μm, no more than about 7μm, no more than about 6μm, no more than about 5μm, no more than about 4μm, no more than about 3μm, no more than about 2μm or no more than about 1μm.

[0114] In some embodiments, the drum 441 can be rotated at a rotational speed of at least about 10 rpm, at least about 20 rpm, at least about 30 rpm, at least about 40 rpm, at least about 50 rpm, at least about 60 rpm, at least about 70 rpm, at least about 80 rpm, at least about 90 rpm, at least about 100 rpm, at least about 150 rpm, at least about 200 rpm, at least about 250 rpm, at least about 300 rpm, at least about 350 rpm, at least about 400 rpm, at least about 450 rpm, or at least about 500 rpm, including all values ​​and ranges therebetween.

[0115] In some embodiments, drum 441 may include a vacuum therein so that the vacuum can pull and push portions of conveyor 448 (and the current collector material disposed thereon) into drum 441, such as Fig. 12C As shown. Vacuum plugging can pull the part of conveyor 448 and the collector material thereon inward to promote the plugging of the collector. Causing plugging from the drum 441 can help prevent the contamination of the electrode material distributed on the collector material. More specifically, if the timing is not right, the plugging arm or the plugging finger may contact the electrode material set on the collector material. The electrode material can be deposited on the plugging arm or the plugging finger. The deposited electrode material may later contaminate the electrode material transferred through the drum 441. Including a vacuum in the drum 441 can prevent a piece of material from contacting and contaminating other materials. In addition, the vacuum inside the drum 441 can help to plug the conveyor 448 and the collector material deeper than the plugging arm or the plugging finger. The drum 441 can move at high speed (e.g., about 30rpm, about 40rpm, about 50rpm, about 60rpm, about 70rpm, about 80rpm, about 90rpm or about 100rpm, including all values ​​and ranges therebetween). These high speeds may make it difficult for the tuck arm or tuck finger to accurately aim and penetrate deep enough into the space between the trays 442 so that the conveyor 448 and the current collector are completely tucked between the trays.

[0116] In some embodiments, the insertion of the conveyor 448 can be time-staggered. In other words, the flat cam 445 can open and close the gap between the trays 442 over a relatively long period of time. More specifically, two adjacent trays 442 can travel around most of the outer edge of the drum 441 when coupled together before separating from each other. Compared to if the trays are simply inserted in a short period of time (e.g., the length of time required for the drum 441 to travel the width of one tray 442), this time-staggered method can allow a longer period of time to distribute the electrode material to the inserted collector material. In some embodiments, adjacent trays 442 can be coupled together to achieve at least about 10%, 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%, or at least about 50% of a complete rotation around the center of the drum 441. In some embodiments, one or more barrel cams can be used to perform the time-staggered insertion of the conveyor 448.

[0117] like FIG. 12A to FIG. 12C As shown, dispenser 436 casts the electrode material vertically. In other words, when conveyor 448 is near its highest point on the drum, dispenser 436 casts in a direction perpendicular to the ground. In some embodiments, dispenser 436 can cast horizontally (i.e., in a direction parallel to the ground). In some embodiments, dispenser 436 can cast horizontally on one side of conveyor 448, such as Fig.12D shown. Fig.12DAngles relative to a vertical plane at the top of the drum 441 are shown for reference (0 degrees, 90 degrees, 180 degrees, 270 degrees. In some embodiments, the dispenser 436 can cast at an angle of about 5 degrees, about 10 degrees, about 15 degrees, about 20 degrees, about 25 degrees, about 30 degrees, about 35 degrees, about 40 degrees, about 45 degrees, about 50 degrees, about 55 degrees, about 60 degrees, about 65 degrees, about 70 degrees, about 75 degrees, about 80 degrees, about 85 degrees, about 90 degrees, about 95 degrees, about 100 degrees, about 105 degrees, about 110 degrees, about 115 degrees, about 120 degrees, about 125 degrees, about 130 degrees, about 135 degrees, about 140 degrees, about 145 degrees, about 150 degrees, about 155 degrees, about , about 160 degrees, about 165 degrees, about 170 degrees, about 175 degrees, about 180 degrees, about 185 degrees, about 190 degrees, about 195 degrees, about 200 degrees, about 205 degrees, about 210 degrees, about 215 degrees, about 220 degrees, about 225 degrees, about 230 degrees, about 235 degrees, about 240 degrees, about 245 degrees, about 250 degrees, about 255 degrees, about 260 degrees , about 265 degrees, about 270 degrees, about 275 degrees, about 280 degrees, about 285 degrees, about 290 degrees, about 295 degrees, about 300 degrees, about 305 degrees, about 310 degrees, about 315 degrees, about 320 degrees, about 325 degrees, about 330 degrees, about 335 degrees, about 340 degrees, about 345 degrees, about 350 degrees or about 355 degrees, including all values ​​and ranges in between.

[0118] In some embodiments, the dispenser 436 can be moved to control the casting gap between the dispenser 436 and the conveyor 448 to an accuracy of less than 10 μm, less than 9 μm, less than 8 μm, less than 7 μm, less than 6 μm, less than 5 μm, less than 4 μm, less than 3 μm, less than 2 μm, or less than 1 μm. In some embodiments, the gap between the dispenser 436 and the conveyor 448 can be adjusted at intervals of the distance traveled by the conveyor 448 (e.g., via a computer algorithm controlling the movement of the dispenser 436). For example, the dispenser 436 can be adjusted once every 10 mm of conveyor 448 travel. These rapid adjustments help produce uniformity in the thickness of the resulting electrode. In some embodiments, the position of the dispenser 448 relative to the conveyor 448 can be adjusted once approximately every 1 mm, approximately every 2 mm, approximately every 3 mm, approximately every 4 mm, approximately every 5 mm, approximately every 6 mm, approximately every 7 mm, approximately every 8 mm, approximately every 9 mm, approximately every 10 mm, approximately every 11 mm, approximately every 12 mm, approximately every 13 mm, approximately every 14 mm, approximately every 15 mm, approximately every 16 mm, approximately every 17 mm, approximately every 18 mm, approximately every 19 mm, approximately every 20 mm, approximately every 25 mm, approximately every 25 mm, approximately every 30 mm, approximately every 35 mm, approximately every 40 mm, approximately every 45 mm, or approximately every 50 mm, including all values ​​and ranges therebetween, as the conveyor 448 travels.

[0119] like Fig.12D As shown, conveyor 448 circulates around the outer edge of drum 441. In some embodiments, conveyor 448 can have a current collector material (not shown) disposed thereon. In some embodiments, the current collector material can circulate around the outer edge of drum 441 without conveyor 448.

[0120] like Fig.12D As shown, conveyor 448 enters drum 441 at the bottom of the drum (ie, approximately 180 degrees relative to a vertical plane at the top of drum 441). In some embodiments, the conveyor 448 can enter the drum 441 at an angle of about 5 degrees, about 10 degrees, about 15 degrees, about 20 degrees, about 25 degrees, about 30 degrees, about 35 degrees, about 40 degrees, about 45 degrees, about 50 degrees, about 55 degrees, about 60 degrees, about 65 degrees, about 70 degrees, about 75 degrees, about 80 degrees, about 85 degrees, about 90 degrees, about 95 degrees, about 100 degrees, about 105 degrees, about 110 degrees, about 115 degrees, about 120 degrees, about 125 degrees, about 130 degrees, about 135 degrees, about 140 degrees, about 145 degrees, about 150 degrees, about 155 degrees, about 160 degrees, about 165 degrees, about 170 degrees, about 180 degrees, about 185 degrees, about 190 degrees, about 200 degrees, about 210 degrees, about 220 degrees, about 230 degrees, about 235 degrees, about 240 degrees, about 255 degrees, about 260 degrees, about 270 degrees, about 280 degrees, about 285 degrees, about 290 degrees, about 300 degrees, about 310 degrees, about 310 degrees, about 310 degrees, about 310 degrees, about 310 degrees , about 75 degrees, about 180 degrees, about 185 degrees, about 190 degrees, about 195 degrees, about 200 degrees, about 205 degrees, about 210 degrees, about 215 degrees, about 220 degrees, about 225 degrees, about 230 degrees, about 235 degrees, about 240 degrees, about 245 degrees, about 250 degrees, about 255 degrees, about 260 degrees, about 265 degrees, about 270 degrees, about 275 degrees, about 280 degrees, about 285 degrees, about 290 degrees, about 295 degrees, about 300 degrees, about 305 degrees, about 310 degrees, about 315 degrees, about 320 degrees, about 325 degrees, about 330 degrees, about 335 degrees, about 340 degrees, about 345 degrees, about 350 degrees or about 355 degrees, including all values ​​and ranges in between.

[0121] like Fig.12DAs shown, conveyor 448 exits drum 441 at the top of the drum (ie, at approximately 0 degrees relative to a vertical plane at the top of drum 441). In some embodiments, the conveyor 448 can be angled away from the drum 441 at about 5 degrees, about 10 degrees, about 15 degrees, about 20 degrees, about 25 degrees, about 30 degrees, about 35 degrees, about 40 degrees, about 45 degrees, about 50 degrees, about 55 degrees, about 60 degrees, about 65 degrees, about 70 degrees, about 75 degrees, about 80 degrees, about 85 degrees, about 90 degrees, about 95 degrees, about 100 degrees, about 105 degrees, about 110 degrees, about 115 degrees, about 120 degrees, about 125 degrees, about 130 degrees, about 135 degrees, about 140 degrees, about 145 degrees, about 150 degrees, about 155 degrees, about 160 degrees, about 165 degrees, about 170 degrees, about 180 degrees, about 185 degrees, about 190 degrees, about 200 degrees, about 210 degrees, about 220 degrees, about 230 degrees, about 235 degrees, about 240 degrees, about 255 degrees, about 260 degrees, about 270 degrees, about 280 degrees, about 285 degrees, about 290 degrees, about 300 degrees, about 310 degrees, about 310 degrees, about 310 degrees, about 310 degrees, about 310 degrees, about 310 degrees , about 75 degrees, about 180 degrees, about 185 degrees, about 190 degrees, about 195 degrees, about 200 degrees, about 205 degrees, about 210 degrees, about 215 degrees, about 220 degrees, about 225 degrees, about 230 degrees, about 235 degrees, about 240 degrees, about 245 degrees, about 250 degrees, about 255 degrees, about 260 degrees, about 265 degrees, about 270 degrees, about 275 degrees, about 280 degrees, about 285 degrees, about 290 degrees, about 295 degrees, about 300 degrees, about 305 degrees, about 310 degrees, about 315 degrees, about 320 degrees, about 325 degrees, about 330 degrees, about 335 degrees, about 340 degrees, about 345 degrees, about 350 degrees or about 355 degrees, including all values ​​and ranges in between.

[0122] like Fig.12D As shown, the conveyor 448 leaves the drum 441 at about 180 degrees from the position where it enters the drum 441. In other words, the conveyor 448 is in contact with or close to the drum 441 for about 180 degrees. In some embodiments, the conveyor 448 can be in contact with the drum 441 for about 5 degrees, about 10 degrees, about 15 degrees, about 20 degrees, about 25 degrees, about 30 degrees, about 35 degrees, about 40 degrees, about 45 degrees, about 50 degrees, about 55 degrees, about 60 degrees, about 65 degrees, about 70 degrees, about 75 degrees, about 80 degrees, about 85 degrees, about 90 degrees, about 95 degrees, about 100 degrees, about 105 degrees, about 110 degrees, about 115 degrees, about 120 degrees, about 125 degrees, about 130 degrees, about 135 degrees, about 140 degrees, about 145 degrees, about 150 degrees, about 155 degrees, about 160 degrees, about 165 degrees, about 170 degrees, about 175 degrees, about 180 degrees, about 185 degrees, about 190 degrees, about 195 degrees, or about 200 degrees, including all values ​​and ranges in between.

[0123] The entry point of the conveyor 448 can be selected so that the conveyor 448 has enough space to flatten onto the outside surface of the tray 442. In addition, the greater the angle between the entry point and the exit point of the conveyor 448, the greater the space (and therefore time) that the dispenser 436 has to cast the electrode material onto the conveyor 448. As shown, one dispenser 436 is casting the electrode material onto the conveyor 448. In some embodiments, the extrusion system 430 can include multiple dispensers that cast the electrode material onto the conveyor 448.

[0124] Fig.12D Including section E, Fig.12E This section is shown in more detail in . Fig.12E A close-up view of two trays 442 being pressed together and squeezing a conveyor 448 is shown. As shown, the conveyor 448 is inserted between the trays 442. Each of the trays 442 includes a gasket or deformable member 444 disposed on the outer edge of the tray 442. The gasket 444 can increase the friction between adjacent trays 442 to prevent the trays 442 from sliding relative to each other. In some embodiments, the trays 442 can be made of stainless steel, aluminum, or a similar metal or material with a smooth surface. If the smooth surfaces of the trays 442 contact each other, they can move laterally relative to each other (i.e., toward the center of the drum 441 and away from the center of the drum 441). In other words, the gasket 444 prevents metal-to-metal contact and possible sliding caused thereby. In addition, the gasket 444 can ensure that the tray 442 clamps the conveyor 448, the collector, and / or any membrane material conveyed around the drum 441 along the entire depth of the tray 444. In some embodiments, the gasket 444 can include an O-ring. In some embodiments, gasket 444 can be made of a deformable material, an elastomeric material, natural rubber, silicone rubber, neoprene, neoprene sponge, cork, or any combination thereof. In some embodiments, gasket 444 can include a seal or sealing member. This can prevent electrolyte or semi-solid electrode material from leaking into the extruded portion of the collector and / or membrane material during production, where metal-to-metal contact may not be as thorough.

[0125] Fig.13 An abutment system 570 having a set of rotating drums 571a, 571b for assembling electrochemical cells is shown according to an embodiment. Fig.13An anode drum 571a and a cathode drum 571b are depicted. As shown, the anode drum 571a includes a tray 572a, a cam rod 573a, a flat cam 575a, and a conveyor 578a with an anode A disposed thereon. As shown, the cathode drum 571b includes a tray 572b, a cam rod 573b, a flat cam 575b, and a conveyor 578b with a cathode C disposed thereon. The separator material SM is distributed between the anode A and the cathode C. The separator material SM is pushed via separator rollers. In some embodiments, the drums 571a, 571c, trays 572a, 572b, cam rods 573a, 573b, flat cams 575a, 575b, and conveyors 578a, 578b may be the same as described above with reference to FIG. 12A to FIG. 12C The drum 441, tray 442, cam rod 443, plate cam 445, and conveyor 448 are identical or substantially similar. Therefore, certain aspects of the drums 571a, 571c, trays 572a, 572b, cam rods 573a, 573b, plate cams 575a, 575b, and conveyors 578a, 578b are not described in more detail herein. In some embodiments, casting can be performed on the drums 571a, 571b. In some embodiments, casting can be performed on one or more drums different from the drums 571a, 571b.

[0126] As shown, anode A and cathode C are aligned with a portion of separator material SM disposed therebetween. Cam rods 573a, 573b and flat cams 575a, 575b can cause the movement of trays 572a, 572b relative to the rest of the drums 571a, 571b, so that anode A and cathode C can be correctly aligned. This increases the margin of error by casting anode A onto tray 572a and casting cathode C onto tray 572c. In other words, if the collector material (not shown) on which anode A and cathode C are placed moves out of phase with each other, the movement of trays 572a, 572b can help correct the difference. More specifically, the error of the timing of distributing anode A and cathode C can be compensated by causing the movement of trays 572a, 572b, so that anode A and cathode C can be correctly aligned when producing electrochemical cells. In certain embodiments, anode drum 571a and / or cathode drum 571b may include a vacuum disposed therein. In some embodiments, the vacuum can help to squeeze the collector material between the trays 572a, 572b. In some embodiments, the vacuum can keep the trays 572a, 572b moving relative to the rest of the drums 571a, 571b. In other words, the inward force applied to the conveyor 578a and the collector material disposed thereon can apply force to the trays 572a on the drum 571a and push them apart from each other. Similarly, the inward force applied to the conveyor 578b and the collector material disposed thereon can apply force to the trays 572b on the drum 571b and push them apart from each other.

[0127] In some embodiments, the movement of the trays 572a, 572b can align the anode A and cathode C in the formed electrochemical cell to a margin of error of less than about 1 mm. In other words, the centerline running through the anode A can be less than about 1 mm from the centerline running through the cathode C. In some embodiments, the margin of error can be less than about 900 μm, less than about 800 μm, less than about 700 μm, less than about 600 μm, less than about 500 μm, less than about 400 μm, less than about 300 μm, less than about 200 μm, or less than about 100 μm, including all values ​​and ranges therebetween.

[0128] In some embodiments, anode A, cathode C, current collector material and / or film may be added with a reference point or reference mark. The use of reference points may help simplify the alignment process of anode A and cathode C. For example, an imaging device (e.g., X-ray, CT machine, ultrasound) may detect reference points on anode A and cathode C and may be communicated with cams 575a, 575b to adjust their positioning so that anode A and cathode C are correctly aligned when they are gathered together to form an electrochemical cell. Reference points may also allow a completed electrochemical cell or a completed electrode with multiple layers to be inspected unilaterally. For example, if the current collector of a completed electrochemical cell has a reference point visible on the outside, the inspection of the reference point is sufficient to confirm the correct alignment of the electrodes and other components of the electrochemical cell because they have been aligned in the production process early on.

[0129] FIG. 14A to FIG. 14C 636 and its various components according to an embodiment are shown. The nozzle 636 includes a nozzle opening 637, a side plate 654, and a clamp 655. In some embodiments, the nozzle opening 637 and the side plate 654 can be as described above with reference to Figure 5 The nozzle opening 237 and the side plate 254 are described as being the same or substantially similar. Therefore, certain aspects of the nozzle opening 637 and the side plate 654 are not described in further detail herein. Fig.14A A view of a corner of the nozzle 636 is shown with the side plate 654 secured to the nozzle via a clamp 655 . Fig. 14B An exploded view of the side plate 654 and clamp 655 detached from the nozzle 636 is shown. Fig. 14C A side view of the nozzle 636 is shown, showing the side plate 634 contacting and applying force to the conveyor 648, thereby forming a seal to prevent semi-solid electrode material from escaping from one side of the nozzle 636.

[0130] like Fig. 14C As shown, the side plate 654 extends beyond the bottom edge of the nozzle 636 by an amplitude M. In some embodiments, the amplitude M can be at least about 0.5mm, at least about 0.6mm, at least about 0.7mm, at least about 0.8mm, or at least about 0.9mm. In some embodiments, the amplitude M can be no more than about 1mm, no more than about 0.9mm, no more than about 0.8mm, no more than about 0.7mm, or no more than about 0.6mm. Combinations of the above-mentioned ranges for the amplitude M are also possible (e.g., at least about 0.5mm and no more than about 1mm, or at least about 0.6mm and no more than about 0.8mm), including all values ​​and ranges therebetween. In some embodiments, the amplitude M can be about 0.5mm, about 0.6mm, about 0.7mm, about 0.8mm, about 0.9mm, or about 1mm.

[0131] Fig.15790 is a diagram of a densification station 790 according to an embodiment. In some embodiments, the densification station 790 can adopt any of the electrode densification methods described in the '192 disclosure. As shown, the densification station 790 includes a conveyor 791 with a tray 797, an absorbent material 792, material spools 793a, 793b (collectively referred to as material spools 793), a contact spool 794, a contact spool press 795, and an insertion arm 796. In use, the electrode material EM is conveyed along the conveyor 791, while the absorbent material 792 is advanced adjacent to the conveyor 791 and in contact with the electrode material EM. As shown, the electrode material EM is disposed on the collector material CCM. In some embodiments, the collector material CCM is disposed on a membrane (not shown). The absorbent material 792 is fed from the material spool 793a and received by the material spool 793b. The absorbent material 792 is in contact with the contact spool 794 and the insertion arm 796. The contact wire shaft 794 is positioned above the conveyor 791 to place the absorbent material 792 in contact with the electrode material EM. A portion of the liquid in the electrode material EM is transferred to the absorbent material 792. The contact wire shaft press 795 can adjust the position of the contact wire shaft 794 relative to the conveyor. For example, if a larger amount of densification and / or liquid absorption is required, the contact wire shaft press 795 can be pushed downward on the contact wire shaft 794 with an increased force. In some embodiments, the horizontal distance between the contact wire shaft 794 and the insertion arm 796 can be adjusted. The horizontal distance between the contact wire shaft 794 and the insertion arm 796 can be adjusted based on how much contact area is required between the absorbent material 792 and the electrode material EM. As shown in the figure, the densification station 790 is included in the cathode casting station. In some embodiments, the anode casting station may include a densification station. In some embodiments, both the anode casting station and the cathode casting station may include a densification station.

[0132] As shown, the densification station 790 is implemented on a flat surface. In some embodiments, the densification station 790 can be implemented on a flat surface. FIG. 12A to FIG. 12E Densification station 790 is implemented on the drum 441 described above. As noted above, the drums can be extensively and robustly constructed so that they can withstand the forces imposed by densification. In some embodiments, the membrane and / or collector material CCM can be stuffed between trays 797 during densification. In some embodiments, densification can be performed on the same drum as casting. In other words, densification can be performed on the electrode material EM immediately after the electrode material EM is cast.

[0133] FIG. 16A to FIG. 16C is an illustration of a conveyor 848 having a web steering system incorporated therein, according to an embodiment. Fig.16A A top view of a conveyor 848 is shown with the belt or web 849 visible. Fig. 16BA top view of conveyor belt 848 is shown with belt 849 removed to show more detail of additional components. Fig. 16C A side view of conveyor 848 is shown. As shown, nozzle 836 dispenses semi-solid electrode material onto a current collector moving along belt 849. Conveyor 848 also includes rollers 851, O-rings 852, sensors 853, and regulators 854. The semi-solid electrode material is then transported to a battery assembly point where electrochemical cells are assembled. The assembly of electrochemical cells has a small margin of error, so proper alignment and precise regulation of the semi-solid electrode material is important. As the semi-solid electrode material leaves belt 849 (e.g., on the right side of belt 849, as shown in FIG. 8 ), the semi-solid electrode material is dispensed onto a current collector moving along belt 849. Conveyor 848 also includes rollers 851, O-rings 852, sensors 853, and regulators 854. FIG. 16A to FIG. 16C ), the positioning of the semi-solid electrode material is important for the alignment of the semi-solid electrode material when assembling the electrochemical cell.

[0134] The roller 851 rotates while the belt 849 is disposed about the roller 851 to rotate the belt 849. An O-ring 852 is disposed about the roller 851 and is configured to increase friction and help prevent the belt 849 from sliding from side to side as it rolls about the roller 851. In some embodiments, the roller 851 may be disposed in a groove about the roller 851. A sensor 853 may be disposed near the belt 849 to monitor the position and movement of the belt 849 from side to side.

[0135] In some embodiments, sensor 853 can monitor the position of the edge of belt 849. In some embodiments, sensor 853 can be positioned to monitor the position of the edge of the semi-solid electrode. As shown, conveyor 848 includes two sensors 853. In some embodiments, conveyor 848 can include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or at least about 10 sensors 853, including all values ​​and ranges therebetween. In some embodiments, sensor 853 can include a photovoltaic cell, a photodiode, a photoresistor, a phototransistor, or any combination thereof.

[0136] Adjuster 854 is configured to adjust one or more of rollers 851 to ensure accurate alignment of belt 849. In some embodiments, belt 849 can rotate around roller 851 at a rate of at least about 100 rpm, at least about 150 rpm, at least about 200 rpm, at least about 250 rpm, at least about 300 rpm, at least about 350 rpm, at least about 400 rpm, at least about 450 rpm, at least about 500 rpm, at least about 550 rpm, at least about 600 rpm, at least about 650 rpm, at least about 700 rpm, at least about 750 rpm, at least about 800 rpm, at least about 850 rpm, at least about 900 rpm, or at least about 1,000 rpm. With the high rotation speed of the belt, adjuster 854 makes rapid adjustments to ensure proper alignment. In some embodiments, adjuster 854 can make micron-level adjustments in a short period of time. In some embodiments, the regulator 854 can make adjustments over a period of less than about 100 ms, less than about 90 ms, less than about 80 ms, less than about 70 ms, less than about 60 ms, less than about 50 ms, less than about 40 ms, less than about 30 ms, less than about 20 ms, or less than about 10 ms. In some embodiments, adjuster 854 can adjust the alignment of band 849 by approximately 10 μm, approximately 20 μm, approximately 30 μm, approximately 40 μm, approximately 50 μm, approximately 60 μm, approximately 70 μm, approximately 80 μm, approximately 90 μm, approximately 100 μm, approximately 200 μm, approximately 300 μm, approximately 400 μm, approximately 500 μm, approximately 600 μm, approximately 700 μm, approximately 800 μm, approximately 900 μm, approximately 1 mm, approximately 1.5 mm, approximately 2 mm, approximately 2.5 mm, approximately 3 mm, approximately 3.5 mm, approximately 4 mm, approximately 4.5 mm, approximately 5 mm, approximately 5.5 mm, approximately 6 mm, approximately 6.5 mm, approximately 7 mm, approximately 7.5 mm, approximately 8 mm, approximately 8.5 mm, approximately 9 mm, approximately 9.5 mm, or approximately 10 mm, including all values ​​and ranges therebetween.

[0137] In some embodiments, the regulator 854 may include a servo mechanism. In some embodiments, the regulator 854 may include a servo motor. In some embodiments, the regulator 854 may include a position rotary motor, a continuous rotary motor, or a linear motor. As shown, the conveyor 848 includes a regulator 854 positioned at one side of the conveyor 848, and the semi-solid electrode material leaves the conveyor 848 at this side. In some embodiments, the conveyor 848 may include multiple regulators 854 to adjust the position of the belt 848 at multiple locations. Multiple regulators 854 can potentially cause more gradual adjustment of the belt 848.

[0138] FIG. 17A to FIG. 17D is a diagram of a bag sealer 980 according to an embodiment. As shown, the bag sealer 980 is an automatic heat seal bag sealing device. Fig.17A An auxiliary view of the bag sealer 980 is shown, and Fig. 17B A secondary view of the bag sealer 980 is shown, wherein additional machinery is visible, Fig. 17C A side view of the bag sealer 980 is shown in a first configuration, and Fig.17D A side view of a bag sealer 980 in a second configuration is shown. As shown, a belt or web 949 is fed into the bag sealer 980. The bag sealer 980 operates continuously. As shown, the bag sealer 980 includes a drum 981 with a tray 982 thereon. An arm 983 is connected to the drum 981 and a sealing device 987. The sealing device 987 contacts the tray connector 988 and the cylinder 991 to seal the bag. The sealing device 987 moves along a tracking path 989.

[0139] Arm 983 adjusts the movement of sealing device 987. As shown, arm 983 has two sections and several characteristic angles. The first section of arm 983 extends outward from the edge of drum 981, where it connects to the second section of arm 983. The second section of arm 983 is coupled to a point near the center of drum 981 (e.g., about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 1 cm, about 2 cm, about 3 cm, about 4 cm, about 5 cm, about 6 cm, about 7 cm, about 8 cm, about 9 cm, or about 10 cm from the center of drum 981, including all values ​​and ranges therebetween). A first imaginary line extends from the center of drum 981 to the coupling point between the first section of arm 983 and drum 981. A second imaginary line extends from the center of the drum to the coupling point between the second section of arm 983 and the drum.

[0140] Angle A1 refers to the angle between the first imaginary line and the second imaginary line. When the sealing device 987 moves from the top position to the bottom position, as the arm 983 becomes fully extended, the angle A1 increases. In some embodiments, when the arm 983 is in the top position, the angle A1 can be about 30°, about 35°, about 40°, about 45°, about 50°, about 55°, about 60°, about 65°, about 70°, about 75° or about 80°, including all values ​​and ranges therebetween. In some embodiments, when the arm 983 is in the bottom position, the angle A1 can be about 100°, about 105°, about 110°, about 115°, about 120°, about 125°, about 130°, about 135°, about 140°, about 145°, about 150°, about 155°, about 160°, about 165° or about 170°, including all values ​​and ranges therebetween.

[0141] Angle A2 refers to the angle between the first imaginary line and the first segment of the arm 983. When the sealing device 987 moves from the top position to the bottom position, as the arm 983 becomes fully extended, the angle A2 increases. In some embodiments, when the arm 983 is in the top position, the angle A2 can be about 50°, about 55°, about 60°, about 65°, about 70°, about 75°, about 80°, or about 85°, including all values ​​and ranges therebetween. In some embodiments, when the arm 983 is in the bottom position, the angle A2 can be about 95°, about 100°, about 105°, about 110°, about 115°, about 120°, about 125°, or about 130°, including all values ​​and ranges therebetween.

[0142] The sealing device 987 controls the supply of air to the cylinder 981 to apply pressure to the web 949 and the bag material thereon. When the drum 981 rotates, the cylinder 991 is pushed to contact the web 949 and the bag material thereon via the guide plate 992. In some embodiments, the guide plate 992 can be configured to move axially along the length of the drum 981. When the sealing device 987 is in the sealing position, the cylinder 991 contacts the web 949. In some embodiments, the sealing position can be the top position of the sealing device 987. In some embodiments, the sealing position can be the bottom position of the sealing device 987. When the sealing device 987 is in the sealing position and the cylinder 991 contacts the web 949, the heat sealing belt (not shown) inside the drum 981 and below the web 949 is energized. In some embodiments, power can be provided to the cylinder 991 via the sealing device 987. Air pressure is provided to the cylinder 991 via the sealing device 987, and pressure is applied to the web 949 and the bag material disposed thereon to ensure uniform pressure and cause heat transfer.

[0143] As the drum 981 rotates, the sealing device 987 is fluidically and / or electronically coupled to n cylinders 991 at a time, where n is a positive integer. As shown, n is 5. In some embodiments, n can be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 or at least about 20. After the sealing device 987 has performed pressurization and sealing, the sealing device 987 moves from the top position of the tracking path 989 to the bottom position of the tracking path 989 (or vice versa) via a cam in the drum 981. In the switching position on the tracking path 989, the sealing device can pass or skip several tray connectors 988 and cylinders 991 (e.g., n tray connectors 988 and n cylinders 991). In some embodiments, a second sealing device (not shown) can be provided on the opposite side of the drum 981. The second sealing device can operate in a staggered arrangement with the first sealing device 987. For example, the first sealing device 987 can seal cells 1 to 5, while the second sealing device can seal cells 6 to 10, the first sealing device 987 can seal cells 11 to 15, the second sealing device can seal cells 16 to 20, and so on.

[0144] Fig.18 1 is a diagram of a web steering apparatus 1000 according to an embodiment. As shown, the web steering apparatus 1000 includes a web 1049, a roller 1051, an O-ring belt 1052, an idler 1054, a dancer 1055, a dancer arm 1056, a pressure roller 1057, and a lift roller 1058. Drums 1081a, 1081b (collectively referred to as drums 1081) can be placed on either side of the web steering apparatus 1000. In some embodiments, the steering apparatus 1000 can be employed in spaces where the web 1049 is not steered onto the drum. In some embodiments, the drum 1081 can include ... FIG. 17A to FIG. 17D Any of the properties or components (eg, arms) of the drum 981. The web turning apparatus 1000 is configured to facilitate alignment of the electrodes and to create a constant tension in the web 1049. The web turning apparatus 1000 also includes a tension control zone established throughout the web turning apparatus 1000.

[0145] In use, the anode, cathode and separator can be united and heat bonded and enter the web turning device 1000 via the web 1049 at the entry point E. As the web 1049 advances along the web turning device 1000, the anode, cathode and separator can be contained inside the web 1049. The web 1049 passes above the roller 1051 and below the swinger 1055 to produce an arc path. The swinger 1055 can be controlled to move up and down by the swinger arm 1056. The movement of the swinger 1055 can shape the movement path of the web 1049. In some embodiments, one or more of the swinger arms 1056 can be controlled via a low friction gas spring (not shown), which applies a force to the swinger arm 1056 so that the swinger arm 1056 moves the swinger 1055 up or down. Then, the web 1049 passes along the O-ring belt 1052, where the web 1049 is aligned before entering the drum 1081a. The edges of the electrochemical cells in the web 1049 are heat sealed in the drum 1081a. The web 1049 advances again through another set of rollers 1051, oscillators 1055, and O-rings 1052 before entering the drum 1081b. A second seal can be formed along the equator of each electrochemical cell in the drum 1081b.

[0146] As shown, rollers 1051 are each oriented in an arc. The arc orientation of rollers 1051 creates a large radius of curvature around which web 1049 advances. A larger radius of curvature is less likely to cause damage to an electrode or battery traveling via web 1049 than a smaller radius of curvature because the electrode or battery can bend more when traveling around a smaller radius of curvature. In some embodiments, large rollers can be used instead of a series of small rollers formed into an arc.

[0147] The O-ring band 1052 includes one or more O-rings that rotate and move the web 1049 by frictionally engaging the web 1049 (i.e., applying a normal force to the web 1049). In some embodiments, a pressure roller 1058 can push down on the web 1049 to frictionally engage the web 1049 with the O-rings. In use, the web 1049 may sometimes roll out of its proper alignment. The idler 1054 can temporarily separate the web 1049 from the O-ring band 1052 (e.g., by moving the O-ring band 1052 relative to the web 1049 or by moving the web 1049 relative to the O-rings) so that the O-ring band 1052 can be repositioned to a central position without dragging the web 1049 along with it. The lifting roller 1058 can lift the web 1049 to allow the O-ring band 1052 to reposition its alignment. O-ring belt 1052 turns web 1049 to drum 1081 for heat sealing. When mounted on a linear bearing with a lever system therebetween as shown, this allows O-ring belt 1052 to advance or decelerate web 1049 entering drum 1081. This can be accomplished in a variety of ways. In some embodiments, each O-ring belt 1052 can be servo-controlled for rpm control. In some embodiments, each O-ring belt 1052 can be automatically positioned to advance or decelerate web 1049 relative to the phase angle of drum 1081.

[0148] As shown, the web 1049 advances around the drum 1081. In some embodiments, the drums 1081a, 1081b can have different angular velocities. In such cases, the swing arm 1056 can control the tension in the web 1049 by applying force. The pressure in the gas spring that propels the swing arm 1056 can be automatically adjusted via the machine control system. In addition, the swing 1055 can allow the web alignment system 1000 to advance and decelerate on demand or in real time. The web alignment system 1000 can advance or decelerate the web 1049 on the drum 1081 to align the heat sealer (not shown) of the drum 1081 to the space between the electrochemical cells in the web 1049. The swing 1055 can supply a section of the web 1049 or take up part of the web 1049 while maintaining constant tension. In some embodiments, if the web 1049 is moving at high speed, the swing 1055 can accelerate faster than the acceleration of gravity, and the gas spring can promote the movement.

[0149] Fig.191 is a diagram showing a system 1100 for semi-continuous or continuous manufacture of semi-solid electrodes according to an embodiment. As shown, the system 1100 includes: a cathode casting station 1130a, which includes a cathode casting drum 1140a and a cathode casting assembly 1190a; an anode casting station 1130b, which includes an anode casting drum 1140b and an anode casting assembly 1190b; one or more belts or conveyors 1148, which can be substantially similar to the conveyor 148 as previously described and can be used to transport cathode or anode collector materials; or a web 1149 (e.g., a first web 1149a and a second web 1149b, collectively referred to as web 1149). The system 1100 may also include one or more rollers 1151, a bag sealer 1180, and a web alignment assembly 1110. In addition, the system 1100 may also optionally include a compressor (e.g., compressor 120), a barrel (e.g., barrel 130), and a forming device (e.g., forming device 150). In some embodiments, the system 1100 may also include a gravity dryer (e.g., gravity dryer 110), a mixer (e.g., mixer 118), a laser cutting device (e.g., laser cutting device 140), a wetting device (e.g., 160, tunnel 168, abutment system 170, and bag sealer 180. In some embodiments, the system 100 may be used to implement the above-mentioned reference Figure 1 The method 10.

[0150] Fig. 20 The system 1100 is shown as Fig.19 A side cross-sectional view of a portion of the cathode casting station 1130a indicated by arrow A. The cathode casting station 1130a is configured to receive a cathode current collector material, such as a metal foil or a metal strip, and is configured to cast a semi-solid cathode material on a predetermined portion of the cathode current collector material that is conveyed in a continuous, near-continuous, or semi-continuous manner via a conveyor 1148. The conveyor 1148 moves the semi-solid electrode through additional processing units of the system 1100. In some embodiments, the system may include multiple conveyors (not shown). In some embodiments, multiple conveyors can be used to place multiple electrodes together as described in the '025 disclosure. The anode casting station 1130b is substantially similar to the cathode casting station 1130a, except that the anode casting station 1130b is configured to receive an anode current collector material, such as a metal foil or a metal strip, and is configured to cast a semi-solid anode material on a predetermined portion of the anode current collector material that is conveyed in a continuous, near-continuous, or semi-continuous manner via a conveyor 1148. Therefore, although relative to Fig. 20 Only the cathode casting station 1130a is described in detail, but it should be understood that the anode casting station 1130b is substantially similar in structure and function to the cathode casting station 1130a.

[0151] like Fig. 20As shown, the cathode casting drum 1140 includes a plurality of trays 1142a, which can be selectively displaced close to or radially away from each other when the drum 1140a rotates. A first portion of the cathode current collector material is disposed on each of the trays 1142a, so that a second portion of the cathode current collector material is curled between adjacent trays when the adjacent trays rotate. In some embodiments, the cathode casting drum 1140a can be substantially similar in structure and function to the rotating drum 441 as previously described, and therefore is not described in detail herein.

[0152] The cathode casting station 1130a may include a mixer 1118 configured to mix the active material, the conductive material, and the electrolyte to form a semi-solid electrode material. In some embodiments, the mixer 1118 may include a blender. In some embodiments, the mixer 1118 may include a single screw extruder. In some embodiments, the mixer 1118 may include a twin screw extruder. In some embodiments, the mixer 1118 may include a twin screw kneader. In some embodiments, the mixer may include any of the mixers mentioned in the '569 patent. In some embodiments, the mixer 1118 may be fluidly coupled to a gravity dryer (e.g., a gravity dryer) 110 so that the material can flow continuously from the gravity dryer 110 to the mixer 1118. In some embodiments, the mixer 1118 may also include a compressor (e.g., a compressor 120), for example, to compress the semi-solid cathode material into an electrode brick. In some embodiments, the mixer 1118 may be configured to receive a semi-solid electrode material or slurry sheet or block via a conveyor or hopper.

[0153] The cathode casting assembly 1190a may include a casting turntable 1191a, which may be mounted on an axis 1193a along its central axis. The axis 1193a may be operably coupled to an actuator (e.g., a motor) configured to rotate the casting turntable 1191a by an angle of at least 180 degrees in a clockwise and / or counterclockwise direction. The casting turntable 1191a defines at least a first chamber 1192a1 and a second chamber 1192a2, each of which is configured to selectively receive a predetermined volume of semi-solid cathode material from a mixer 1118, and selectively distribute the predetermined volume of semi-solid cathode material on a corresponding tray 1142a of the casting drum 1140a. Each of the first chamber 1192a1 and the second chamber 1192a2 may be arranged to be axially parallel to the axis 1192a and radially offset from the axis. The first dispensing mechanism 1194a1 and the second dispensing mechanism 1194a2 are operably coupled to the first chamber 1192a1 and the second chamber 1192a2, respectively, and are configured to selectively dispense the semi-solid cathode material disposed therein onto the corresponding tray 1142a of the casting drum 1140a. Any dispensing mechanism, such as, for example, a piston, a compressor, which is configured to deliver a compressed gas (e.g., air, nitrogen, etc.) through the first chamber 1192a1 or the second chamber 1192a2 to force the semi-solid cathode material contained therein to leave the first chamber 1192a1 or the second chamber 1192a2 and arrive at the corresponding tray 1142a, i.e., arrive at a portion of the cathode current collector disposed on the corresponding pellet at that particular time.

[0154] Further expanding, in some embodiments, the first chamber 1192a1 may be radially offset from the second chamber 1192a2 by an angle of approximately 180 degrees. Fig. 20 In the first configuration shown, the first chamber 1192a1 can be axially aligned with the outlet of the mixer 1118a so as to be in fluid communication with the outlet of the mixer. In some embodiments, a sealing member 1119a can be disposed at or around the outlet of the mixer 1118a to form a seal with the inlet of a corresponding one of the first chamber 1192a1 or the second chamber 1192a2, which is axially aligned with the outlet of the mixer 1118a, depending on whether the assembly 1190a is in the first configuration or the second configuration.

[0155] In the first configuration, the first chamber 1192a1 receives a predetermined volume of semi-solid cathode material from the mixer 1118a. In some embodiments, the rotation speed can cause the casting turntable 1191a to have a residence time while axially aligned with the outlet of the mixer 1118a. In some embodiments, the residence time can be selected so that a predetermined volume of semi-solid cathode material is received in the first chamber 1192a1 from the mixer 1118a. In the first configuration, the second chamber 1192a2 is axially aligned with the corresponding tray 1142a of the casting drum 1140a. When the first chamber 1192a1 is filled with semi-solid cathode material, the second dispensing mechanism 1194a2 is selectively actuated to distribute the semi-solid cathode material disposed therein to the corresponding tray 1142a (e.g., the first tray).

[0156] In the second configuration, the casting turntable 1191a is rotated about the axis 1193a so that the first chamber 1192a1 is now aligned with the corresponding tray 1142a (e.g., a second tray radially adjacent to the first tray), and the second chamber 1192a2 is axially aligned with the outlet of the mixer 1118a. Therefore, in the second configuration, the second chamber 1192a2 is filled with a predetermined volume of the semi-solid cathode material, and the semi-solid cathode material already disposed in the first chamber 1192a1 is distributed via the first dispensing mechanism 1194a1 to a portion of the cathode current collector material disposed on the corresponding tray 1142a which is now axially aligned with the first chamber 1192a1. For example, once the first chamber 1192a1 is filled with semi-solid cathode material, loading of the semi-solid cathode material is stopped, the first chamber 1192a1 is gated (e.g., closed via a portion of the casting assembly 1190a or a movable door), and pressure can be built in the first chamber 1192a1 so that when the first chamber 1192a1 is rotated approximately 180 degrees (e.g., from approximately the 6 o'clock position to the 12 o'clock position), dispensing can be immediately initiated once the first chamber 1192a1 is approximately axially aligned with the corresponding tray 1142a.

[0157] In some embodiments, the rotation of the casting turntable 1191a about the axis 1193a between filling the first chamber 1192a1 and dispensing the semi-solid electrode material from the first chamber 1192a can be about 80 degrees, about 90 degrees, about 100 degrees, about 110 degrees, about 120 degrees, about 130 degrees, about 140 degrees, about 150 degrees, about 160 degrees, about 170 degrees, about 180 degrees, about 190 degrees, about 200 degrees, about 210 degrees, about 220 degrees, about 230 degrees, about 240 degrees, about 250 degrees, about 260 degrees, about 270 degrees or about 280 degrees, including all values ​​and ranges therebetween.

[0158] The rotation of the casting drum 1140a and the casting turntable 1191a and the dispensing speed of the mixer 1118a can be synchronized so that during the time period when the first chamber 1192a1 is filled with semi-solid cathode material and undergoes a 180-degree rotation, the first tray in the tray 1142a on which the semi-solid cathode material from the second tray 1142a is dispensed has rotated away, and the adjacent second tray in the tray 1142a is axially aligned with the first chamber 1192a1, thereby allowing the semi-solid cathode material to be dispensed onto the cathode collector material disposed on the second tray. In this way, continuous, nearly continuous or semi-continuous dispensing of semi-solid cathode material can be performed on the cathode collector material. In some embodiments, the filling and rotation time of the casting turntable 1191a can be in the range of about 5 seconds to about 30 seconds (including end values).

[0159] In some embodiments, the casting turntable 1190a can be configured to allow for quality control checks of the semisolid electrode material filled in each of the first chamber 1192a1 and / or the second chamber 1192a2 during operation, for example, via a load piston or any other suitable sensor that can sense various parameters of the loaded semisolid cathode material (e.g., through the wall of the casting turntable 1191a). If the loaded semisolid cathode slurry fails quality control, the casting turntable 1191a can be configured to be moved to a third configuration between the first configuration and the second configuration, for example, wherein the first chamber 1192a1 is at the 9 o'clock position and the second chamber 1192a2 is at the 3 o'clock position. The discarded semisolid cathode material can be discharged from the corresponding first chamber 1192a1 or second chamber 1192a2, for example, in a waste or recycling bin, and then the first chamber 1192a1 or second chamber 1192a2 can be aligned with the mixer 1118a via rotation of the casting turntable 1191a.

[0160] Although Fig. 20 The casting turntable 1191a is shown as defining only a first chamber 1192a1 and a second chamber 1192a2, but in other embodiments, the casting turntable 1191a can define multiple chambers, such as 3, 4, 5, 6 or even more. A larger number of chambers can increase throughput by allowing faster rotation of the casting drum 1140a without significantly increasing the rotation speed of the casting turntable 1191a.

[0161] Reference again Fig.19, the system 1100 may further include a first plurality of rollers 1151a configured to route the cathode current collector material having the semi-solid cathode material thereon toward other components included in the system 100. Similarly, the system 1100 may further include a second plurality of rollers 1151b configured to route the anode current collector material having the semi-solid anode material thereon toward other components included in the system 1100.

[0162] In some embodiments, each of cathode casting station 1130a and anode casting station 1130b may include an optical measuring device and x-rays. The optical measuring device and x-rays may be used for quality control to confirm the thickness of the semi-solid electrode after formation. In some embodiments, an anode may be formed at anode casting station 1130b, wherein the anode material is disposed on a current collector and / or a bag material. In some embodiments, a cathode may be formed at cathode casting station 1130a, wherein the cathode material is disposed on a current collector and / or a bag material.

[0163] In some embodiments, after being formed at the cathode casting station 1130a, the cathode material can pass through the spray hood. In some embodiments, a wetting device (e.g., a wetting device 160) and / or a tunnel (e.g., a tunnel 168) can be located inside the spray hood. In some embodiments, a solvent can be sprayed onto the anode material and / or cathode material in the spray hood. In some embodiments, the solvent sprayed on the cathode material can be flammable. Using a spray hood can help prevent ignition by keeping the concentration level of the flammable material outside the flammable range. In some embodiments, the spray hood includes an exhaust device to ventilate the spray hood to the surrounding environment and keep the concentration of the flammable material below the flammable limit. In some embodiments, the spray hood can be explosion-proof. In some embodiments, the cathode material can pass through the spray hood. In some embodiments, the anode material can pass through the spray hood. In some embodiments, the anode material can pass through the first spray hood, and the cathode material can pass through the second spray hood. In some embodiments, the anode material and the cathode material can pass through the same spray hood.

[0164] In some embodiments, the spray hood can be purged of oxygen to reduce the risk of ignition inside the hood. In some embodiments, the oxygen purging can be performed by evacuating the spray hood. In some embodiments, the oxygen purging can be performed by flowing an inert gas (e.g., nitrogen, argon) into the spray hood. In some embodiments, the oxygen purging can be performed by evacuating the spray hood and flowing an inert gas into the spray hood.

[0165] In some embodiments, the formed anode material, the formed cathode material, and the separator material can be fed into a vacuum drum (not shown), wherein the anode material, the cathode material, and the separator are combined together. In some embodiments, each of the anode material, the cathode material, and the separator can be wrapped around the vacuum drum at different points along the vacuum drum to form layers of the electrochemical cell. In some embodiments, the vacuum drum can apply force to the electrodes to increase their density, as described in detail with respect to system 100. As shown, the separator material is fed adjacent to the anode casting station 1130b. In some embodiments, the separator material can be fed adjacent to the cathode casting station 1130a. In other words, the positioning of the anode casting station 1130b and the cathode casting station 1130a can be related to their Fig.19 Switches the way it is depicted.

[0166] In some embodiments, the diameter of the vacuum drum can be at least about 1 cm, at least about 5 cm, at least about 10 cm, at least about 20 cm, at least about 30 cm, at least about 40 cm, at least about 50 cm, at least about 60 cm, at least about 70 cm, at least about 80 cm, or at least about 90 cm. In some embodiments, the diameter of the vacuum drum can be no more than about 1 m, no more than about 90 cm, no more than about 80 cm, no more than about 70 cm, no more than about 60 cm, no more than about 50 cm, no more than about 40 cm, no more than about 30 cm, no more than about 20 cm, no more than about 10 cm, or no more than about 5 cm. Combinations of the above-mentioned diameters of the vacuum drum are also possible (e.g., at least about 1 cm and no more than about 1 m, or at least about 10 cm and no more than about 50 cm), including all values ​​and ranges therebetween. In some embodiments, the vacuum drum may have a diameter of about 1 cm, about 5 cm, about 10 cm, about 20 cm, about 30 cm, about 40 cm, about 50 cm, about 60 cm, about 70 cm, about 80 cm, about 90 cm, or about 1 m.

[0167] In some embodiments, the vacuum drum can be held in place with tacks. In some embodiments, the vacuum drum can include a plurality of components arranged around the periphery of the vacuum drum. In some embodiments, the components can include a tray. In some embodiments, the vacuum drum can include a central duct with a vacuum for removing liquid from the material outside the vacuum drum. After merging together, a laser cutter can cut the anode material, cathode material, and separator to form a separate electrochemical cell. As shown, a separate electrochemical cell can be transported across a vacuum conveyor. In some embodiments, a vacuum conveyor can remove stray particles from the electrochemical cell. The separate electrochemical cell can be measured via optical measurement for quality control. Then, the separate electrochemical cells can selectively slide off the vacuum conveyor, depending on whether they pass the quality control test.

[0168] In some embodiments, the system 1100 may include a first vacuum drum receiving a feed of cathode material and separator material and a second vacuum drum receiving a feed of anode material. In some embodiments, the first vacuum drum presses the separator material and cathode material onto a conveyor, and then the second vacuum drum presses the anode material onto the cathode material and separator.

[0169] In some embodiments, the anode casting station and / or the cathode casting station may include a densification station (not shown). In some embodiments, the densification station may employ any of the electrode densification methods described in the '192 publication.

[0170] In some embodiments, system 100 can produce at least about 100, at least about 150, at least about 200, at least about 250, at least about 300, at least about 350, at least about 400, at least about 450, at least about 500, at least about 550, at least about 600, at least about 650, at least about 700, at least about 750, at least about 800, at least about 850, at least about 900, at least about 950, or at least about 1,000 electrodes per minute, including all values ​​and ranges therebetween. In some embodiments, system 100 can produce at least about 100, at least about 150, at least about 200, at least about 250, at least about 300, at least about 350, at least about 400, at least about 450, at least about 500, at least about 550, at least about 600, at least about 650, at least about 700, at least about 750, at least about 800, at least about 850, at least about 900, at least about 950, or at least about 1,000 electrochemical cells per minute, including all values ​​and ranges therebetween.

[0171] In some embodiments, system 1100 includes a bag sealer 1180, which can be configured to receive, for example, a merged electrochemical cell material disposed between layers of bag material from a web alignment assembly. Bag sealer 1180 can be configured to seal the bag around the outside edge of the electrochemical cell. In some embodiments, bag sealer 1180 can include a pulse heater. In some embodiments, bag sealer 1180 can have a shape so that it can be sealed around the outside edge of the electrochemical cell in a single step. In some embodiments, bag sealer 1180 is substantially similar to bag sealer 980 in structure and function, and therefore is not described in further detail herein.

[0172] Figure 21 to Figure 25Various views of a web alignment assembly 1110 (hereinafter referred to as "assembly 1110") that can be included in system 1100 or any other system described herein (e.g., system 100) are shown. In some embodiments, web alignment assembly 1100 can be configured for continuous or near-continuous motion alignment of a first web with a second web, with a merging component of an electrochemical cell disposed between the first web and the second web. In some embodiments, as Fig. 22 and Fig.23 As shown, the assembly 1110 includes a first web alignment subassembly 1110a (hereinafter referred to as "first subassembly 1110a") and a second web alignment subassembly (hereinafter referred to as "second subassembly 1110b") disposed below the first subassembly 1110a in the Z direction. Figure 21 to Figure 25 As shown, the Y direction refers to the direction of travel of the web 1149, the X direction refers to the lateral or cross-web direction, and the Z direction refers to the vertical direction.

[0173] The first subassembly 1110a includes a first plurality of vacuum chucks 1120a disposed on or coupled to a first conveyor 1126a (e.g., a timing belt, transmission, or chain mounted on a first motor 1128a (e.g., a servo motor)). In addition, the second subassembly 1110b includes a second plurality of vacuum chucks 1120b disposed on or coupled to a second conveyor 1126b (mounted on a second motor 1128b (e.g., a servo motor) (e.g., a timing belt, transmission, or chain)). Each of the vacuum chucks 1120a / b can be spaced apart from an adjacent chuck 1120a / b by a predetermined pitch P, for example, in a range of about 50 mm to about 750 mm, inclusive. The first motor 1128a and the second motor 1128b can be configured to rotate in opposite directions so that the first plurality of vacuum chucks 1120a and the second plurality of vacuum chucks 1120b move in the same direction, such as Fig. 22 and Fig.23 Shown in the Y direction.

[0174] Each of the first vacuum chucks 1120a has a first engagement portion 1121a, and each of the second vacuum chucks 1120b has a second engagement portion 1121b that extends in the X direction beyond the axial extent of the motors 1128a and 1128b above the web 1149 and is configured to engage and align the webs 1149 relative to each other. In addition, each of the vacuum chucks 1120a / b has three degrees of freedom or is configured to be selectively displaced in each of the X, Y, and Z directions. As shown, the first engagement portion 1121a and the second engagement portion 1121b include vacuum holes (not shown) to provide a fluid passage for applying a vacuum. This allows a first vacuum chuck 1120a of the first plurality of first vacuum chucks 1120a to move with a corresponding second vacuum chuck 1120b in the direction of web travel (i.e., the Y direction) while being in proximity and alignment with a corresponding second vacuum chuck 1120b in the X and Y directions, and to maintain the first web 1149a above the corresponding second web 1149b at a variable and controllable "ride height" or spacing relative to each other. The vacuum apertures may have any form factor, including circular, oval, rectangular, square, slotted, star-shaped, or any combination thereof.

[0175] In some embodiments, Fig.25 As shown, each of the first vacuum chucks 1120a (and similarly, the second vacuum chucks 1120b) can be mounted on one or more first bearings 1132a that allow linear translation of the corresponding first vacuum chuck 1120a (and similarly, the second vacuum chuck 1120b), and optionally, can also be mounted on one or more second bearings (not shown) that allow movement of the first vacuum chuck 1120a (and similarly, the second vacuum chuck 1120b) in the Z direction. A steering mechanism 1136a (e.g., a linear actuator or a servo motor) is coupled to the first vacuum chuck 1120a (and similarly, the second vacuum chuck 1120b) and is configured to move the first vacuum chuck 1120a in the X direction. In some embodiments, the servo motor can adjust the position of the vacuum chucks 1120a, 1120b and align the electrochemical cell between the first web 1149a and the second web 1149b when moving.

[0176] In some embodiments, assembly 1100 (e.g., first subassembly 1100a and / or second subassembly 1100b) may include a machine vision system 1124a (e.g., a camera such as a charge coupled device (CCD) camera, an infrared (IR) camera, etc.) or any other sensing system that is configured to determine the relative spacing between first web 1149a and second web 1149b and adjust the relative position of at least a portion of first plurality of vacuum chucks 1120a and corresponding portions of second plurality of vacuum chucks 1120b to align webs 1149 relative to each other during operation of assembly 1100.

[0177] In some embodiments, the vacuum chucks 1120a, 1120b can be fastened to a timing belt (e.g., a conveyor 1126a, 1126b, included in the conveyor 1126a, 1126b, or coupled to the conveyor 1126a, 1126b) to provide synchronized movement of the vacuum chucks 1120a, 1120b. In some embodiments, an additional set of timing belts can be connected to the trays 1142a, 1142b via a vacuum transfer connection. In some embodiments, the vacuum connection can be spring loaded against the back side of the vacuum chucks 1120a, 1120b. In some embodiments, the vacuum connection can be fed through a slot in the vacuum chucks 1120a, 1120b to allow movement in the X direction while maintaining alignment of the vacuum connection. In some embodiments, the vacuum chucks 1120a, 1120b can include bearings to allow movement in the Z direction. Movement in the Z direction can allow the first web 1149a and the second web 1149b to be brought closer together before being aligned and mated with each other. Movement in the Z direction can also prevent the chord action of the vacuum chucks 1120a, 1120b from hitting the web 1149 as it travels around the first conveyor 1126a and the second conveyor 1126b.

[0178] In some embodiments, a rotary slide (not shown) may allow the vacuum chucks 1120a, 1120b to be actuated while the vacuum chucks 1120a, 1120b are being advanced. In some embodiments, a linear slide (not shown) may allow the vacuum chucks 1120a, 1120b to be actuated while the vacuum chucks 1120a, 1120b are being advanced. The length of the movement of the vacuum chucks 1120a, 1120b along the web 1149 may allow a measuring device (not shown) sufficient time to measure the position of the first web 1149a and the second web 1149b so that the vacuum chucks 1120a, 1120b may be adjusted to the correct alignment. In some embodiments, the machine vision system 1124a may include a camera to check the relative position of the first web 1149a and the second web 1149b and calculate the distance the tray 1142 should move in the X direction and / or the Y direction.

[0179] like Fig.25 As shown, the first subassembly 1110a (and similarly, the second subassembly 1110b) includes a vacuum line 1129a extending in the X direction, which is fluidly coupled to each of the first vacuum chucks 1120a via a vacuum transfer coupling 1134a. The transfer coupling 1134a may include a piston and provide a vacuum channel to the vacuum chucks 1120a, 1120b. The piston in the transfer coupling 1134a may include a slot that keeps the transfer coupling 1134a in fluid contact with the vacuum line 1129a when the transfer coupling 1134a moves laterally. The web alignment assembly 1110 utilizes a conveyor-like motion to bring the vacuum chucks 1120a, 1120b into contact with the web 1149. Alignment in the X and Y directions is performed at high speed and precision, while using a continuous motion tool to widen the time period over which an event may occur.

[0180] Various concepts can be embodied as one or more methods, wherein at least one example is provided. The actions performed as part of the method can be ordered in any appropriate manner. Therefore, embodiments can be constructed in which actions are performed in an order different from that shown, which can include performing some actions simultaneously, even if shown as continuous actions in the illustrative embodiments. In other words, it should be understood that such features are not necessarily limited to a specific execution order, but any number of threads, processes, services and / or servers, etc., that can be executed serially, asynchronously, concurrently, in parallel, simultaneously, synchronously, etc. in a manner consistent with the present disclosure. Therefore, some of these features may contradict each other because they cannot exist in a single embodiment at the same time. Similarly, some features are applicable to one aspect of the innovation and are not applicable to other aspects.

[0181] In addition, the present disclosure may include other innovations not currently described. Applicants reserve all rights to such innovations, including the right to embody such innovations, submit additional applications, continuations, continuations in part, divisions, etc. Therefore, it should be understood that the advantages, embodiments, examples, functions, features, logic, operations, organizations, structures, topologies and / or other aspects of the present disclosure should not be considered as limitations on the present disclosure as defined by the embodiments or limitations on the equivalents of the embodiments. Depending on the specific expectations and / or characteristics of individual and / or enterprise users, database configurations and / or relational models, data types, data transmission and / or network architectures, grammatical structures, etc., various embodiments of the technology disclosed herein can be implemented in a manner that supports the large amount of flexibility and customization described herein.

[0182] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0183] As used herein, in certain embodiments, the term "about" or "approximately" when preceding a numerical value represents a range of that value plus or minus 10%. Where a range of values ​​is provided, it is understood that each intermediate value between the upper and lower limits of the range (to one-tenth of the unit of the lower limit, unless the context clearly indicates otherwise) and any other stated value or intermediate value within the range are included in the present disclosure. The upper and lower limits of these smaller ranges can be independently included in smaller ranges and are also included in the present disclosure, subject to any specific exclusion limit within the range. Where the stated range includes one or two of the limits, the range excluding any one or two of the included limits is also included in the present disclosure.

[0184] The phrase "and / or" as used herein in the specification and examples should be understood to mean "either or both" of the elements so combined, i.e., elements that exist jointly in some cases and separately in other cases. Multiple elements listed with "and / or" should be interpreted in the same manner, i.e., "one or more elements" of the elements so combined. In addition to the elements specifically identified with the "and / or" clause, other elements may optionally be present, whether related or unrelated to those specifically identified elements. Thus, as a non-limiting example, when used in conjunction with open language such as "comprising", references to "A and / or B" may refer to only A (optionally including elements other than B) in one embodiment; only B (optionally including elements other than A) in another embodiment; both A and B (optionally including other elements) in yet another embodiment; etc.

[0185] As used herein in the specification and the embodiments, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when the items in the list are separated, "or" or "and / or" should be interpreted as inclusive, that is, including at least one element in many elements or element lists, but also including more than one element and optionally other unlisted items. Only terms with clear indication of opposite meanings, such as "only one in ... " or "just one in ... ", or when used in the embodiments, "consisting of ... " will refer to including just one element in several elements or element lists. In general, when there is an exclusive term before, such as "any one", "one of ... ", "only one in ... " or "just one in ... ", the term "or" as used herein should only be interpreted as indicating exclusive alternatives (that is, "one or another, rather than two"). When used in the embodiments, "mainly consisting of ... " should have its common meaning as used in the field of patent law.

[0186] As used herein in the specification and in the embodiments, the phrase "at least one" of a list of one or more elements is understood to mean at least one element selected from any one or more elements in the list of elements, but does not necessarily include at least one of each element specifically listed in the list of elements, and does not exclude any combination of elements in the list of elements. This definition also allows that there may be optionally elements other than the elements specifically identified in the list of elements referred to by the phrase "at least one", regardless of whether they are related or unrelated to those elements specifically identified. Therefore, as a non-limiting example, "at least one of A and B" (or equivalently, "at least one of A or B", or equivalently, "at least one of A and / or B") may refer to at least one in one embodiment, optionally including more than one A, without B (and optionally including elements other than B); in another embodiment, at least one, optionally including more than one B, without A (and optionally including elements other than A); in yet another embodiment, at least one, optionally including more than one A, and at least one, optionally including more than one B (and optionally including other elements); etc.

[0187] In the embodiments and in the above description, all transitional phrases such as "comprising", "including", "carrying", "having", "containing", "involving", "holding", "comprising", etc. should be understood as open-ended, i.e., meaning including but not limited to. As set forth in Section 2111.03 of the Manual of Patent Examining Procedures of the United States Patent Office, only the transitional phrases "consisting of" and "consisting essentially of" are closed or semi-closed transitional phrases, respectively.

[0188] Although specific embodiments of the present disclosure have been summarized above, many substitutions, modifications and variations are apparent to those skilled in the art. Therefore, the embodiments as described herein are intended to be illustrative rather than restrictive. Various changes may be made without departing from the spirit and scope of the present disclosure. Where the above methods and steps indicate specific events occurring in a particular order, those of ordinary skill in the art who benefit from the present disclosure will recognize that the order of specific steps may be modified, and such modifications are variations according to the present invention. In addition, as described above, certain steps in the steps may be performed simultaneously in a parallel process, as well as sequentially. Embodiments have been specifically shown and described, but it will be appreciated that various changes in form and detail may be made.

Claims

1. A method comprising: transferring a first semisolid electrode material into the chamber in a first direction; rotating the chamber about a central axis in a direction orthogonal to the first direction; dispensing the first semisolid electrode material from the chamber onto a current collector in contact with the drum in a second direction, the second direction being opposite to the first direction; and The first semi-solid electrode material and the second electrode material are coupled to a separator. 2 . The method of claim 1 , wherein rotating the chamber about the central axis is performed to an angle between about 160° and about 200°.

3. The method of claim 1, wherein transferring the first semi-solid electrode material in the first direction is performed from a blender.

4. The method according to claim 1, further comprising: The drum is rotated while dispensing the first semisolid electrode material onto the current collector.

5. The method of claim 1, wherein dispensing the first semi-solid electrode material onto the current collector is performed via an actuator in physical contact with the semi-solid electrode material.

6. The method according to claim 1, further comprising: A vacuum is applied to the drum to strengthen the coupling between the current collector and the drum.

7. The method of claim 1, wherein the current collector is a first current collector, the method further comprising: The second electrode material is dispensed onto a second current collector.

8. The method according to claim 7, further comprising: The first electrode material, the first current collector, the second electrode material, the second current collector, and the separator are enclosed in a bag material.

9. The method according to claim 8, further comprising: conveying the encapsulated material as a web; as well as Portions of the web are sealed to form an electrochemical cell.

10. A method comprising: conveying a web around an outside surface of the drum, the web including anode material, cathode material, and separator material disposed therein; rotating a sealing device relative to the drum to align the sealing device with a sealing location on the web; moving a plurality of cylinders toward the outer side surface of the drum and into contact with the web such that the web is disposed between the cylinders and the drum; and Air is distributed from the sealing device to the plurality of cylinders to apply pressure to the web to form a plurality of individual electrochemical cells.

11. The method of claim 10, wherein the sealing device moves along a tracking path integrated into the structure housing the drum.

12. The method of claim 11, wherein a sealing device is moved between a top position in the tracking path and a bottom position in the tracking path via a cam in the drum.

13. The method of claim 10, wherein moving the plurality of cylinders toward the outer side surface of the drum is continued via axial movement of a guide plate in contact with the plurality of cylinders.

14. The method of claim 10, wherein rotating the sealing device relative to the drum is performed via movement of an arm connected to the sealing device and the drum.

15. The method of claim 14, wherein the arm comprises a first portion and a second portion, the first portion and the second portion having a common connection point and a variable angle between the first portion and the second portion of the arm.

16. The method of claim 15, wherein the first portion of the arm is coupled to the drum at a first connection point and the second portion of the arm is coupled to the sealing device at a second connection point.

17. A method according to claim 16, wherein a first imaginary line extends from the center axis of the drum to the first connection point, and a second imaginary line extends from the center axis of the drum to the second connection point, the first imaginary line and the second imaginary line form a first angle when the sealing device is in a top position of a tracking path integrated into a structure that accommodates the drum, and the first imaginary line and the second imaginary line form a second angle when the sealing device is in a bottom position of the tracking path, and the second angle is greater than the first angle.

18. A method comprising: advancing a web including an anode material, a cathode material, and a separator material disposed therein between a top conveyor and a bottom conveyor, the top conveyor and the bottom conveyor each including a plurality of vacuum chucks; aligning a vacuum chuck from the top conveyor with a vacuum chuck from the bottom conveyor; as well as Sections of the web are sealed via the vacuum chuck to form a plurality of electrochemical cells.

19. The method according to claim 18, further comprising: Rotational motion is induced in at least one of the top conveyor or the bottom conveyor via a servo motor.

20. The method of claim 18, further comprising: An x-direction position of at least one of the vacuum chucks is adjusted via a bearing.

21. The method of claim 18, further comprising: The z-direction position of at least one of the vacuum chucks is adjusted via a bearing.

22. The method of claim 21 wherein said adjusting prevents chordal action of said vacuum chuck from striking said web as said web advances between said top conveyor and said bottom conveyor.

23. The method of claim 18, wherein the web is a first web, the method further comprising: A second web is advanced between the top conveyor and the bottom conveyor.

24. The method of claim 23, further comprising: The relative positions of the first web and the second web are inspected via a vision system.

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