Intermittently coated dry electrode for energy storage device and method of manufacturing the same

Abstract

To provide: methods for manufacturing intermittently coated dry electrodes for energy storage devices; the intermittently coated dry electrodes; and energy storage devices including the intermittently coated dry electrodes.SOLUTION: A method for manufacturing dry electrodes for energy storage devices comprises: providing a metal layer; providing an electrochemically active free-standing film formed of a dry active material; combining the electrochemically active free-standing film and the metal layer to form a combined layer; and removing a portion of the electrochemically active free-standing film from the combined layer so that multiple film portions included in the electrochemically active free-standing film are spaced and intermittently formed on the metal layer in a longitudinal direction of the metal layer.SELECTED DRAWING: None

Description

[Technical field]

[0001] This application claims priority to the benefit of U.S. patent application Ser. No. 16 / 675,012, filed Nov. 5, 2019, and Provisional Application No. 62 / 757,609, filed in the U.S. Patent and Trademark Office on Nov. 8, 2018, the entire contents of which are incorporated herein by reference.

[0002] The described technology relates generally to energy storage devices, and more particularly to an intermittently coated dry electrode for an energy storage device and a method for manufacturing an energy storage device including the intermittently coated dry electrode. [Background technology]

[0003] 2. Description of Related Art Electrical energy storage cells are widely used to power electronic, electromechanical, electrochemical, and other useful devices, such as hybrid, plug-in hybrid, and pure electric vehicles. Such cells include batteries, such as primary chemical cells and secondary (rechargeable) cells, fuel cells, and various types of capacitors, including ultracapacitors. Increasing the operating power and energy of energy storage devices, such as capacitors and batteries, is desirable to enhance energy storage, increase power performance, and expand real-world use cases. Summary of the Invention

[0004] For purposes of summarizing the described technology, certain objects and advantages of the described technology are described herein. Not all such objects or advantages may be achieved in a particular embodiment of the described technology. Thus, for example, one of ordinary skill in the art will recognize that the described technology can be embodied or implemented in a manner that achieves or optimizes one advantage or advantages taught herein without necessarily achieving other objects or advantages as taught or suggested.

[0005] One aspect of the invention is an intermittently coated dry electrode for an energy storage device.

[0006] Another aspect is a method for making an intermittently coated dry electrode for an energy storage device.

[0007] Another aspect is an energy storage device comprising an intermittently coated dry electrode.

[0008] Another aspect is a method of making a dry electrode for an energy storage device, the method including: providing a metal layer; providing an electrochemically active free-standing film formed from dry active material; bonding the electrochemically active free-standing film and the metal layer to form a bonding layer; and removing a portion of the electrochemically active free-standing film from the bonding layer such that the electrochemically active free-standing film is intermittently formed in the metal layer in a longitudinal direction of the metal layer.

[0009] Another aspect is a dry electrode for an energy storage device comprising: a metal layer; and an electrochemically active free-standing film formed from dry active material, the electrochemically active free-standing film including a plurality of film portions intermittently formed in the metal layer in a longitudinal direction of the metal layer such that portions of the metal layer are exposed.

[0010] Another aspect is an energy storage device comprising: a first electrode; a second electrode; and a separator interposed between the first electrode and the second electrode, each of the first electrode and the second electrode including: a metal layer; and an electrochemically active free-standing film formed from a dry active material, the electrochemically active free-standing film including a plurality of film portions intermittently formed in the metal layer in a longitudinal direction thereof such that portions of the metal layer are exposed.

[0011] Another aspect is a method of making a dry electrode for an energy storage device, comprising: providing a metal layer; providing a first electrochemically active free-standing film formed from dry active material; providing a second electrochemically active free-standing film formed from dry active material; bonding the first and second electrochemically active free-standing films to the metal layer to form a bonding layer such that the metal layer is interposed between the first and second electrochemically active free-standing films; and removing a first portion of the first electrochemically active free-standing film and a second portion of the second electrochemically active free-standing film from the bonding layer such that each of the first and second electrochemically active free-standing films is intermittently formed in the metal layer in a longitudinal direction of the metal layer.

[0012] Any feature of an embodiment is applicable to all embodiments identified herein. Moreover, any feature of an embodiment can be independently, partially or entirely combined in any manner with other embodiments described herein, for example, one, two or more embodiments can be entirely or partially combined. Moreover, any feature of an embodiment can be optional with other embodiments. Any embodiment of the method for manufacturing an energy storage device or a dry electrode for an energy storage device can include other embodiments of the dry electrode for an energy storage device or the energy storage device. And any embodiment of the dry electrode for an energy storage device or the energy storage device can be configured to implement the method for manufacturing a dry electrode for an energy storage device or the energy storage device. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a block diagram illustrating a manufacturing process for a dry electrode for an energy storage device. [Diagram 2] FIG. 2 shows an electrochemically active free-standing film disposed on a metal foil that is continuously coated with an adhesive before heat and / or pressure is applied. [Diagram 3]FIG. 3 shows the electrochemically active free-standing film laminated to a metal foil continuously coated with adhesive after heat and pressure have been applied. [Figure 4] FIG. 4 shows an example of a continuous coated dry electrode. [Diagram 5] FIG. 5 shows an electrochemically active free-standing film disposed on a metal foil intermittently coated with adhesive before heat and pressure are applied. [Figure 6] FIG. 6 shows the electrochemically active free-standing film laminated to a metal foil intermittently coated with adhesive after heat and pressure have been applied. [Figure 7] FIG. 7 illustrates an example of an intermittently coated dry electrode, according to one embodiment. [Figure 8] FIG. 8 illustrates an electrochemically active free-standing film, according to one embodiment. [Figure 9] FIG. 9 illustrates an example of a metal foil that includes metal foil sections intermittently coated with adhesive and uncoated metal foil sections, according to one embodiment. [Figure 10] FIG. 10 illustrates an intermittently coated dry electrode according to another embodiment. [Figure 11] FIG. 11 shows an example of an electrochemically active free-standing film disposed on an uncoated metal foil, according to another embodiment. [Figure 12] FIG. 12 illustrates a laminator roll assembly according to one embodiment for producing an intermittently coated electrode laminate. [Figure 13] FIG. 13 illustrates an intermittently coated dry electrode produced by the laminator roll assembly of FIG. 12, according to one embodiment. [Figure 14] FIG. 14 illustrates an electrochemically active free-standing film disposed on an exemplary uncoated metal foil according to another embodiment. [Figure 15] FIG. 15 illustrates a laminator roll assembly according to another embodiment. [Figure 16]FIG. 16 illustrates an intermittently coated dry electrode produced by the laminator roll assembly of FIG. 15 according to another embodiment. [Figure 17] FIG. 17 illustrates a laminator roll assembly for producing the asymmetric intermittent double sided coated dry laminate of FIG. 18 according to another embodiment. [Figure 18] FIG. 18 is a cross-sectional view of an asymmetric intermittent double-sided coated dry laminate produced by the laminator roll assembly of FIG. 17 according to one embodiment. [Figure 19] FIG. 19 illustrates a laminator roll assembly for producing the asymmetric intermittent double sided coated dry laminate of FIG. 20 according to another embodiment. [Figure 20] FIG. 20 is a cross-sectional view of an asymmetric intermittent double-sided coated dry laminate produced by the laminator roll assembly of FIG. 19 according to another embodiment. [Figure 21] FIG. 21 illustrates an intermittent coating dry electrode connected to an electrode tab, according to one embodiment. [Figure 22] FIG. 22 illustrates an energy storage device according to one embodiment. [Figure 23] FIG. 23 illustrates a method of manufacturing a dry electrode for an energy storage device according to one embodiment. [Figure 24] FIG. 24 illustrates a method of manufacturing a dry electrode for an energy storage device according to another embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Provided herein are various embodiments of dry electrodes for use in energy storage devices. In particular, in certain embodiments, the energy storage devices disclosed herein include intermittently coated dry electrodes. For example, the described techniques may provide the ability to coat dry electrodes to include intermittent patterns for use in cylindrically wound cells with current collectors designed across the width of the electrode. Also provided are methods of manufacturing such intermittently coated dry electrodes. The disclosed embodiments may provide a simple, cost-effective electrode coating procedure for energy storage devices.

[0015] Energy storage devices such as lithium-ion batteries have been relied upon as the power source in many commercial and industrial applications, such as consumer devices, industrial devices, and battery-powered vehicles. However, the demand for energy storage devices is continually and rapidly expanding. For example, the automotive industry is developing vehicles that rely on compact and efficient energy storage, such as plug-in hybrid vehicles and pure electric vehicles. Lithium-ion batteries are well-suited to meet future demands.

[0016] The primary components of the storage capacity of an energy storage device are the electrodes. The electrochemical performance of the electrodes, e.g., the capacity and efficiency of a battery electrode, is governed by a variety of factors, such as the distribution of active materials, binders, and additives; the physical properties of the materials involved, such as particle size and surface area of ​​the active materials; the surface properties of the active materials; and the physical properties of the electrode film, such as density, porosity, cohesion, adhesion to conductive elements, etc. Traditionally, dry processing methods involve high shear and / or high pressure processing steps to break down and mix the electrode film materials, which may confer structural advantages over electrode films produced by wet processes.

[0017] FIG. 1 is a block diagram illustrating a process 10 for manufacturing a dry electrode for an energy storage device. As used herein, the term "dry" means that no liquid phase solvents or additives are used in the mixing and coating of the electrode in the processing steps described herein, other than the final electrolyte impregnation step. The process 10 shown in FIG. 1 begins with dry mixing 18 of dry active material particles 12, dry conductive particles 14, and dry binder particles 16 to form a dry mixture. Further, dry conductive particles 21 and dry binder particles 22 are mixed together to form a dry mixture. Dry blending 19 of the particles 23 is also performed to form a dry mix that can be provided to an optional dry fibrillation step 26 or 29. The dry mix is ​​fibrillated in dry fibrillation step 20, for example using a jet mill (not shown). During dry fibrillation step 20, high shear forces are applied to the dry mix to physically stretch it to form a thin web-like network of fibers. In dry feed steps 22 or 29, each separate mix of dry particles formed in steps 19 and 20 is fed to a respective container (not shown) to form a dry film. The dry film is then dry compressed and calendered by a roll mill or calender 24 to provide an embedded / blended dry film or a self-supporting electrode film (or an electrochemically active free-standing film). The embedded / blended dry film is attached or bonded to a current collector (e.g., metal foil) 28. A more detailed process for making the embedded / mixed dry film, including the types of materials that form the dry film and the materials that form the current collector, is disclosed in U.S. Pat. No. 7,352,558, which is incorporated herein by reference in its entirety.

[0018] The self-supporting dry electrode films produced may provide improved properties compared to typical electrode films produced by wet processes. For example, the dry electrode films provided herein may provide one or more of improved film strength, improved cohesion, improved adhesion, improved electrical performance, or reduced incidence of defects. The defects may include holes, cracks, surface pits in the electrode film. The adhesion may be adhesion to a current collector. The electrical performance may be specific capacitance. The film strength may be tensile strength.

[0019] The materials and methods provided herein can be implemented in a variety of energy storage devices. As provided herein, the energy storage device may be a capacitor, a lithium ion capacitor (LIC), an ultracapacitor, a battery such as a lithium ion battery, or a hybrid energy storage device that combines two or more of the above aspects.

[0020] 2-4 show a manufacturing process of an example of a dry electrode. This example of a dry electrode can be an anode or a cathode. Referring to FIG. 2, an electrochemically active free-standing film 34 is disposed on a metal foil 30. The electrochemically active free-standing film 34 may be formed from an electrochemically active material. The electrochemically active material can be an anode active material or a cathode active material. The anode active material can include, for example, graphite, silicon, tin, lithium titanate, lithium metal, lithium alloy compounds, or composites derived from these compositions. The cathode active material can include, for example, nickel manganese cobalt oxide (NMC), nickel cobalt aluminum oxide (NCA), lithium cobalt oxide (LCO), lithium iron phosphate (LFP), activated carbon, lithium manganese oxide (LMO), lithium nickel manganese oxide (LNMO), iron sulfide, sulfur, or composites derived from these compositions. The metal foil 30 can be formed from, for example, copper, aluminum, titanium, stainless steel, or combinations thereof. The description in this paragraph applies to the remaining embodiments.

[0021] The metal foil 30 includes a continuous adhesive coated metal foil portion 32 and an uncoated metal foil portion 36. The continuous adhesive coated metal foil portion 32 is continuously coated with adhesive along the length of the metal foil 30. An electrochemically active free-standing film 34 may be disposed on a majority of the adhesive coated metal foil portion 32. The active free-standing film 34 may also be disposed on a portion of the uncoated metal foil portion 36, as shown in FIG. 2. In some embodiments, the active free-standing film 34 may not be disposed on any portion of the uncoated metal foil portion 36 (not shown). After applying heat and / or pressure to the active free-standing film 34 and the adhesive coated metal foil portion 32, the active free-standing film 34 is laminated to the adhesive coated metal foil portion 32 (FIG. 3). The laminated film of FIG. 3 shows the areas of the electrochemically active free-standing film 42 that are not attached and the areas of the coated metal foil portion 32 that are not coated with the electrochemically active free-standing film 42. The adhesive coated metal foil portion 32 includes an area of ​​the film laminated to the active free-standing film 34 and an area of ​​the film laminated to the active free-standing film 34. The adhesive coated metal foil portion 32 that is not directly attached to the active free-standing film 34 may be removed, for example, by peeling or cutting. A continuous adhesive coated dry electrode 46 is then formed (FIG. 4). The dry electrode 46 of FIG. 4 includes an uncoated metal foil portion 48 that can be used to electrically connect the dry electrode 46 to other electrical components, such as an electrode tab, located within the final electrical device. The size or dimensions of the uncoated foil portion 48 generally constitute a significant portion of the final dry electrode 46. That is, the dimensions of the continuous adhesive coated dry electrode 46 may be limited by the dimensions of the uncoated portion 48.

[0022] 5-7 illustrate a process for manufacturing an example of an intermittently coated dry electrode, according to one embodiment. Referring to FIG. 5, an electrochemically active free-standing film 56 is disposed on a metal foil 58. The metal coil 58 is discontinuously or intermittently coated along its length with an adhesive or adhesive layer (not shown). The adhesive layer may be formed from one or more thermoplastic resins or adhesives, such as polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), acrylic, fluoropolymer, polyester, polyimide, polyamide, polyurethane, polycarbonate, carbon, or combinations thereof. The adhesive layer may be conductive (e.g., a carbon adhesive layer). The coating weight of the conductive adhesive layer is about 1 to about 5 g / m per side. 2 and the dry coating density is about 0.2 to about 1.1 g / cm per side. 2 The coating weight and density may be selected from the group consisting of 10 ...

[0023] After applying heat and / or pressure to the laminated layers (58, 56), the active free-standing film 56 is laminated to the adhesive coated metal foil portion 52 (FIG. 6). The laminated film in FIG. 6 includes an area 62 of unattached electrochemically active free-standing film and an area 64 of the film laminated to the coated metal foil. The area 62 of unattached electrochemically active free-standing film includes the top and center portions of the active free-standing film 56 shown in FIG. 6 (see the two arrows shown in the top region of FIG. 6). The area 64 of the film laminated to the coated metal foil includes the left and right portions of the active free-standing film 56 that vertically overlap the adhesive coated metal foil portion 52 (see the two arrows shown in the bottom region of FIG. 6).

[0024] After removing the portion 56 of the active free-standing film that vertically overlaps the uncoated metal foil portion 54, a discontinuously or intermittently coated dry electrode 72 is formed (FIG. 7). Peeling / cutting or removal of the unattached overlapping portion 62 of the free-standing film may be performed, for example, with an air knife and / or vacuum. Because the uncoated metal foil portion 54 is not coated with adhesive and is not adhered to the corresponding portion of the active free-standing film 56, the overlapping portion of the free-standing film can be more easily removed compared to the continuously adhesive coated electrodes shown in FIGS. 2-4. The dry electrode 72 includes two active free-standing film portions 64a and 64b that are discontinuously or intermittently formed with respect to each other. The dry electrode 72 includes the uncoated foil portion 54 that is used to electrically connect the electrode 72 to other elements such as an electrode tab. The uncoated foil portion 54 is used to electrically connect the electrode 72 to other elements such as an electrode tab. The dimensions of the coated foil portion 54 may be substantially smaller than the uncoated portion 48 of the continuously coated dry electrode 46 of FIG. 4. For example, the width of the uncoated foil portion 54 may be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20 mm, or any width within a range between any two of these values. In other embodiments, the width of the uncoated foil portion 54 may be 5-10, 10-20, 20-30, 30-40, or 40-50 mm or more. In this manner, the embodiments shown in FIGS. 5-7 may provide a simple and cost-effective manufacturing procedure for dry electrodes for energy storage devices.

[0025] 8-10 illustrate a process for manufacturing an exemplary dry electrode according to another embodiment. FIG. 8 illustrates an electrochemically active free-standing film 80. The active free-standing film 80 may be longer than the active free-standing film 34 illustrated in FIG. 2 and the active free-standing film 56 illustrated in FIG. 5. FIG. 9 illustrates a metal foil 90. The metal foil 90 is discontinuously or intermittently coated with adhesive in the longitudinal direction as illustrated in FIG. 9. The active free-standing film 80 may be comparable in dimensions to the metal foil 90. The metal coil 90 includes a coated portion 92 (or a metal foil portion intermittently coated with adhesive) and an uncoated portion 94 (or an uncoated metal foil portion). The coated portions 92 and the uncoated portions 94 are alternately formed as illustrated in FIG. The discontinuously coated metal foil portion 92 may be formed by intermittently coating the metal foil 90 with adhesive (as described above) by, for example, gravure roll coating, slot die coating, screen printing, or laser jet printing.

[0026] 9 and 10, x represents the width of each uncoated metal foil portion 94 measured along the length of the metal foil 90, and y represents the width of each coated metal foil portion 92 / 102 measured along the length. Although only three pairs of coated and uncoated portions 92 and 94 are shown in FIG. 9, many more pairs of coated and uncoated portions may be formed (not shown). These many more pairs may be formed in alternation. It should be understood that the ratio of x / y may be any value, with y typically being greater than x, such that the width of the coated portion is greater than that of the uncoated portion. In one embodiment, as discussed more fully below, the width y is related to the circumference of the final electrode windings such that the uncoated portions 94 are aligned with each other when the laminate film is wound into a rolled electrode format.

[0027] Similar to Figures 5 and 6, after the active free-standing film 80 is placed on the intermittently adhesive-coated metal foil portion 92 and the uncoated metal foil portion 94 of the metal foil 90, heat and / or pressure may be applied to the laminated layers (80, 90) so that the active free-standing film 80 is laminated to the adhesive-coated metal portion 92. Again, the active free-standing film 80 may not be adhered to or may only be very weakly adhered to the uncoated metal foil portion 94 where no adhesive is formed. Since three uncoated metal foil portions 94 are provided in Figure 9, the laminate film 100 in Figure 10 initially includes three portions (not shown) of the active free-standing film 80 that vertically overlap the three uncoated metal foil portions 94, respectively (before the three portions are removed). After removing the overlapped portions of the active free-standing film 80, a discontinuously or intermittently coated dry electrode 100 is formed (Figure 10). Peeling or removal of the overlapped portions of active free-standing film 80 may be accomplished in a manner similar to that discussed above in connection with the embodiment of FIGS.

[0028] The electrode 100 includes intermittent coated portions 102 and uncoated foil portions 94. At least one of the uncoated foil portions 94 may be used to electrically connect the electrode 100 to other elements, such as an electrode tab. The dimensions of each of the uncoated portions 94 may be substantially smaller than the uncoated portions 48 of the continuously coated dry electrode 46 of FIG. 4. In this manner, the embodiment illustrated in FIGS. 8-10 provides a simple, cost-effective, energy-efficient electrode. A manufacturing procedure for dry electrodes for gas storage devices can be provided.

[0029] 11-13 illustrate a process for making an example dry electrode according to another embodiment. FIG. 11 shows an electrochemically active free-standing film 110 and a metal foil 120 that is not coated with an adhesive. The active free-standing film 110 may have the same dimensions as the active free-standing film 80 shown in FIG. 8. The active free-standing film 110 is placed on and aligned with the uncoated metal foil 120 prior to the laminator roll procedure of FIG. 12. For purposes of illustrating both the active free-standing film 110 and the uncoated metal foil 120, FIG. 11 shows the two elements 110 and 120 as being slightly offset from one another, however, the elements 110 and 120 are aligned prior to the laminator roll procedure.

[0030] Referring to FIG. 12, the active free-standing film 110 and the uncoated metal foil 120 are inserted into a laminator roll assembly 130 and laminated. The laminator roll assembly 130 includes a pair of rollers 132 and 134. The rollers 132 and 134 may have substantially the same diameter. The rollers 132 and 134 may be formed of the same material or different materials having the same or similar levels of hardness such that a substantially uniform pressure is applied to the laminated layers (110, 120) by both rollers 132 and 134. The rollers 132 and 134 have openings 136 and 138, respectively. The openings 136 and 138 may have the same dimensions. In one embodiment, the openings 136 and 138 may have the same width or circumferential length (x) and the same depth. In other embodiments, the openings 136 and 138 may have the same width (x) but different depths. The width (x) of each of the openings 136 and 138 is the same as the width of each of the uncoated metal foil portions 144 shown in Figure 13. The length (y) of the remaining portions of the rollers 132 and 134 is the same as the width of each of the intermittently coated portions 142 shown in Figure 13.

[0031] Those skilled in the art will appreciate that each of the lamination rollers 132 and 134 may have different x and y dimensions depending on the required dimensions of the intermittently coated portion 142 and the uncoated metal foil portion 144. For example, the greater the width (x) of an uncoated metal foil portion, the greater the circumferential length of its opening. In contrast, the smaller the width (x) of each uncoated metal foil portion, the smaller the circumferential length of its opening. Once the x dimension is determined, the remaining dimensions (y) are automatically determined.

[0032] During the lamination procedure of Figure 12, rollers 132 and 134 are positioned adjacent to one another such that openings 136 and 138 are aligned with one another as shown in Figure 12. Upon inserting the laminated layers (110, 120) between rollers 132 and 134, the laminated layers (110, 120) are not pressed by rollers 132, 134 at openings 136 and 138, so that the two layers (110, 120) are laminated to one another except where they pass through openings 136 and 138. The unpressed portions of the active free-standing film 110 may be peeled off to form an intermittent coated dry electrode 140 as shown in Figure 13. The peeling procedure may be performed in the same manner as described with respect to the previous embodiment.

[0033] Although each of the rollers 132 and 134 in Figure 12 has an aperture, it is possible for only one of the rollers 132 and 134 to have an aperture. In this embodiment, only one of the two layers (110, 120) is in direct contact with the rollers 132 and 134 in the area of ​​the aperture during the lamination rolling procedure.

[0034] In another embodiment, each of the rollers 132 and 134 may include multiple openings (not shown). In this embodiment, each roller may have a larger size than the rollers 132 and 134 shown in FIG. 12. For example, each of the rollers 132, 134 may have two or more openings formed therein that are spaced apart from one another. The rollers may have the same size and number of openings. Additionally, the openings in each roller may be circumferentially aligned with one another during the lamination rolling procedure such that the same portion of the active free-standing film 110 forming the x regions is not pressed directly against either roller. The length of each opening may be the same as the width (x) of each of the uncoated metal foil portions 144. The distance between adjacent openings may be the same as the width (y) of each of the intermittently coated portions 142. In this embodiment, the lamination and peeling procedures may be more efficient.

[0035] The above dry electrode manufacturing procedure is applicable to single-sided, double-sided and offset-coated electrodes or asymmetric intermittent double-sided coated dry laminates (double-sided coated electrodes with different intermittent patterns on one side and the other, as described with reference to Figures 17-20). In double-sided coated electrodes, the intermittent pattern on one side may be symmetrical to that on the other side.

[0036] Figures 14-16 illustrate a process for manufacturing an example dry electrode according to another embodiment. In Figure 14, an electrochemically active free-standing film 150 and a metal foil 162 are shown that are not coated with an adhesive. The active free-standing film 150 can have the same dimensions as the active free-standing film 110 shown in Figure 11. Prior to performing the laminator roll procedure of Figure 15, the active free-standing film 150 is placed on and aligned with the uncoated metal foil 162.

[0037] 15, the active free-standing film 150 and the uncoated metal foil 162 are inserted into a laminator roll assembly 170 and laminated. The laminator roll assembly 170 includes a pair of rollers 175 and 177. The rollers 175 and 177 may have substantially the same diameter. The rollers 175 and 177 may be formed from the same material or different materials having similar levels of hardness such that a substantially uniform pressure is applied to the laminated layers (150, 162) by both rollers 175 and 177.

[0038] The relative positions (e.g., vertical positions) of the rollers 175 and 177 may be controlled so that the gap between them opens and closes periodically while the rollers 175 and 177 rotate. In FIG. 15, reference numerals 172 and 176 indicate a closed gap, and reference numeral 174 indicates an open gap. In one embodiment, the intermittent period of the intermittent coating dry electrode 180 shown in FIG. 16 is governed by the time of pressure applied to the two layers 150 and 162 that produces the dimension x and dimension y. In this embodiment, the dimension y where the free-standing film 150 adheres to the metal foil 162 occurs when the rollers 175 and 177 are closed (see 172 and 176 in FIG. 15). The length (y) or width of the intermittent coating portion 184 shown in FIG. 16 may be proportional to the time that the rollers 175 and 177 are closed (172, 176). For example, the longer the rollers 175 and 177 are closed, the longer the length y will be, and vice versa. Additionally, the dimension x where the free-standing film 150 is not attached (simply resting) on ​​the metal foil 162 occurs when the rollers 175 and 177 are open (see 174 in FIG. 15). The length (x) between adjacent intermittent coating portions 184 may be proportional to the time that the rollers 175 and 177 are open (174). For example, the longer the time that the rollers 175 and 177 are open (174), the greater the length x will be, and vice versa. In one embodiment, both rollers 175 and 177 are moved to open and close the gap between them. In another embodiment, only one of the rollers 175 and 177 is moved to open and close the gap between them.

[0039] When the gap between rollers 175 and 177 is closed (172, 176), the stacked layers (150 and 162) are pressed by rollers 175 and 177 and laminated together. When the gap between rollers 175 and 177 is open (174), the stacked layers (150 and 162) are not pressed by rollers 175 and 177 and therefore are not laminated together (i.e., simply overlapped). The pressed active free-standing film 150 The uncoated portions are then removed to form an intermittently coated dry electrode 180, as shown in Figure 16. The removal procedure can be carried out in a similar manner as described with respect to the previous embodiment. In this manner, the lamination and removal procedures can be carried out more efficiently.

[0040] The dry electrode fabrication procedure described above can be applied to single-sided coated electrodes, double-sided coated electrodes, and offset coated electrodes or asymmetric intermittent double-sided coated dry laminates (double-sided coated electrodes with different intermittent patterns on one side and the other, as illustrated in Figures 17-20).

[0041] 17 and 18 illustrate a process for producing an asymmetric intermittent double-sided coated dry laminate 300 using a laminator roll assembly 320, according to one embodiment. FIG. 17 illustrates a laminator roll assembly 320 for producing the asymmetric intermittent double-sided coated dry laminate 300 shown in FIG. 18, according to one embodiment. FIG. 18 illustrates a cross-sectional view of the asymmetric intermittent double-sided coated dry laminate 300 produced by the laminator roll assembly 320 shown in FIG. 17, according to one embodiment. As described above with respect to FIGS. 14-16 and as shown in FIG. 18, the asymmetric intermittent double-sided coated dry laminate 300 (or offset coated dry electrode) is a double-sided electrode where one side has a different intermittent pattern than the other side.

[0042] 17, the laminator roll assembly 320 includes upper and lower laminator rollers 307 and 309. The roll assembly 320 receives a first film roll 304, a second film roll 306, and a roll of adhesive metal foil 305. The first film roll 304 represents a roll of electrochemically active free-standing film for the first intermittent dried laminate 301 shown in FIG. 18. The second film roll 306 represents a roll of electrochemically active free-standing film for the second intermittent dried laminate 302 shown in FIG. 18. The adhesive metal foil roll 305 represents a roll of asymmetric intermittent coated adhesive metal foil 303 shown in FIG. 18. When the adhesive metal foil roll 305 is inserted into the roll assembly 320, it is inserted between the first and second film rolls 304 and 306. The first film roll 304, metal foil roll 305, and second film roll 306 may be unwound simultaneously as the film and metal layers are inserted between and pressed by upper and lower rollers 307 and 309. As shown in FIG. 15, the upper roller 307 is controlled to periodically press the first film roll 304 against the adhesive metal foil 305 to produce a first intermittent dry laminate 301. For example, the first film roll 304 is pressed for a length "a" and not pressed for a length "b" shown in FIG. 18. Additionally, the lower roller 309 is controlled to periodically press the first second film roll 306 against the adhesive metal foil 305 to produce a second intermittent dry laminate 302. For example, the second film roll 306 is pressed for a length "c" and not pressed for a length "d" shown in FIG. 18. The non-pressed areas can be removed from the laminate layer 308 in the same manner as described above to produce the asymmetric intermittent double-sided coated dry laminate 300 shown in Figure 18. The removed portions can at least partially vertically overlap one another. As shown in Figure 18, the film portions of the first intermittent dried laminate 301 can at least partially vertically overlap the film portions of the second intermittent dried laminate 302.

[0043] 18, the first intermittently dried laminate 301 and the second intermittently dried laminate 302 are asymmetric with respect to each other. For example, the length a of each laminated portion of the first intermittently dried laminate 301 is different from the length c of each laminated portion of the second intermittently dried laminate 302. Furthermore, the length b of the exposed portion of the upper surface of the metal foil 303 is different from the length d of the exposed portion of the lower surface of the metal foil 303. In some embodiments, the length b is less than the distance d as shown in FIG. 18. In other embodiments, the length b is greater than the length d (not shown). Furthermore, in some embodiments, the length c is greater than the distance d as shown in FIG. Thus, length c is shorter than length a. In other embodiments, length c is longer than length a (not shown).

[0044] 17 and 18 show a process for producing an asymmetric intermittent double-sided coated dry laminate, a symmetric intermittent double-sided coated dry laminate can also be produced in a similar manner, except that the press interval or time is the same for the upper and lower laminator rollers 307 and 309. Additionally, Figures 17 and 18 show only one example of a process for producing an asymmetric intermittent double-sided coated dry laminate, and other roller assembly configurations and / or other arrangements of film rolls and metal foil rolls are possible.

[0045] 19 and 20 show a process for producing an asymmetric intermittent double-sided coated dry laminate 310 using a laminator roll assembly 340 according to another embodiment. FIG. 19 shows a laminator roll assembly 340 for producing an asymmetric intermittent double-sided coated dry laminate 310 shown in FIG. 20 according to another embodiment. FIG. 20 shows a cross-sectional view of an asymmetric intermittent double-sided coated dry laminate 310 produced by the laminator roll assembly 340 shown in FIG. 19 according to another embodiment. Referring to FIG. 19, the laminator roll assembly 340 includes a first laminator roll assembly 350 and a second laminator roll assembly 360. The first laminator roll assembly 350 includes a first pair of laminator rollers 317 and 321, and the second laminator roll assembly 360 includes a second pair of laminator rollers 323 and 318. Roller 317 has an opening 352 with a width or circumferential length (b). Roller 318 has an opening 354 with a width or circumferential length (d) different than circumferential length (b).

[0046] The first roll assembly 350 receives a first film roll 314 and an uncoated metal foil roll 315. The first film roll 314 represents a roll of electrochemically active free-standing film for the first intermittent dry laminate 311 shown in FIG. 20. The second roll assembly 360 receives the first film roll 314, the uncoated metal foil roll 315 and the second film roll 316. The second film roll 316 represents a roll of electrochemically active free-standing film for the second intermittent dry laminate 312 shown in FIG. 20. The uncoated metal foil roll 315 represents a roll of asymmetric intermittently coated adhesive metal foil 313 shown in FIG. 20. When the uncoated metal foil roll 315 is inserted into the second roll assembly 360, it is inserted between the first and second film rolls 314 and 316. In other embodiments, the second film roll 316 and the uncoated metal foil roll 315 are inserted into the first roll assembly 350 while the first film roll 314 (with the second film roll 316 and the uncoated metal foil roll 315) is inserted into the second roll assembly 360. In these embodiments, roller 321 has an opening of length d and roller 323 has an opening of circumferential length b. The first film roll 314 and the metal foil roll 315 may be unwound before the second film roll 316 is unwound.

[0047] Similar to the process shown in Figure 17, a first film roll 314 and an uncoated metal foil roll 315 are inserted between rollers 317 and 321 to produce a first laminate layer 330 as they exit a first roll assembly 350, and then the first laminate layer 330 and a second film roll 316 are inserted between rollers 323 and 318 to produce a second laminate layer 319 as they exit a second roll assembly 360. The three layers 314, 315 and 316 are laminated together except for the portions that pass through openings 352 and 354. The unpressed portions are removed from the second laminate layer 319 to form an asymmetric intermittent double-sided coated dry laminate 310 as shown in Figure 20.

[0048] 19 and 20 show a process for producing an asymmetric intermittent double-sided coated dry laminate. 19 and 20 show only one example of a process for producing an asymmetric intermittent double sided coated dry laminate, other roller assembly configurations and / or other film and metal foil roll arrangements are possible.

[0049] FIG. 21 illustrates an intermittently coated dry electrode 198 connected to an electrode tab, according to one embodiment. The intermittently coated dry electrode 198 includes laminate sections 192 and 194, in which an electrochemically active free-standing film is laminated to a metal foil. The intermittently coated dry electrode 198 further includes an uncoated metal foil section 196, as described above. The uncoated metal foil section 196 is used to connect the dry electrode 198 to an electrode tab (see FIG. 21) or other electrical components for connecting to an external device (not shown). Although FIG. 21 illustrates a single uncoated metal foil section 196, the electrode tab or other electrical components can be connected to one or more of the multiple uncoated metal foil sections, for example, as shown in FIGS. 10, 13, and 16.

[0050] FIG. 22 illustrates an energy storage device 200 according to an embodiment. The energy storage device 200 may be a battery, a capacitor, or a hybrid type combining a battery and a capacitor. The battery may include a liquid electrolyte battery, a polymer electrolyte battery, or a solid-state battery. The polymer electrolyte may include a solid polymer electrolyte and a plasticized gel polymer electrolyte. The liquid electrolyte battery may include a lithium ion battery. The polymer electrolyte battery may include a lithium polymer battery. The battery may have a cylindrical, prismatic, or a pouch shape.

[0051] The energy storage device 200 includes an electrode assembly 210. The electrode assembly 210 includes a first electrode 220, a second electrode 240, and a separator 230 disposed between the first electrode 220 and the second electrode 240. The separator 230 is configured to allow ionic communication between the two electrodes 220 and 240 while electrically insulating the first and second electrodes 220 and 240.

[0052] The first electrode 220 may be an anode ("negative electrode") and the second electrode 240 may be a cathode ("positive electrode"). Each of the anode and cathode electrodes 220 and 240 may be intermittently coated dry electrodes manufactured by one of the procedures described above in Figures 5-19. The first and second electrodes 220 and 240 each include an uncoated metal foil portion 222 and 242, respectively, connected to an electrode tab 224 and 244, respectively, or other electrical component (not shown).

[0053] The energy storage devices provided herein may be in any suitable configuration, for example, planar, spirally wound, button-shaped, or pouch. The energy storage devices provided herein may be components of systems, such as, for example, power generation systems, uninterruptible power supply systems (UPS), solar power systems, energy recovery systems, for example, used in industrial machinery and / or transportation. The energy storage devices provided herein may be used to power various electronic devices and / or automobiles, including hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), and / or electric vehicles (EVs).

[0054] 23 illustrates a flowchart 2300 of a method of manufacturing a dry electrode for an energy storage device, according to one embodiment. Although the process flow diagram 2300 is described in a particular order, in various embodiments, steps may be performed in a different order or omitted, or additional steps may be added. This is true for the flowchart 2400 illustrated in FIG.

[0055] In step 2310, a metal layer is provided. For example, the metal layer can include metal foils (58, 90, 120, 162) as shown in Figures 5, 9, 11, and 14, respectively. In step 2320, an electrochemically active free-standing film formed from the dry active material is provided. For example, the electrochemically active free-standing film can be the electrochemically active dry-films (56, 80, 110, 150) as shown in Figures 5, 8, 11, and 14, respectively. In step 2330, the electrochemically active free-standing film and the metal layer are bonded to form a bonded layer. For example, the metal layer can be coated with an adhesive, the electrochemically active free-standing film placed on the metal layer, and heat and / or pressure applied to the film and metal layer to bond the two elements as described in Figures 6 and 9. As another example, the electrochemically active free-standing film can be placed on the metal layer and inserted between a pair of opposing rollers and pressed by the rollers as described in Figures 12 and 15.

[0056] In step 2340, a portion of the electrochemically active free-standing film is removed from the bonding layer. For example, as shown in Figures 7, 10, 13, and 16, the portion of the electrochemically active free-standing film that is not attached with adhesive or pressed by a roller may be removed from the metal layer portion of the bonding layer by peeling or cutting. In step 2350, an electrochemically active free-standing film is intermittently formed on the metal layer in the longitudinal direction of the metal layer, as shown in Figures 7, 10, 13, and 16. As mentioned above, the electrochemically active free-standing film may be formed on only one side or the opposite side of the metal layer.

[0057] FIG. 24 shows a flowchart 2400 of a method of manufacturing a dry electrode for an energy storage device, according to another embodiment. In step 2410, a metal layer is provided. For example, the metal layer may comprise a roll of metal foil (305, 315) as shown in FIGs. 17 and 19. In step 2420, a first electrochemically active free-standing film formed from dry active material is provided. For example, the first electrochemically active free-standing film may comprise a roll of first film (304, 314) as shown in FIGs. 17 and 19.

[0058] In step 2430, a second electrochemically active free-standing film formed from the dry active material is provided. For example, the second electrochemically active free-standing film can include a roll of the second film roll (306, 316) shown in Figures 17 and 19. In step 2440, the first and second electrochemically active free-standing films are bonded with a metal layer to form a bond layer such that the metal layer is interposed between the first and second electrochemically active free-standing films. For example, the rolls of the first and second electrochemically active free-standing films, with the interposed metal layer therebetween, are pressed by a set of opposing rollers (e.g., one pair of rollers or two pairs of rollers) as shown in Figures 17 and 19.

[0059] In step 2450, a first portion of the first electrochemically active free-standing film and a second portion of the first electrochemically active free-standing film are removed from the bonding layer, as illustrated in Figures 18 and 20. In step 2460, an intermittent electrochemically active free-standing film is formed on an opposing surface of the metal layer, for example, as shown in Figures 18 and 21.

[0060] As used herein, the terms "battery" and "capacitor" should be given their ordinary and customary meaning to those of ordinary skill in the art. The terms "battery" and "capacitor" are not mutually exclusive. A capacitor or battery may refer to a single electrochemical cell operated alone or as a component of a multi-cell system.

[0061] It should be understood that features, materials, characteristics, or groups described in connection with a particular aspect, embodiment, or example are applicable to other aspects, embodiments, or examples described in this section or elsewhere herein, except to the extent they are incompatible. All features disclosed in this specification (including the accompanying claims, abstract, and drawings), and / or all steps of any method or process so disclosed, may be combined with any combination of at least some of such features and / or steps. The invention may be combined in any combination, except where at least some of the combinations are mutually exclusive. Protection is not limited to the details of the above embodiments. Protection extends to any novel or novel combination of features disclosed in this specification (including the accompanying claims, abstract and drawings), or any novel or novel combination of steps of any method or process disclosed.

[0062] Moreover, certain features that are described in this disclosure in the context of separate implementations may also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation may also be implemented in multiple implementations separately or in any suitable subcombination. Further, while features may be described above as functioning in a particular combination, one or more features from a claimed combination may, in some cases, be deleted from that combination and the combination may be claimed as a subcombination or a variation of the subcombination.

[0063] Furthermore, although operations may be illustrated or described in a particular order, such operations need not be performed in the particular order shown or sequential order, and not all operations need to be performed, to achieve desirable results. Other operations not illustrated or described may be incorporated into the exemplary methods and processes. For example, one or more additional operations may be performed before, after, simultaneously with, or during any of the described operations. Furthermore, in other implementations, operations may be rearranged or resequenced. Those skilled in the art will appreciate that in some embodiments, the actual steps performed in the illustrated and / or disclosed processes may differ from those illustrated. Depending on the embodiment, some of the steps may be eliminated and other steps may be added. Furthermore, the nature and attributes of certain disclosed embodiments may be combined in different ways to form additional embodiments, all of which are within the scope of the present disclosure. Also, the separation of various system components in the above implementations should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems may generally be integrated together in a single product or packaged in multiple products. For example, any of the energy storage system components described herein may be provided separately or integrated together (e.g., packaged together or mounted together) to form an energy storage system.

[0064] For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages are achieved in accordance with a particular embodiment. Thus, for example, one skilled in the art will recognize that the present disclosure can be embodied or performed in a way that achieves one advantage or group of advantages taught herein without necessarily achieving other advantages taught or suggested herein.

[0065] Conditional language such as "can," "may," "might," or "could," unless otherwise specified or understood otherwise within the context in which it is used, generally contemplates that certain embodiments include certain features, elements, and / or steps, while other embodiments do not include them. Thus, such conditional language generally does not imply that the features, elements, and / or steps are in any way required by one or more embodiments, or that one or more embodiments necessarily include decision logic, with or without user input or prompting, as to whether those features, elements, and / or steps are included or performed in a particular embodiment.

[0066] Conjunctions such as "at least one of X, Y, and Z" should be understood in the context in which they are generally used to mean that an item, term, etc. can be either X, Y, or Z, unless otherwise specified. Thus, such conjunctions should be understood to mean that a particular embodiment is at least one of X, Y, or Z. The term does not generally mean to require the presence of at least one of, at least one of Y, and at least one of Z.

[0067] As used herein, terms of degree, such as "approximately," "about," "generally," and "substantially," refer to a value, amount, or characteristic that performs a desired function or achieves a desired result, approaching a recited value, amount, or characteristic.

[0068] The scope of the present disclosure is not intended to be limited by the specific disclosure of embodiments in this section or elsewhere herein, but may be defined by the claims presented in this section or elsewhere herein or presented in the future. The language of the claims should be interpreted broadly based on the language employed in the claims, and not limited to the examples described herein or during the prosecution of the application, and the examples should be interpreted as non-exclusive.

[0069] Although specific embodiments have been described, these embodiments are presented by way of example only and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions, and modifications may be made in the systems and methods described herein without departing from the spirit of the disclosure. The appended claims and their equivalents are intended to cover such forms or modifications as fall within the scope and spirit of the disclosure. Thus, the scope of the present invention is defined solely by reference to the appended claims.

Claims

1. 1. A method for manufacturing a dry electrode for an energy storage device, comprising: Providing a metal layer; providing an electrochemically active free-standing film formed of dry active material; bonding the electrochemically active free-standing film and the metal layer to form a bonding layer; and Removing a portion of the electrochemically active free-standing film from the tie layer such that the electrochemically active free-standing film is intermittently formed on the metal layer in a longitudinal direction of the metal layer.

2. 10. The method of claim 1 , removing a portion of the electrochemically active free-standing film to expose a portion of the metal layer disposed thereunder.

3. The method according to claim 1 or 2, The method, wherein the portion of the electrochemically active free-standing film that is removed extends in a direction transverse to the longitudinal direction.

4. The method according to any one of claims 1 to 3, The metal layer includes at least one coated portion coated with an adhesive and at least one non-coated portion not coated with an adhesive so that the metal layer is intermittently coated with the adhesive; The method of claim 1, wherein the adhesive is disposed on a surface of the metal layer that faces the electrochemically active free-standing film such that the adhesive adheres to the electrochemically active free-standing film.

5. 5. The method of claim 4, The method wherein the intermittently coated metal layer is formed by gravure roll coating or slot die coating.

6. The method according to any one of claims 1 to 5, The method, wherein said bonding comprises laminating said electrochemically active free-standing film to said metal layer.

7. 7. The method of claim 6, The method, wherein the laminating comprises applying heat and / or pressure to at least one of the electrochemically active free-standing film and the metal layer.

8. 5. The method of claim 4, The method, wherein the portion of the electrochemically active free-standing film that is removed vertically overlaps the uncoated portion of the metal layer.

9. 5. The method of claim 4, The adhesive comprises a conductive adhesive layer having a coating weight of about 1 to about 5 g / m2 per side. ２ and the dry coating density is about 0.2 to about 1.1 g / cm per side. ２ That is, the method.

10. The method according to any one of claims 1 to 9, The method, wherein the removing comprises peeling the portion of the electrochemically active free-standing film with an air knife and / or a vacuum.

11. The method according to any one of claims 1 to 10, The method wherein the metal layer is not entirely coated with an adhesive.

12. 12. The method of claim 11, The method, wherein the bonding comprises intermittently pressing the electrochemically active free-standing film and the metal layer against one another with a laminator roll assembly.

13. 13. The method of claim 12, The laminator roll assembly comprises a pair of rollers, at least one of which has an opening of a predetermined length.

14. 14. The method of claim 13, The method, wherein the predetermined length of each opening is the same as a width of the portion of the electrochemically active free-standing film that is removed, the width being measured in the longitudinal direction.

15. 14. The method of claim 13, The method, wherein the bonding includes aligning at least one of the openings in the roller with the portion of the electrochemically active free-standing film to be removed such that the portion of the electrochemically active free-standing film is not pressed by the roller during rotation of the roller.

16. 13. The method of claim 12, The laminator roll assembly includes a pair of rollers adjacent to each other, The method, wherein the coupling includes moving at least one of the rollers relative to one another such that a gap between two of the rollers periodically opens and closes during rotation of the rollers.

17. 17. The method of claim 16, A method wherein the time the gap is open is controlled to be proportional to a width of the portion of the electrochemically active free-standing film that is removed, the width being measured in the longitudinal direction.

18. The method according to any one of claims 1 to 17, The method of claim 1, wherein the electrochemically active free-standing film comprises sulfur.

19. The method according to any one of claims 1 to 18, The method of claim 1, wherein the electrochemically active free-standing film is formed on only one side of the metal layer.

20. The method according to any one of claims 1 to 19, The method, wherein the electrochemically active free-standing film comprises first and second electrochemically active free-standing films formed respectively on opposing surfaces of the metal layer.

21. 21. The method of claim 20, The method, wherein the intermittent patterns of the first and second electrochemically active free-standing films are symmetrical to each other on opposite surfaces of the metal layer.

22. 21. The method of claim 20, The method, wherein the intermittent patterns of the first and second electrochemically active free-standing films are asymmetric with respect to one another on opposite surfaces of the metal layer.

23. 1. A dry electrode for an energy storage device, comprising: A metal layer; and 1. An electrochemically active free-standing film formed from a dry active material, the electrochemically active free-standing film including a plurality of film portions intermittently formed in the metal layer in a longitudinal direction of the metal layer so as to expose a portion of the metal layer. A dry electrode comprising:

24. 24. The dry electrode of claim 23, A dry electrode, wherein the exposed portion of the metal layer is not coated with adhesive and extends in a direction transverse to the longitudinal direction.

25. 25. The dry electrode of claim 24, the adhesive comprises a conductive adhesive layer; The coating weight of the conductive adhesive layer is from about 1 to about 5 g / m per side. ２ and the dry coating density is about 0.2 to about 1.1 g / cm per side. ２ That is, dry electrodes.

26. The dry electrode according to any one of claims 23 to 25, The electrochemically active free-standing film comprises sulfur.

27. The dry electrode according to any one of claims 23 to 26, A dry electrode, wherein the metal layer includes opposed first and second surfaces, and the electrochemically active free-standing film is disposed on at least one of the first and second surfaces of the metal layer.

28. 28. The dry electrode of claim 27, A dry electrode, wherein the film portions are equally spaced from one another.

29. A dry electrode according to any one of claims 23 to 28, the metal layer includes opposed first and second surfaces; The dry electrode, wherein the electrochemically active free-standing film comprises first and second electrochemically active free-standing films disposed on the first and second surfaces, respectively, of the metal layer.

30. 30. The dry electrode of claim 29, the first electrochemically active free-standing film includes a plurality of first film portions spaced a first distance apart; The second electrochemically active free-standing film includes a plurality of second film portions spaced apart a second distance different from the first distance.

31. 1. An energy storage device comprising: first electrode; A second electrode; and A separator interposed between the first electrode and the second electrode. Equipped with Each of the first electrode and the second electrode is A metal layer; and 1. An electrochemically active free-standing film formed from a dry active material, the electrochemically active free-standing film including a plurality of film portions intermittently formed in the metal layer in a longitudinal direction of the metal layer such that a portion of the metal layer is exposed. An energy storage device comprising:

32. 32. The energy storage device of claim 31 , The energy storage device further comprising an electrode tab attached to the exposed portion of the metal layer.

33. The energy storage device according to any one of claims 31 to 32, The energy storage device may include a battery, a capacitor, or a combination thereof.

34. 34. The energy storage device of claim 33, The battery is an energy storage device including a lithium ion battery for use in a hybrid vehicle, a plug-in hybrid vehicle, or a pure electric vehicle.

35. The energy storage device according to any one of claims 31 to 34, The electrochemically active free-standing film comprises sulfur.

36. 1. A method for manufacturing a dry electrode for an energy storage device, comprising: Providing a metal layer having opposed first and second surfaces; providing a first electrochemically active free-standing film formed from dry active material; providing a second electrochemically active free-standing film formed from dry active material; bonding the first and second electrochemically active free-standing films with the metal layer such that the metal layer is interposed between the first and second electrochemically active free-standing films to form a bonding layer; and removing a first portion of the first electrochemically active free-standing film and a second portion of the second electrochemically active free-standing film from the tie layer such that the first and second electrochemically active free-standing films are intermittently formed on the first and second surfaces of the metal layer, respectively, in a longitudinal direction of the metal layer. A method comprising:

37. 37. The method of claim 36, The method, wherein the first and second portions of the first and second electrochemically active free-standing films have the same length.

38. 38. The method of claim 36 or 37, The method, wherein the first and second portions of the first and second electrochemically active free-standing films have different lengths.

39. The method according to any one of claims 36 to 38, the first portion of the first electrochemically active free-standing film includes a plurality of first film portions having the same length; the second portion of the second electrochemically active free-standing film includes a plurality of second film portions having the same length and facing the plurality of first film portions, respectively; each of the plurality of first film portions has a first length; Each of the plurality of second film portions has a second length different from the first length.

40. 40. The method of claim 39, A method wherein each of the plurality of first film sections vertically overlaps, at least in part, a corresponding one of the plurality of second film sections.

41. 37. The method of claim 36, 11. A method, comprising: a laminator roll assembly having first and second rollers adjacent to one another, the laminator roll assembly including: inserting the first and second electrochemically active free-standing films and inserting the metal layer between the first and second rollers such that the first roller faces the first electrochemically active free-standing film and the second roller faces the second electrochemically active free-standing film; moving the first and second rollers relative to one another such that a gap between the first roller and the first electrochemically active free-standing film is periodically opened and closed for a first time and a gap between the second roller and the second electrochemically active free-standing film is periodically opened and closed for a second time, wherein the first and second times are different from one another; and laminating said first and second electrochemically active free-standing films to said metal layer with said first and second rollers to create said bond layer.

42. 42. The method of claim 41, each of the first and second electrochemically active free-standing films is formed from a roll of electrochemically active free-standing film; the metal layer is formed from a roll of metal foil; The rolls of the first and second electrochemically active free-standing films and the roll of metal foil are unwound simultaneously as the active free-standing films and the metal layer are inserted between and pressed by the first and second rollers.

43. 37. The method of claim 36, the combining is performed with a laminator roll assembly including a pair of first and second rollers and a pair of spaced apart third and fourth rollers; The method of claim 1, wherein the binding comprises: inserting the first electrochemically active free-standing film and the metal layer into the set of first and second rollers, where the first roller has a first opening and the second roller does not have an opening; laminating the first electrochemically active free-standing film to the metal layer with the pair of first and second rollers to produce a laminate layer; inserting the laminate layer and the second electrochemically active free-standing film between the set of third and fourth rollers such that the third roller faces the first electrochemically active free-standing film of the laminate layer and the fourth roller faces the second electrochemically active free-standing film, where the fourth roller has a second opening and the third roller has no opening, the first and second openings having different circumferential lengths and facing opposite sides of the metal layer; and laminating said second electrochemically active free-standing film to said metal layer of said laminate layer using said set of third and fourth rollers to create said bond layer.

44. 42. The method of claim 41, wherein each of the first and second electrochemically active free-standing films is formed from a roll of electrochemically active free-standing film and the metal layer is formed from a roll of metal foil, and the roll of the first electrochemically active free-standing film and the roll of metal foil are unwound before the roll of the second electrochemically active free-standing film is unwound.

45. 37. The method of claim 36, The method of claim 1, wherein the second electrochemically active free-standing film comprises sulfur.

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