Method and apparatus for manufacturing electrodes for energy storage devices

Abstract

To provide apparatuses and methods for forming an energy storage device electrode film mixture.SOLUTION: An apparatus for forming an electrode film mixture can have a first source, a second source, and a fluidized bed coating apparatus. The first source includes a polymer dispersion. The polymer dispersion includes a liquid and a polymer. The second source includes a second component of the electrode film mixture. The fluidized bed coating apparatus includes a first inlet configured to receive the dispersion from the first source, and a second inlet configured to receive the second component from the second source.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] [Description of Related Applications] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 382,675, filed Sep. 1, 2016, the entire contents of which are hereby incorporated by reference herein.

[0002] The present invention relates to energy storage devices, and more particularly to an apparatus and method for manufacturing electrodes for energy storage devices. [Background technology]

[0003] A variety of energy storage devices can be used to power electronic devices, such as capacitors, batteries, hybrid capacitor-battery, and fuel cells. Such energy storage devices can have an anode and a cathode that include one or more electrode films. The electrode film can include a polymer binder and one or more active electrode components. The electrical performance of the energy storage device can depend on one or more properties of the binder and the active electrode components. The desired electrical performance of the energy storage device can be obtained by selecting the type of binder, the type of active electrode components, and / or the process used to manufacture the electrode film. Summary of the Invention [Problem to be solved by the invention]

[0004] However, energy storage devices can be costly to manufacture. In particular, custom electrode manufacturing can require substantial resources. One challenge is removing solvents and other processing additives from the electrode film after manufacturing. In wet electrode manufacturing, solvent removal requires significant power and time, which can monopolize valuable manufacturing resources. Improved manufacturing techniques can result in higher performance electrodes, for example, by dispersing active binder materials more uniformly. While conventional dry electrode manufacturing techniques avoid some of these challenges, they entail the occurrence of others, which are further described herein. Thus, improved electrode manufacturing techniques are needed. [Means for solving the problem]

[0005] Some embodiments provide an apparatus for forming an electrode membrane mixture for an energy storage device. The apparatus includes a first source including a polymer dispersion. The polymer dispersion includes a liquid and a polymer. The polymer is a first component of the electrode membrane mixture for the energy storage device. The apparatus further includes a second source. The second source includes a second component of the electrode membrane mixture for the energy storage device. The apparatus further includes a fluidized bed coating apparatus. The fluidized bed coating apparatus includes a first inlet configured to receive the polymer dispersion from the first source and a second inlet configured to receive the second component of the electrode membrane mixture from the second source.

[0006] A further embodiment provides a method for preparing an electrode membrane mixture for an energy storage device. The method includes providing a polymer dispersion to a first inlet of a fluidized bed coating apparatus. The polymer dispersion includes a liquid and a polymer. The polymer is a first component of the electrode membrane mixture for the energy storage device. The method further includes providing a second component of the electrode membrane mixture for the energy storage device in the fluidized bed coating apparatus. The method further includes evaporating a liquid portion of the polymer dispersion in the fluidized bed coating apparatus to form a dry polymer. The method further includes forming a fluidized bed in the fluidized bed coating apparatus that includes the second component of the electrode membrane mixture.

[0007] In a first aspect, an apparatus for forming an electrode membrane mixture for an energy storage device is provided. The apparatus includes a first source, a second source, and a fluidized bed coating apparatus. The first source includes a polymer dispersion. The polymer dispersion includes a liquid and a polymer. The polymer is a first component of the electrode membrane mixture for the energy storage device. The second source includes a second component of the electrode membrane mixture for the energy storage device. The fluidized bed coating apparatus includes a first inlet configured to receive the polymer dispersion from the first source and a second inlet configured to receive the second component from the second source to form the electrode membrane mixture.

[0008] In some embodiments of the first aspect, the apparatus is configured to evaporate the liquid of the dispersion to form a dry polymer and to form a fluidized bed of the second component and cover the second component with the dry polymer.

[0009] In some embodiments of the first aspect, the second component comprises dry particles and the fluidized bed coating apparatus is configured to form a fluidized bed from the dry particles.

[0010] In some embodiments according to the first aspect, the second component comprises an active electrode component of the electrode membrane mixture.

[0011] In some embodiments according to the first aspect, the second component comprises a lithium metal oxide.

[0012] In some embodiments according to the first aspect, the second component comprises carbon.

[0013] In some embodiments according to the first aspect, the second component comprises graphite.

[0014] In some embodiments according to the first aspect, the polymer comprises polytetrafluoroethylene.

[0015] In some embodiments according to the first aspect, the liquid comprises water.

[0016] In some embodiments of the first aspect, the second component comprises dry particles, and the fluidized bed coating apparatus is configured to receive the dry particles via the second inlet and form a fluidized bed from the dry particles.

[0017] In some embodiments according to the first aspect, the fluidized bed coating apparatus is configured to evaporate water and provide a dry polytetrafluoroethylene coating on the dry particles.

[0018] In some embodiments of the first aspect, the fluidized bed coating apparatus is configured to provide a continuous amount of gas to form a fluidized bed with the second component.

[0019] In some embodiments of the first aspect, the apparatus comprises a rotor.

[0020] In a second aspect, a method for preparing an electrode membrane mixture for an energy storage device is provided, the method comprising the steps of: supplying a polymer dispersion including a liquid and a polymer that is a first component of the electrode membrane mixture for the energy storage device to a first inlet of a fluidized bed coating apparatus; supplying a second component of the electrode membrane mixture for the energy storage device to a second inlet of the fluidized bed coating apparatus; and dispersing a liquid portion of the polymer dispersion in the fluidized bed. forming a fluidized bed of the dry polymer and a second component of the electrode mixture in the fluidized bed coating apparatus to form an electrode membrane mixture.

[0021] In some embodiments according to the second aspect, the step of providing a polymer dispersion comprises providing a dispersion comprising water and polytetrafluoroethylene.

[0022] In some embodiments of the second aspect, the step of providing the second component comprises providing dry particles.

[0023] In some embodiments of the second aspect, the step of providing the second component comprises providing an active electrode component of an electrode membrane mixture.

[0024] In some embodiments of the second aspect, the step of providing the second component comprises providing carbon.

[0025] In some embodiments according to the second aspect, providing carbon includes providing graphite.

[0026] In some embodiments of the second aspect, the step of providing the second component includes providing a lithium metal oxide.

[0027] In some embodiments according to the second aspect, the step of evaporating the liquid of the dispersion comprises passing the dispersion through a spray nozzle of a fluidized bed coating apparatus.

[0028] In some embodiments of the second aspect, the method further comprises covering the second component with a dry polymer in a fluidized bed coating apparatus.

[0029] In some embodiments of the second aspect, the step of providing the second component occurs before providing the polymer dispersion.

[0030] In some embodiments according to the second aspect, a method of forming an electrode film is provided, the method comprising rolling the electrode film mixture to form the electrode film.

[0031] In some embodiments according to the second aspect, the step of rolling the electrode membrane mixture includes fiberizing the polymer.

[0032] In some embodiments according to the second aspect, the electrode film is a free-standing electrode.

[0033] Certain objects and advantages are described herein for purposes of summarizing the invention and the advantages achieved over the prior art. It is to be understood, of course, that not necessarily all of these objects or advantages must be achieved in accordance with any particular embodiment. Thus, for example, one skilled in the art will appreciate that the invention may be embodied or carried out in such a way that one advantage or group of advantages is achieved or optimized while other objects or advantages are not necessarily achieved.

[0034] All of these embodiments are intended to be within the scope of the invention disclosed herein. These and other embodiments will become readily apparent to those of ordinary skill in the art upon review of the following detailed description and accompanying drawings. The invention is not limited to any particular embodiment disclosed. [Brief description of the drawings]

[0035] These and other features, aspects, and advantages of the present disclosure will now be described with reference to the drawings, which illustrate specific embodiments and are not intended to limit the invention. [Figure 1] FIG. 1 is a schematic diagram of an energy storage device including one or more electrode films. [Diagram 2] FIG. 2 is a process flow diagram according to one embodiment of a process for forming an electrode membrane mixture. [Diagram 3] FIG. 3 is a schematic diagram of one embodiment of an apparatus for producing an electrode membrane mixture. [Figure 4] FIG. 4 is a diagram showing one embodiment of an apparatus for producing an electrode membrane mixture. [Diagram 5] FIG. 5 is a cross-sectional view of one embodiment of a fluidized bed apparatus. [Figure 6] FIG. 6 is a cross-sectional view of one embodiment of a fluidized bed apparatus including a rotor. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] Although specific embodiments and examples are described below, those skilled in the art will understand that the invention is not limited to the specifically disclosed embodiments and / or uses, as well as obvious modifications and equivalents thereof. Accordingly, it is not intended that the scope of the invention disclosed herein be limited to any of the specific embodiments described below.

[0037] Provided herein is an apparatus and process for forming an electrode membrane mixture for an energy storage device. The apparatus or process may provide a first component of the electrode membrane mixture. The first component may include a polymer dispersion. The polymer dispersion may include a liquid and a polymer. The apparatus or process may further provide a second component of the electrode membrane mixture. The second component may include an active material. The apparatus or process may further provide a flow bed in fluid communication with a first inlet configured to receive the polymer dispersion and a second inlet configured to receive the second component of the electrode membrane mixture.

[0038] The apparatus or process described herein may provide one or more advantages over conventional apparatus or processes for forming wet or dry electrode films, or the raw materials used to form these films. For example, the apparatus or process described herein may facilitate the formation of thicker electrode films, thereby providing higher device energy density performance compared to electrode films produced by wet coating processes. As a further example, the apparatus or process described herein may reduce production costs over other electrode manufacturing apparatus or processes.

[0039] Some conventional electrode film processes use wet raw materials to form a slurry, which is then applied to a current collector and dried to form an electrode film. The rate at which these wet electrode films can be dried can be affected by the drying kinetics of one or more solvents in the slurry used in the wet coating process. The rate at which the electrode films can be dried can also be affected by the thickness of the electrode film. For example, the rate at which thicker electrode films can be dried is often slowed down to reduce or avoid drying failures. Thus, the evaporation kinetics of one or more solvents can affect the length of time of the drying step used to desirably dry the electrode films and / or the physical length of the dryer used to dry these electrode films. The length of time of drying and the length of the dryer can contribute to the manufacturing cost of these electrodes. While thicker electrodes are desired to obtain higher device energy density, the cost of manufacturing electrode films beyond a certain thickness can be prohibitive. For example, the cost of equipment used to dry wet coated electrode films can increase commensurately with longer drying ovens. For example, the thickness of the electrode film produced using the wet coating process may increase approximately exponentially. Therefore, the thickness of the electrode film produced using the wet coating process may be limited by the drying kinetics of one or more solvents used in the slurry, i.e., by the drying resources required to obtain satisfactory results. Provided herein is an apparatus and method for producing an electrode film for a lithium-ion-based energy storage device without using drying equipment or a separate drying step and / or without a step of drying the electrode film.

[0040] Conventional dry electrode membrane processes use dry raw materials, reducing or eliminating the need for dryers required in wet electrode membrane processes, as discussed above. Such dry electrode membrane manufacturing processes use high shear equipment and processes, such as jet mills, to provide sufficient shear for size reduction and / or fiberization of the binder material. Such processes may be limited to using only fiberizable binders. Or, may be further limited to using only a single specific binder, such as polytetrafluoroethylene (PTFE). For example, a mixture containing a binder material, such as PTFE, and other electrode membrane components may be subjected to a jet milling process that provides high shear to separate agglomerated particles of the binder material into finely divided particles and / or fiberize the binder material. As a result, the binder material may coat the remaining electrode membrane components. The resulting processed dry powder may be compressed using heat and pressure using a roll mill to form a membrane in which the PTFE is intimately attached and adhered to the other components of the membrane, for example in a fiberized matrix. The membrane thickness may vary depending on the roll gap of the roll mill, the pressure applied during the compression process, and / or the number of times the membrane is compressed. The dry manufacturing process may result in a fiberized matrix such that the electrode membrane is a free-standing electrode membrane. As described herein, a "free-standing" electrode membrane is one that includes a binder matrix structure sufficient to support the membrane and maintain its shape such that the electrode membrane may be a free-standing membrane. A free-standing electrode membrane when employed in an energy storage device incorporates such a binder matrix structure. In general, and depending on the method employed, such free-standing electrode membranes are robust enough to be used in an energy storage device manufacturing process without an external support element. For example, a free-standing electrode membrane may be handled or rolled without additional support elements.

[0041] However, such high shear processes used in typical dry electrode manufacturing may damage one or more other components of the electrode membrane mixture. This damage may reduce the performance of a device having an electrode formed from these components. For example, the use of a jet mill process that exerts high shear forces to separate agglomerated particles of the binder material and / or fiberize the binder material may inadvertently degrade the surface properties of one or more other components of the electrode membrane mixture. The forces applied in the high shear process may change the morphology of one or more active materials and / or cause surface damage to the active materials. For example, particles of the active materials may be broken, dissolved, flaked, or chemically altered during such processes.

[0042] The active material added to the electrode of the energy storage device may have a coated and / or treated surface. For example, carbon materials, particularly graphite materials, may be covered with amorphous carbon. Alternatively, or in addition, the graphite material may be surface treated to reduce first cycle inefficiencies during the formation of the solid electrolyte interfacial phase or to improve the cycle life of the battery. For example, one or more surface properties of the carbon in the electrode film mixture may be degraded in the absence of an amorphous carbon surface coating of the graphite particles. Such degradation of surface properties may adversely affect one or more electrical properties of the energy storage device.

[0043] Without wishing to be limited by theory, it is believed that the composition of the active material surface affects the degradation processes (e.g., of the electrolyte and impurities therein) within the energy storage device as well as affecting the formation of a solid-electrolyte interphase (SEI) layer. Surface-treated active materials exhibit improved electrode properties in energy storage devices compared to active materials having untreated surfaces. The increased performance may be due to, for example, reduced crack formation and / or cracking, separation of active material from the current collector, electrolyte decomposition, and / or gassing. Thus, dry electrode films manufactured using dry electrode film materials made by one or more processes described herein may exhibit improved electrical properties, for example, due to greater integrity of one or more components of the electrode film.

[0044] Disclosed herein are materials and methods that provide active materials with reduced surface damage during fabrication. Certain embodiments of the energy storage devices described herein may reduce surface damage of graphite materials after processing. In particular, free-standing electrode films are provided that include such active materials. One or more processes described herein may easily protect the integrity of electrode film components by avoiding exposure of the components to high shear forces. In some embodiments, production costs may be reduced if the use of jet mills and other high shear devices and associated equipment such as air compressors and / or associated mixers is avoided or eliminated.

[0045] Furthermore, electrode films produced using typical dry electrode manufacturing processes that include high shear processes may be limited to binder materials that can be fiberized at high shear forces, such as PTFE. Thus, typical dry electrode manufacturing processes may limit the selection of binders, which in turn may limit the materials used in energy storage devices. As an example, the use of a PTFE binder may lead to poor performance, reduced battery life, and incompatibility with materials used in certain types of energy storage devices, such as with one or more other components of a particular electrode film. For example, PTFE may be an unsuitable binder for certain electrode film applications due to its potential reaction with lithium ions. One or more processes described herein may be applicable to binder materials other than PTFE, which may facilitate the use of binder materials that are more compatible with lithium in producing electrodes for lithium-ion based energy storage devices. Thus, dry electrode processes are provided herein that are compatible with binders used as alternatives to PTFE or in combination with PTFE.

[0046] In some embodiments, electrode film mixtures for energy storage devices and processes and apparatuses for preparing these electrode film mixtures are provided. The electrode film mixture may include a first component and a second component. The first component may include a polymer dispersion. The second component may include an active material. In some embodiments, the electrode film mixture includes particles of the electrode film component coated with a polymer binder. The electrode film component is a different material than the polymer. For example, the polymer may be a polymer binder such as PTFE. In some embodiments, the electrode film component may include an active electrode material. In some embodiments, the electrode film component may include carbon, such as graphite, activated carbon, soft carbon, and / or hard carbon. The electrode film component may include a carbon composite with a metal oxide. In some embodiments, the electrode film component may include an intercalable metal oxide, such as a lithium metal oxide. The electrode film component may include amorphous carbon. The electrode film component may include a composite of two or more carbons, such as graphitic carbon and amorphous carbon. The electrode film mixture may include a plurality of graphite particles coated with PTFE, where "coated" may include a substantially continuous film of polymer binder surrounding and covering each electrode film component (e.g., active material, such as graphite) particle. This may be accomplished, for example, by induced dipole interactions and / or London forces, where the polymer forms a plurality of particles that coalesce with and surround the electrode film component (e.g., active material, such as graphite) particles.

[0047] In some embodiments, one or more electrode membrane mixtures described herein are produced. The apparatus includes a first supply source, a second supply source, and a fluidized bed coating apparatus. The first supply source is for supplying a first component of the electrode membrane mixture, for example, a dispersion including a polymer. The second supply source includes a second component of the electrode membrane mixture. The fluidized bed coating apparatus may be any of those known in the art, such as a Wurster accelerator, that may be configured to receive the dispersion and the second component of the electrode membrane mixture. In further embodiments, the fluidized bed coating apparatus may include a conical rotor processing apparatus. The fluidized bed coating apparatus may include a first inlet for receiving the polymer dispersion and a second inlet for receiving the second component of the electrode membrane mixture. In further embodiments, the second component of the electrode membrane mixture may be applied in a batchwise manner. In further embodiments, the polymer dispersion and the second component of the electrode membrane mixture may be applied in a continuous flow process. Although some embodiments are described herein within the scope of a Wurster accelerator, it will be understood that other types of fluidized bed coating apparatuses are also possible within the scope of the present invention.

[0048] As used herein, a "dispersion," including a "polymer dispersion," is a composition that includes solid or semi-solid particles dispersed in a liquid phase. The solid or semi-solid particles may be a polymer as described herein. A dispersion as described herein may be a solution of said solid or semi-solid.

[0049] A fluidized bed coating apparatus may include typical components, such as one or more spray nozzles or spray guns, a process chamber, a rotating disk or rotor, a stationary vessel or stator, and a ventilation duct or vent.

[0050] In some embodiments, the process of preparing one or more electrode membrane mixtures described herein includes feeding a dispersion including a polymer from a first source into a first inlet of a fluidized bed coating apparatus. The process may include feeding a second component of the electrode membrane mixture into the fluidized bed apparatus. For example, the second component of the electrode membrane mixture may be fed from a second source into a second inlet of the fluidized bed coating apparatus. In some embodiments, the second component of the electrode membrane mixture may be dispersed and fluidized with a successive amount of heated gas or heated air to form a fluidized bed. In some embodiments, the liquid of the polymer dispersion may be evaporated in the fluidized bed coating apparatus by heated air to result in a dry polymer. The dry polymer and the fluidized bed may be fed simultaneously in the fluidized bed coating apparatus such that the second component of the electrode membrane mixture is covered with the dry polymer. For example, a dispersion including PTFE may be fed into a first inlet of the fluidized bed coating apparatus. Also, dry particles of graphite may be fed into a second inlet of the fluidized bed coating apparatus such that a fluidized bed including graphite particles is formed. The liquid portion of the polymer dispersion may be evaporated in the fluidized bed coater, causing the dry PTFE to cover the dry particles of graphite in the fluidized bed coater, either as a film and / or as small particles that adhere to the graphite surface. A second component of the electrode membrane mixture may be present in the fluidized bed coater prior to the step of providing the polymer dispersion.

[0051] In some embodiments, the binder is not PTFE. In further embodiments, the polymer dispersion does not include PTFE.

[0052] In some embodiments, one or more of the electrode membrane mixtures described herein may be mixed with one or more other components of the electrode membrane mixture and then rolled to form an electrode membrane. The other components may be, for example, a third component of the electrode membrane mixture. The third component of the electrode membrane mixture may be mixed with the electrode membrane mixture after the coating process described herein. For example, the third component of the electrode membrane mixture may be added to the electrode membrane mixture including the first and second components of the electrode membrane mixture. Alternatively or in addition, the third component of the electrode membrane mixture may be mixed with the electrode membrane mixture after the coating process described herein. The components may be mixed with the first component and / or the second component prior to being combined in the fluidized bed apparatus. As a non-limiting example, the third component of the electrode membrane mixture may be dispersed within the liquid of the polymer dispersion.

[0053] The third component of the electrode membrane mixture may include an additional binder material. This additional binder material may be the same or different from the binder material included in the polymer dispersion. The additional binder material may be any of those provided herein. The additional binder material may be, for example, PTFE or may include PTFE. Alternatively or in addition, the third component of the electrode membrane mixture may include, for example, an additional active material. This active material may be any of those described herein. For example, it may be a carbon material or a metal oxide. Alternatively or in addition, the third component of the electrode membrane mixture may include, for example, a conductive electrode membrane material.

[0054] The electrodes may be used to form anodes or cathodes for use in energy storage devices. For example, the electrode films may be connected to anode or cathode current collectors, such as by a lamination process. The electrode films described herein may be used to form anodes and / or cathodes of energy storage devices, such as batteries, capacitors, hybrid capacitors and batteries, fuel cells, and combinations thereof. The energy storage devices may operate with or without lithium. In some embodiments, the electrode films may be used to manufacture batteries, such as lithium ion cells, or other metal ion batteries. In some embodiments, the electrode films may be used to manufacture ultracapacitors, such as electric double layer capacitors (EDLCs). In some embodiments, the electrode films may be used to manufacture lithium ion capacitors. The electrode films may be free-standing electrode films as described herein.

[0055] FIG. 1 is a schematic cross-sectional side view of an example of an energy storage device 100. The energy storage device 100 can be any number of energy storage devices, such as a lithium ion capacitor, a lithium ion battery, or an electric double layer capacitor. Of course, other energy storage devices are within the scope of the present invention, and the device 100 can be other types of capacitors, batteries, hybrid capacitors and batteries, or fuel cells. The energy storage device 100 can have a first electrode 102, a second electrode 104, and a separator 106 located between the first electrode 102 and the second electrode 104. For example, the first electrode 102 and the second electrode 104 can be disposed adjacent to opposing sides of the separator 106. The first electrode 102 can include a cathode and the second electrode 104 can include an anode, or vice versa. The energy storage device 100 can include an electrolyte to facilitate the movement of ions between the electrodes 102 and 104 of the energy storage device 100. For example, the electrolyte may be in contact with the first electrode 102, the second electrode 104, and the separator 106. The electrolyte, the first electrode 102, the second electrode 104, and the separator 106 may be contained within the energy storage device housing 120. For example, the energy storage device housing 120 may be sealed following insertion of the first electrode 102, the second electrode 104, and the separator 106 and filling the energy storage device 100 with electrolyte, thereby physically sealing the first electrode 102, the second electrode 104, the separator 106, and the electrolyte from the environment outside the housing.

[0056] The separator 106 may be configured to electrically insulate two adjacent electrodes (e.g., the first electrode 102 and the second electrode 104) on opposite sides of the separator 106 while allowing ionic movement between the two adjacent electrodes. The separator 106 may include a variety of porous or non-woven electrically insulating materials. In some embodiments, the separator 106 may include a polymeric material. The separator 106 may be made of a combination of polymeric materials. The separator 106 may include a composite of one or more polymeric materials and a ceramic and / or metal oxide. The ceramic or metal oxide may be a powder. For example, the separator 106 may include a cellulosic material, such as paper. The separator 106 may include a porous or non-woven polyethylene (PE) material. The separator 106 may include a polytetrafluoroethylene material, such as a porous polytetrafluoroethylene material. The separator 106 may include a polypropylene (PP) material, such as a porous PP material or a non-woven PP material. The separator 106 may include a polyethylene coating, for example, on the porous PP material or non-woven PP material or on the composite of the polymeric materials.

[0057] As shown in FIG. 1, the first electrode 102 and the second electrode 104 may include a first current collector 108 and a second current collector 110, respectively. The first current collector 108 and the second current collector 110 may facilitate an electrical connection between the corresponding electrode and an external circuit (not shown). The first current collector 108 and the second current collector 110 may include one or more conductive materials. The first current collector 108 and the second current collector 110 may have various shapes and / or dimensions. The first current collector 108 and the second current collector 110 may be configured to facilitate the transfer of charge between the corresponding electrode and an external circuit. For example, the first current collector 108 may be electrically connected to a first energy storage device terminal 122, e.g., an electrical anode terminal, via a first connection 126. The second current collector 110 may be electrically connected to a second energy storage device terminal 124, e.g., an electrical negative terminal, via a second connection 128. The first energy storage device terminal 122 and the second energy storage device terminal 124 may be electrically connected to respective terminals of an external circuit, thereby connecting the energy storage device 100 to an external circuit.

[0058] The current collectors may include metallic materials, such as materials including aluminum, nickel, copper, silver, alloys thereof, and / or other metallic materials, or non-metallic materials, such as graphite, that remain inert to the electrode potential of the device. The first current collector 108 and / or the second current collector 110 may include a foil. The first current collector 108 and the second current collector 110 may have a rectangular or substantially rectangular shape. They may be sized to provide a desired charge transfer between the corresponding electrodes and an external electrical circuit. The energy storage device 100 may have any of a number of different configurations to provide the above-mentioned electrical communication between the electrodes 102 and 104 and the external electrical circuit via the current collectors 108 and 110, respectively. For example, the above-mentioned charge transfer may be via a current collector plate and / or another energy storage device component.

[0059] The first electrode 102 may have a first electrode film 112 (e.g., an upper electrode film) on a first surface of the first current collector 108 (e.g., a top surface of the first current collector 108). The first electrode 102 may have a second electrode film 114 (e.g., a lower electrode film) on a second, opposite surface of the first current collector 108 (e.g., a bottom surface of the first current collector 108). Similarly, the second electrode 104 may have a first electrode film 116 (e.g., an upper electrode film) on a first surface of the second current collector 110 (e.g., a top surface of the second current collector 110). The second electrode 104 may have a second electrode film 118 on a second, opposite surface of the second current collector 110 (e.g., on a bottom surface of the second current collector 110). For example, a first surface of the second current collector 110 can face a second surface of the first current collector 108 such that the separator 106 is adjacent to the second electrode film 114 of the first electrode 102 and the first electrode film 116 of the second electrode 104.

[0060] The electrode films 112, 114, 116, and / or 118 can have a variety of suitable shapes, dimensions, and / or thicknesses. For example, the electrode films can have a thickness of about 30 microns (μm) to about 2000 microns, including thicknesses ranging from about 100 microns to about 250 microns, and even ranging from about 30 microns to about 250 microns. The electrode films 112, 114, 116, and / or 118 can each have the same or different thicknesses, compositions, and thicknesses. For example, electrode film 112 and electrode film 114 may have a different thickness, composition, or density than electrode film 116 and electrode film 118.

[0061] In some embodiments, the anode and / or cathode electrode film of the energy storage device includes an electrode film mixture including a polymer, e.g., a polymeric binder material, and one or more other components. Polymer is a general term and can include homopolymers, copolymers, and polymer mixtures as described herein. In some embodiments, the anode and / or cathode electrode film may include one or more active electrode components. In some embodiments, the active electrode component is carbon-based. In some embodiments, the one or more active electrode components include a porous carbon material, such as activated carbon. In some embodiments, the one or more active electrode components include carbon configured to reversibly intercalate lithium ions, such as graphite, soft carbon, and / or hard carbon. In some embodiments, the active electrode component includes a lithium metal oxide. In some embodiments, the anode and / or cathode electrode film can include one or more additives, such as a conductivity-promoting additive or an ionic conductivity-promoting additive. In some embodiments, the conductivity-promoting additive can be carbon black. In some embodiments, the electrode membrane mixture includes a binder material, one or more active electrode components, and / or one or more conductivity-promoting additives. In some embodiments, the binder material may include one or more of a variety of suitable polymeric materials, such as polytetrafluoroethylene (PTFE), ultra-high molecular weight polyethylene (UHMWPE), binders described herein, and / or other suitable, optionally fiberizable materials, alone or in combination. In some embodiments, the active electrode components employ a rich source of lithium ions, in order to pre-lithiate the anode, advantageously reducing or eliminating first cycle inefficiencies.

[0062] FIG. 2 is a process flow diagram according to one embodiment of a process 200 for forming an electrode membrane mixture. In step 202, a first component of the electrode membrane mixture, such as a polymer dispersion, is fed into a first inlet of a fluidized bed coating system, which may also be known as a "spray dryer." Step 202 may include spraying the polymer dispersion into a spray chamber of the apparatus, for example, via a spray nozzle. The polymer dispersion may include, consist essentially of, or consist only of a liquid and solid or semi-solid polymer particles dispersed within the liquid. In some embodiments, the liquid may include, consist essentially of, or consist only of water. For example, the polymer dispersion may be an aqueous dispersion. In some embodiments, the liquid may include, consist essentially of, or consist only of one or more other solvents common in polymer solutions or dispersions and known to those skilled in the art. In some embodiments, the polymer may include, consist essentially of, or consist only of an electrode membrane binder material. The electrode membrane binder material may include a material that remains electrochemically inactive during operation of the energy storage device. The electrode membrane binder material may be dispersed as fine particles in a carrier fluid, or dissolved in a solvent, or a combination of dispersion and dissolution. The electrode membrane binder material may mechanically form a membrane when mixed with the energy storage active material. Other types of polymers that may be used include, but are not limited to, thermoplastics, thermosets, or elastomers. The polymer may be a mixture or copolymer of two or more polymers. The copolymer may be a graft copolymer, a block copolymer, a random copolymer, or a combination thereof. Some polymers include those provided herein. Specific examples include, for example, carboxymethyl cellulose, styrene-butadiene and copolymers, polyvinylidene fluoride and polyvinylidene fluoride-hexafluoropropylene copolymers, polyacrylic acid, polymethacrylic acid, and mixtures and copolymers thereof. In some embodiments, the polymer comprises, consists essentially of, or consists of PTFE. For example, the polymer dispersion may be an aqueous dispersion that comprises, consists essentially of, or consists only of PTFE. In some embodiments, the polymer dispersion is a commercially available aqueous dispersion that includes PTFE particles. In some embodiments, the polymer dispersion may be a suspension. In further embodiments, the polymer dispersion may be a solution. In further embodiments, the polymer may not be dissolved in a liquid.

[0063] In step 204, the second component of the electrode membrane mixture is provided separately from the first component of the electrode membrane mixture in the fluidized bed coating apparatus. Step 204 may include providing the second component to the second inlet of the fluidized bed coating apparatus and into the fluidized bed coating apparatus. Thus, the first component of the electrode membrane mixture and the second component of the electrode membrane mixture may be separate from each other until entering the coating chamber of the fluidized bed coating apparatus. Generally, the first inlet and the second inlet are downstream components of the first source and the second source, respectively, and provide fluid communication with the coating chamber of the fluidized bed apparatus. Step 204 may include providing the second component at a time different from (e.g., before) or at the same time as the step of providing the polymer dispersion in step 202. In some embodiments, the second component is a different material from the polymer dispersion of step 202. In some embodiments, the second component is in dry particulate form. The second component may include, consist essentially of, or consist only of the active electrode material. For example, the second component may comprise, consist essentially of, or consist only of dry particles of an active electrode material. In some embodiments, the second component comprises, consist essentially of, or consist only of an active electrode material of a cathode or anode of an electric double layer capacitor. In some embodiments, the second component comprises, consist essentially of, or consist only of an active electrode material of a cathode or anode of a lithium ion capacitor. In some embodiments, the second component comprises, consist essentially of, or consist only of an active electrode material of a cathode or anode of an electrochemical battery, such as a lithium ion battery. In some embodiments, the second component comprises, consist essentially of, or consist only of carbon. In some embodiments, the carbon may comprise, consist essentially of, or consist only of graphite, soft carbon, and / or hard carbon. In some embodiments, the carbon comprises, consist essentially of, or consist only of activated carbon. In some embodiments, the second component comprises, consists essentially of, or consists of lithium metal oxide.For example, the second component may include, consist essentially of, or consist of one or more of lithium nickel manganese cobalt oxide (NMC), lithium manganese oxide (LMO), lithium iron phosphate (LFP), lithium cobalt oxide (LCO), and lithium nickel cobalt aluminum oxide (NCA), or other lithiated metal oxide materials suitable for use as cathodes in rechargeable lithium-ion batteries.

[0064] In step 206, the liquid portion of the polymer dispersion may be evaporated in the coating chamber of the fluidized bed coating apparatus. For example, the liquid portion of the dispersion may be vaporized to form a dry polymer. In some embodiments, the fluidized bed coating apparatus includes a spray nozzle to disperse the polymer dispersion in the fluidized bed coating apparatus. The spray nozzle, such as an atomizing spray nozzle or an ultrasonic spray nozzle, may be configured to inject fine droplets of the polymer dispersion into the coating chamber of the fluidized bed coating apparatus. In some embodiments, the exposure temperature of the droplets is controlled by directly or indirectly heating one or more components of the fluidized bed coating apparatus with heated fluidizing air, so that the liquid portion of the polymer dispersion is evaporated as desired. The temperature of one or more components of the fluidized bed coating apparatus may be controlled to regulate the temperature within the coating chamber. In some embodiments, one or more side walls of the coating chamber may be heated. In some embodiments, the spray nozzle may be heated. In some embodiments, the polymer dispersion may be heated by a coating chamber that is heated by a heating element. The second component, such as the active material, may be heated before being introduced into the coating chamber. In some embodiments, the second component, such as the active material, may be preheated before the introduction of the polymer dispersion. This may help control the evaporation rate of the liquid portion of the polymer dispersion. The droplets may be exposed to heat, such as, for example, a heated spray nozzle and / or heated fluidizing air, or heat from one or more heated side walls of the coating chamber. As a result, the liquid portion of the polymer dispersion evaporates in the coating chamber to provide a dry polymer. Thus, evaporation step 206 may include heating the polymer dispersion before, during, and / or after it is introduced (e.g., sprayed) into the coating chamber. Other methods of evaporating the polymer dispersion (or, in other words, other methods of adding heat to the process) include, for example, directly or indirectly heating the walls of the coating chamber of the fluidized bed coating apparatus. For example, a heated gas may be provided to evaporate. This heated gas also fluidizes the powder layer of the second component of the electrode film in step 208, as described below. The polymer dispersion itself and / or the spray nozzle may be heated. A microwave generator, infrared lamp, oven, or other heat source may be used to preheat the polymer dispersion and / or the second component of the electrode of the energy storage device prior to introduction into the coating chamber. All of these heating sources can be used to facilitate evaporation of the polymer dispersion and / or stabilize the temperature of all materials prior to the start of the coating process, resulting in improved and increased throughput of the coated material.

[0065] In step 208, a fluidized bed including, consisting of, or consisting essentially of the second component of the electrode membrane mixture may be formed in the fluidized bed coating apparatus. In some embodiments, the second component of the electrode membrane mixture may be provided (i.e., contained) in the fluidized bed coating apparatus in the form of dry particles. The step of forming the fluidized bed may include simultaneously or sequentially introducing dry particles of the second component and a compressed gas, such as compressed air, into a coating chamber of the fluidized bed coating apparatus. For example, the second component may be contained in the coating chamber to form a "layer" of material. The compressed gas may be passed through the layer to form the "fluidized bed".

[0066] The evaporation step 206 and the fluidized bed formation step 208 are performed to flow the polymer dispersion and the second component of the electrode film in the coating chamber to form a dry electrode mixture. The dry electrode mixture includes particles of the second component of the electrode film covered with the dry polymer binder of the polymer dispersion. For example, the steps of forming a fluidized bed from the second component and evaporating the liquid portion of the polymer dispersion can be performed simultaneously in the coating chamber of a fluidized bed coating apparatus. As a result, the second component can be covered with the dry polymer in the coating chamber.

[0067] In some embodiments, feeding the second component in the fluidized bed coating apparatus includes feeding the second component by a screw feeder, pneumatically, manually, or by another device configured to feed the particulate material through the second inlet.

[0068] As described herein, in some embodiments, the polymer dispersion is an aqueous dispersion comprising polymer particles as described herein. In further embodiments, the polymer is PTFE. The polymer dispersion can be fed into a first inlet of a fluidized bed coating apparatus such that droplets of the polymer dispersion are dispersed in a coating chamber of the fluidized bed coating apparatus. As described herein, in some embodiments, the second component comprises graphite. In some embodiments, a dry powder comprising dry particles of graphite can be fed into a second inlet of the fluidized bed coating apparatus. A fluidized bed comprising graphite can be formed in a coating chamber of the fluidized bed coating apparatus. One or more components of the fluidized bed coating apparatus can be heated to provide graphite particles with a desired degree of dryness in the coating chamber and to allow the liquid portion of the polymer dispersion to evaporate to a desired extent in the coating chamber. For example, the water and / or other liquid components of the polymer dispersion evaporate to provide dry PTFE in the coating chamber of the fluidized bed coating apparatus. The graphite-containing aerosol and dry PTFE can be present simultaneously in the coating chamber of the fluidized bed coating apparatus. This allows the graphite particles to be covered with dry PTFE in the coating chamber.

[0069] In some embodiments, the dry particles of the second component are larger than the smallest dimension. In some embodiments, the dry particles may have a dimension (e.g., diameter, length, or longest dimension, etc.) of about 3 microns (μm) or more. In some embodiments, the approximate particle size of the second component may be 0.01 microns, 0.1 microns, 0.2 microns, 0.3 microns, 0.5 microns, 0.7 microns, 1 micron, 1.5 microns, 2 microns, 2.5 microns, 3 microns, or any numerical range therebetween. In some embodiments, the polymer particles of the polymer dispersion droplets present in the fluidized bed coating apparatus may not be larger than the largest dimension. In some embodiments, the polymer particles are atomized particles. For PTFE dispersions, the particle size may typically be less than 1 micron, typically 0.1 to 0.2 microns. For other solutions or dispersions of polymers, the particle size may be smaller. For example, it may be 0.01 to 0.1 microns, or even smaller. In some embodiments, the approximate particle size of the polymer dispersion may be 0.01 microns, 0.03 microns, 0.05 microns, 0.1 microns, 0.2 microns, 0.3 microns, 0.5 microns, 0.7 microns, 1 micron, or a range of values ​​therebetween. The nozzle may be configured to adjust the particle size. Other factors that may affect the polymer particle size include the concentration of the solution or dispersion. In the case of a dispersion, this also includes the particle size of the dispersion itself.

[0070] FIG. 3 is a schematic diagram illustrating an example of an apparatus 300 for producing an electrode membrane mixture. In some embodiments, the process 200 described with reference to FIG. 2 can be performed using the apparatus 300. With reference to FIG. 3, the apparatus 300 can include a source 302 of a polymer dispersion, a source 304 of a second component of the electrode membrane mixture, a fluidized bed coating apparatus 306 (including a coating chamber 310), and a current collection vessel 308. The source 302 of the polymer dispersion can include a polymer dispersion including a polymer and a liquid as described herein. The polymer dispersion 302 can include additional mixture components, as required. The additional mixture components can be, for example, a third component of the electrode membrane mixture as provided herein. The source 304 of the second component of the electrode membrane mixture can include a second component of the electrode membrane mixture as described herein. The polymer dispersion can be provided from the polymer dispersion source 302 to a first inlet 312 of the fluidized bed coating apparatus 306. The second component of the electrode membrane mixture may be filled batchwise into the open current collection vessel 308 or may be substantially continuously fed through an opening such as the second inlet 314 using a powder delivery means such as a screw feeder. The polymer dispersion may be fed into the coating chamber 310 through a nozzle 316. The nozzle 316 may be separate from the first inlet 312 or may be included as one piece. The nozzle 316 may be configured to introduce the liquid polymer dispersion into the coating chamber 310 in various orientations in addition to the orientation shown. For example, the nozzle 316 may be an up-down tangential spray nozzle, or other orientations. The nozzle 316 may perform top spray, bottom spray, tangential, or other spray orientation processes. The process performed may be an atomization process.

[0071] A screw feeder or other components can be used to batchwise introduce the second component of the electrode membrane mixture into the coating chamber 310 through the second inlet 314. In some embodiments, the polymer dispersion can be dispersed as droplets in the coating chamber of the fluidized bed coater 306. This can cause the liquid portion of the polymer dispersion to evaporate, resulting in a dry polymer or particles thereof. A fluidized bed containing the second component of the electrode membrane mixture can be introduced into the coating chamber of the fluidized bed coater 306 such that the dry polymer can cover the particles of the second component. In some embodiments, particles of the second component of the electrode film mixture covered with a dry polymer can exit the fluidized bed coater 306 through an outlet 318 and be collected in a current collection vessel 308. For example, a vortex can be formed by air flowing through the coating chamber 310. The vortex can draw the second electrode component into the coating chamber to enable the coating process.

[0072] Figure 4 illustrates an embodiment of an apparatus 400 for producing an electrode membrane mixture. The apparatus 400 illustrates some example components that may be employed with the apparatus 300 described with reference to Figure 3 and / or the process described with reference to Figure 2. The apparatus 400 may include a fluidized bed coating apparatus such as a Wurster accelerator. The apparatus 400 may include a current collection vessel 402, a source of polymer dispersion 404 and an air source 406 for spraying the polymer dispersion into the apparatus through an inlet and a nozzle.

[0073] FIG. 5 is a cross-sectional view of one embodiment of a fluidized bed apparatus 500. The apparatus 500 may be similar to or include the apparatus 400 shown in FIG. 4. As shown in FIG. 5, a polymer dispersion 501 may be provided in a coating chamber 503 of the apparatus 500. The polymer dispersion 501 may include a liquid and a polymer. The polymer is a first component of an electrode membrane mixture of an energy storage device. The polymer dispersion 501 may be provided in the apparatus 500, for example, via an inlet 504. The inlet 504 may include or be in fluid communication with a nozzle 505 capable of injecting and / or spraying the polymer dispersion 501 into the coating chamber 503. The nozzle 505 may provide a finely divided (e.g., atomized) polymer dispersion 501. The inlet 504 may be in fluid communication with an upstream source of polymer dispersion (not shown). The polymer dispersion 501 may be heated directly or indirectly to evaporate at least the liquid components of the polymer dispersion within the apparatus 500 to form a dry polymer, or a substantially dry polymer.

[0074] The second component 502 of the electrode membrane mixture can be fed into the coating chamber 503, for example, by a batch-type filling process. The component 502 can be fed into the apparatus 500, for example, via an inlet (not shown). The second component can be fed onto the support 506, forming a layer of material. The gas 508 can be a heated gas. The gas 508 can pass through the layer of material to form a fluidized layer of the component 502. For example, the support 506 can include one or more holes, which can allow a flow of the gas 508, such as air, through the support 506 into the layer of the second component 502, resulting in a fluidized layer. The fluidized layer of the second component 502 and one or more portions of the polymer dispersion 501, such as the dry polymer, can be in fluid communication in the coating chamber 503, resulting in a portion of the polymer dispersion, such as the dry polymer, covering the component 502. The timing at which the polymer dispersion is sprayed through nozzle 505 may be based on temperatures measured within apparatus 500 (e.g., the temperature of the first component of the mixture, the temperature of the second component of the mixture, the temperature of the walls, and / or the temperature of other parts of apparatus 500).

[0075] The coating chamber 503 and the support 506 may be configured to create a gap 507 therebetween. As the gas 508 passes through the support 506, a fluidized bed of the second component 502 is formed. As the polymer dispersion 501 is sprayed into the device 500, the gap 507 allows one or more of the electrode film mixture components in the device 500 to move in the direction of the arrows shown, resulting in the formation of a rotating vortex. This flow enhances the uniformity of the coating formed by the polymers in the polymer dispersion 501 on the second component 502. The height of the gap 507 and / or the height of the walls of the coating chamber 503 may be adjusted to control the vortex characteristics, such as the flow rate. The size and shape of the coating chamber 503, the gap 507, and / or the nozzle 505 may also be adjusted to control the vortex characteristics. Such control may affect the uniformity of the coating.

[0076] In some embodiments, the spray nozzle may be located at or adjacent (e.g., facing upward) to the lower end portion of the fluidized bed coating apparatus. The droplets of the polymer dispersion and the fluidized bed including the second component of the electrode membrane mixture may be formed in a coating chamber of the fluidized bed coating apparatus located above the spray nozzle. One or more components of the fluidized bed coating apparatus may be heated. This heating facilitates the desired evaporation of the liquid portion of the polymer dispersion and / or maintains the desired dryness of the second component of the electrode membrane mixture. These parts include the spray nozzle and / or one or more side walls of the fluidized bed coating apparatus. In some embodiments, the polymer dispersion may include water and a water-soluble or water-dispersible polymer as a latex. Thus, the evaporation of water in the fluidized bed coating apparatus results in a dry polymer. In some embodiments, the second component of the electrode membrane mixture includes dry particles of graphite. The fluidized bed including the graphite is formed in the fluidized bed coating apparatus by using a heated gas or air. Although some of the atomized polymer dispersion may deposit on the swirling particles, the liquid may evaporate before the particles can coalesce. A dry polymer, such as dry PTFE, may coat dry particles of a second component of the electrode membrane mixture (such as dry particles of graphite) in the coating chamber of a fluidized bed coating apparatus.

[0077] FIG. 6 is a cross-sectional view of one embodiment of a fluidized bed apparatus 600. As shown in FIG. 6, a polymer dispersion can be provided in a stationary coating chamber 612 of the apparatus 600. The polymer dispersion can be as described herein. The polymer dispersion can be provided in the apparatus 600, for example, via a nozzle 608 capable of injecting and / or spraying the polymer dispersion in the coating chamber 612. The nozzle 608 can provide a finely divided (e.g., atomized) polymer dispersion. The nozzle 608 can be in fluid communication with an upstream source of polymer dispersion (not shown). The polymer dispersion can be heated directly or indirectly to evaporate at least liquid components of the polymer dispersion in the apparatus to form a dry polymer, or a substantially dry polymer.

[0078] The second component of the electrode film mixture can be fed into the coating chamber 612. The illustrated apparatus 600 includes a rotor 602. The rotor 602 can be, for example, a flat rotor, a curved rotor, or a conical rotor. The rotor 602 can be smooth or have some texture. The second component of the electrode film mixture can be added in batches and / or can be added continuously through a nozzle 604. The second component can be fluidized and circulated in the coating chamber 612. A gas (e.g., a heated gas) can flow through the bed of material, resulting in a fluidized bed of the second component of the electrode film mixture. For example, the gas flow can be coaxial with the rotor. The gas can be dry air. The gas can pass in contact with and around the rotor 602. The fluidized bed of the second component of the electrode membrane mixture and one or more portions of the polymer dispersion, such as a dry polymer, can be in fluid communication within the coating chamber 612, such that a portion of the polymer dispersion, such as a dry polymer, coats the second component of the electrode membrane mixture. The timing at which the polymer dispersion and / or the second component of the electrode membrane mixture is introduced into the coating chamber 612 can be based on temperatures measured within the apparatus 600 (e.g., the temperature of the first component of the mixture, the temperature of the second component of the mixture, the temperature of the walls, and / or the temperature of other parts of the apparatus 600).

[0079] The coating chamber 612 and rotor 602 can be configured to create a gap 606 therebetween. The gas flow can cause one or more of the electrode film mixture components within the apparatus 600 to move, for example, in the direction of the arrows shown. Such flow can enhance the uniformity of the coating formed by the polymer in the polymer dispersion on the second component of the electrode film mixture. By adjusting the dimensions and shape of the walls of the coating chamber 612, the configuration and orientation of the nozzles 604 and 608, and the shape and texture of the rotor 602, the uniformity of the coating can be improved. By adjusting these parameters, one skilled in the art can obtain the desired coating properties.

[0080] In some embodiments, one or more electrode film mixtures described herein may be combined with one or more other electrode film components and then rolled to form an electrode film. The electrode film may be one or more of the electrode films described with reference to FIG. 1. The electrode film may be incorporated into an energy storage device.

[0081] Although the present invention has been disclosed in connection with specific embodiments and examples, those skilled in the art will understand that the present invention extends to other alternative embodiments and / or uses of the present invention, obvious improvements and equivalents thereof, in addition to the specifically disclosed embodiments. Moreover, while several variations of the embodiments of the present invention have been shown and described in detail, other modifications within the scope of the present invention will be readily apparent to those skilled in the art based on this disclosure. It is also considered that various combinations or subcombinations of specific features and aspects of the embodiments may be made and still fall within the scope of the present invention. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another to realize various modes or embodiments of the disclosed invention. Therefore, the scope of the invention disclosed herein should not be limited by the specific embodiments described above.

[0082] The headings herein, if any, are provided for convenience only and do not necessarily affect the scope or meaning of the devices and methods disclosed herein.

Claims

1. 1. An apparatus for forming an electrode film mixture for an energy storage device, comprising: A first source comprising a polymer dispersion, the polymer dispersion comprises a liquid and a polymer, the polymer being a first component of the electrode membrane mixture of the energy storage device; A first source; and a second source comprising a second component of the electrode membrane mixture of the energy storage device; and A fluidized bed coating apparatus comprising a coating chamber, a first inlet, and a second inlet, configured to receive the polymer dispersion from the first source through the first inlet and the second component from the second source through the second inlet to form the electrode film mixture in the coating chamber, the first source and the second source being different sources. A fluidized bed coating apparatus; Equipped with the second component is a particle having a particle size of 0.1 to 3 microns, and the polymer dispersion is a particle having a particle size of 0.01 to 1 micron; The apparatus does not include an electrode membrane dryer.

2. The fluidized bed coating apparatus further comprises: evaporating the liquid of the polymer dispersion to form a dry polymer; The apparatus of claim 1 , configured to form a fluidized bed of the second component in the coating chamber and to coat the second component with the dry polymer.

3. the second component comprises dry particles; The apparatus of claim 1 , wherein the fluidized bed coating apparatus is further configured to form a fluidized bed from the dry particles in the coating chamber.

4. The apparatus of claim 1 , further comprising a rolling device configured to receive the electrode film mixture and form a free-standing electrode film.

5. The device of claim 1 , wherein the polymer comprises polytetrafluoroethylene.

6. The apparatus of claim 5 , wherein the liquid comprises water.

7. the second component comprises dry particles; The apparatus of claim 6 , wherein the fluidized bed coating apparatus is configured to receive the dry particles entering the coating chamber via the second inlet and form a fluidized bed from the dry particles.

8. 10. The fluidized bed coating apparatus of claim 1, further configured to supply a continuous amount of gas to form a fluidized bed with the second component within the coating chamber. The equipment.

9. The apparatus of claim 1 further comprising a rotor.

10. The apparatus of claim 1 , wherein the coating chamber does not include a high shear device.

11. 1. A method for preparing an electrode membrane mixture for an energy storage device, comprising: Supplying a polymer dispersion from a first source to a first inlet of a fluidized bed coating apparatus; the polymer dispersion comprises a liquid and a polymer, the polymer being a first component of an electrode membrane mixture for the energy storage device; Providing a polymer dispersion; supplying a second component of the energy storage device electrode membrane mixture from a second source to a second inlet of the fluidized bed coating apparatus; the first inlet and the second inlet are separate inlets; Providing a second component; and evaporating a liquid portion of the polymer dispersion in a coating chamber of the fluidized bed coating apparatus to form a dry polymer; forming a fluidized bed of the dry polymer and the second component of the electrode film mixture in the coating chamber to form an electrode film mixture; Equipped with The method wherein said second component is a particle having a particle size of 0.1 to 3 microns and said polymer dispersion is a particle having a particle size of 0.01 to 1 micron.

12. The method of claim 11 , wherein providing the polymer dispersion comprises providing a dispersion comprising water and polytetrafluoroethylene.

13. The method of claim 11 , wherein providing the second component comprises providing dry particles.

14. The method of claim 11 , wherein providing the second component comprises providing an active electrode component of the electrode membrane mixture.

15. The method of claim 11 , wherein providing the second component comprises providing carbon.

16. The method of claim 15 , wherein providing carbon comprises providing graphite.

17. The method of claim 11 , wherein providing the second component comprises providing a lithium metal oxide.

18. 12. The method of claim 11, wherein evaporating the liquid portion of the polymer dispersion comprises passing the polymer dispersion through a spray nozzle of the fluidized bed coating apparatus.

19. The method of claim 11 further comprising coating the second component with the dry polymer in the coating chamber.

20. The method of claim 11 , wherein providing the second component occurs prior to providing the polymer dispersion.

21. 12. The method of claim 11, wherein forming the electrode film mixture does not include subjecting the dry polymer and the second component of the electrode film mixture in the coating chamber to high shear forces.

22. The method of claim 11 , wherein forming the fluidized bed comprises providing a rotating vortex.

23. The method of claim 11 , wherein the evaporating provides a uniform coating on the second component.

24. The method of claim 11 , wherein the providing of the second component is performed in a continuous flow process.

25. A method for forming an electrode film, comprising the steps of: forming an electrode film composite for an energy storage device using the method of claim 11; and rolling the electrode film mixture to form an electrode film.

26. 26. The method of claim 25, wherein rolling the electrode membrane mixture comprises fiberizing the polymer.

27. The method of claim 26 , wherein the electrode film is free-standing.

28. The method of claim 11 , wherein the fluidized bed coating apparatus includes a rotor.

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