Continuous and semi-continuous fabrication methods for electrochemical cells.

Abstract

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

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 089,957, filed October 9, 2020, entitled "Methods of Continuous and Semi-Continuous Production of Electrochemical Cells," and U.S. Provisional Patent Application No. 63 / 115,293, filed November 18, 2020, entitled "Methods of Continuous and Semi-Continuous Production of Electrochemical Cells," the disclosures of which are incorporated herein by reference in their entireties. [Background technology]

[0002] The embodiments described herein generally relate to systems and methods for continuous and / or semi-continuous manufacturing of electrochemical cells having semi-solid electrodes. Battery manufacturing processes typically involve coating a conductive substrate (i.e., a current collector) with a slurry containing an active material, a conductive additive, and a binder dissolved or dispersed in a solvent. After the slurry is coated onto the metal substrate, the slurry is dried (e.g., by evaporating the solvent) and calendered to a specific thickness. Battery electrode manufacturing also generally involves material mixing, casting, calendering, drying, slitting, and processing (bending, rolling, etc.) according to the battery architecture being constructed. Because electrodes are manipulated during assembly and to ensure the conductive network is in place, all components are compressed into a cohesive assembly, for example, by using a binder. However, the binder itself can occupy space, increase processing complexity, and hinder ionic and electronic conductivity. Fabrication of semi-solid electrodes with little or no binder can address some of these issues. However, several problems can arise during the fabrication of semi-solid electrodes.

[0003] First, edge control of semi-solid electrodes can be difficult. Stencils and masks often form the edges of semi-solid electrodes. Stencils and masks are often inefficient and can result in less-defined edges (i.e., edge collapse). Loss of electrolyte and / or electrolyte solvent via evaporation can occur during processing, leading to inefficient battery performance. The small-batch process of electrode fabrication can result in various concentration gradients or a lack of homogeneity in the electrode. Additionally, cutting current collectors via mechanical means can also lead to inefficiencies due to the need to frequently replace worn tools. Summary of the Invention

[0004] Embodiments described herein generally relate to systems and methods for continuous and / or semi-continuous manufacturing of electrochemical cells having semi-solid electrodes. In some embodiments, the method may include mixing an active material, a conductive material, and an electrolyte to form a semi-solid electrode material. The method may further include drawing a vacuum on the semi-solid electrode material, compressing the semi-solid electrode material to form an electrode brick, and dispensing a portion of the electrode brick onto a current collector via a dispensing device to form an electrode. In some embodiments, the current collector is disposed on a pouch material. In some embodiments, the dispensing device includes an upper blade for thickness control and two side plates for side edge control. In some embodiments, the method may further include conveying the electrode through the upper blade and the two side plates to form the electrode. In some embodiments, the dispensing device may apply a downward force on the pouch such that the two side plates form a seal with the pouch. [Brief explanation of the drawings]

[0005] [Figure 1] FIG. 1 is a schematic diagram of a semi-continuous or continuous manufacturing method for a semi-solid electrode, according to one embodiment. [Figure 2]FIG. 1 is a schematic diagram of a system for semi-continuous or continuous manufacturing of semi-solid electrodes, according to one embodiment. [Figure 3] FIG. 1 is a diagram of a gravity dryer, according to one embodiment. [Figure 4] FIG. 2 is a diagram of a compressor, according to one embodiment. [Figure 5] FIG. 1 is a diagram of a cartridge with a molding device, according to one embodiment. [Figure 6] FIG. 1 is a diagram of a laser cutting device, according to one embodiment. [Figure 7] FIG. 1 is a diagram of a wetting device and tunnel, according to one embodiment. [Figure 8A] FIG. 1 is a diagram of a sealing device, according to one embodiment. [Figure 8B] FIG. 1 is a diagram of a sealing device, according to one embodiment. [Figure 9] FIG. 1 is a diagram of a gravity dryer, according to one embodiment. [Figure 10A] FIG. 1 is a diagram of components of a brick formation system, according to one embodiment. [Figure 10B] FIG. 1 is a diagram of components of a brick formation system, according to one embodiment. [Figure 11A] FIG. 2 is a diagram of a compressor, according to one embodiment. [Figure 11B] FIG. 2 is a diagram of a compressor, according to one embodiment. [Figure 11C] FIG. 2 is a diagram of a compressor, according to one embodiment. [Figure 11D] FIG. 2 is a diagram of a compressor, according to one embodiment. [Figure 11E] FIG. 2 is a diagram of a compressor, according to one embodiment. [Figure 11F] FIG. 2 is a diagram of a compressor, according to one embodiment. [Figure 12A] FIG. 1 is a diagram of an extrusion system, according to one embodiment. [Figure 12B] FIG. 1 is a diagram of an extrusion system, according to one embodiment. [Figure 12C] FIG. 1 is a diagram of an extrusion system, according to one embodiment. [Figure 12D] FIG. 1 is a diagram of an extrusion system, according to one embodiment. [Figure 12E] FIG. 1 is a diagram of an extrusion system, according to one embodiment. [Figure 13] 1 illustrates a proximity system having a set of rotating drums for assembling electrochemical cells, according to one embodiment. [Figure 14A] 1 illustrates a cartridge and its various components, according to one embodiment. [Figure 14B] 1 illustrates a cartridge and its various components, according to one embodiment. [Figure 14C] 1 illustrates a cartridge and its various components, according to one embodiment. [Figure 15] FIG. 2 is a diagram of a densification station, according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0006] Embodiments described herein generally relate to systems and methods for continuous and / or semi-continuous manufacturing of electrochemical cells having semi-solid electrodes. In some embodiments, an electrode brick can be formed from an active material, a conductive material, and an electrolyte. In some embodiments, the brick can be substantially large, such that more than about 100 semi-solid electrodes can be formed from the material of a single electrode brick. In some embodiments, the brick can be formed from densified semi-solid electrode material. Examples of densified semi-solid electrodes and methods for their manufacture are described in U.S. Provisional Patent Publication No. 2021 / 0226192 (the '192 publication), entitled "Apparatuses and Processes for Forming a Semi-Solid Electrode Having High Active Solids Loading and Electrochemical Cells Including The Same," filed January 21, 2020, the entire disclosure of which is incorporated herein by reference. In some embodiments, the electrode brick can be infused with an electrolyte. An example of an infusion process is described in U.S. Pat. No. 11,005,087 (the '087 patent), entitled "Systems and Methods for Infusion Mixing a Slurry-Based Electrode," filed Jan. 17, 2017, the entire disclosure of which is incorporated herein by reference.

[0007] In some embodiments, pretreatment (e.g., drying) may be applied to the active material and conductive material. After forming the electrode brick, the electrode brick may be disposed within a cartridge. In some embodiments, the brick may have a high level of homogeneity. From the cartridge, a portion of the electrode brick is dispensed onto a current collector to form a semi-solid electrode. In some embodiments, the semi-solid electrode may then be molded with both a top blade and a side plate. In some embodiments, the electrode may be wetted with a solvent (e.g., an electrolyte or electrolyte solvent). In some embodiments, the electrode may be a first electrode and may be adjacent to a second electrode with a separator disposed therebetween to form an electrochemical cell. In some embodiments, the outer pouch material of the electrochemical cell may be sealed in a single step. Other possible processing steps are described in U.S. Patent Publication No. 2020 / 0014025 (the '025 publication), entitled "Continuous and Semi-Continuous Methods of Semi-Solid Electrode and Battery Manufacturing," filed July 9, 2019, the entire disclosure of which is incorporated herein by reference. As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, the term "element" is intended to mean a single element or a combination of elements, and "material" is intended to mean one or more materials, or a combination thereof.

[0008] The term "substantially," when used in connection with "cylindrical," "linear," and / or other geometric relationships, is intended to convey that the structure so defined is nominally cylindrical, linear, etc. As an example, a portion of a support member described as "substantially linear" is intended to convey that while linearity of the portion is desired, some nonlinearity may occur in the "substantially linear" portion. Such nonlinearity may result from manufacturing tolerances or other practical considerations (e.g., pressure or force applied to the support member, etc.). Thus, a geometric configuration modified by the term "substantially" includes such geometric characteristics within a ±5% tolerance of the stated geometric configuration. For example, a "substantially straight" portion is one that defines an axis or centerline that is within ±5% of being straight.

[0009] As used herein, the terms "set" and "plurality" can refer to multiple features or a single feature having multiple portions. For example, when referring to a set of electrodes, the set of electrodes may be considered one electrode having multiple portions, or the set of electrodes may be considered multiple separate electrodes. Additionally, for example, when referring to multiple electrochemical cells, the multiple electrochemical cells may be considered multiple separate electrochemical cells, or one electrochemical cell having multiple portions. Thus, a set of portions or multiple portions may include multiple portions that are either contiguous or discontinuous with one another. Multiple particles or multiple materials may also be made from multiple items that are fabricated separately and later joined together (e.g., via mixing, adhesive, or any suitable method).

[0010] As used herein, the term "z-direction" generally refers to a third direction, with the longitudinal and transverse directions being the first and second directions. In other words, the z-direction refers to the depth or thickness of a feature, as opposed to its length and width.

[0011] As used herein, the terms "about" and "approximately" generally mean ±10% of the stated value, for example, about 250 μm would include 225 μm to 275 μm, and about 1,000 μm would include 900 μm to 1,100 μm.

[0012] As used herein, the term "semi-solid" refers to a material that is a mixture of a liquid and a solid phase, such as, for example, a particle suspension, a colloidal suspension, an emulsion, a gel, or a micelle.

[0013] As used herein, the terms "activated carbon network" and "networked carbon" refer to the general qualitative state of an electrode. For example, an electrode having an activated carbon network (or networked carbon) is one in which the carbon particles within the electrode assume an individual particle morphology and arrangement relative to one another that promotes electrical contact and conductivity between the particles. Conversely, the terms "non-activated carbon network" and "non-networked carbon" refer to an electrode in which the carbon particles exist as either individual particle islands or multi-particle agglomerate islands that may not be sufficiently connected to provide adequate electrical conduction through the electrode.

[0014] 1 is a schematic diagram of a semi-continuous or continuous manufacturing method 10 of a semi-solid electrode, according to one embodiment. As shown, method 10 optionally includes gravity drying the active material and conductive material in step 11. Method 10 then includes mixing the active material, conductive material, and electrolyte to form a semi-solid electrode material in step 12. Method 10 optionally includes drawing a vacuum on the semi-solid electrode material in step 13. Method 10 further includes compressing the semi-solid electrode material to form a semi-solid electrode brick in step 14 and dispensing a portion of the semi-solid electrode brick onto a current collector in step 16 to form a semi-solid electrode. Method 10 then optionally includes conveying the electrode through a former in step 17, wetting the semi-solid electrode with a solvent in step 18, conveying the semi-solid electrode through a tunnel in step 19, adjoining the semi-solid electrode to additional electrodes interposed by a separator in step 21 to form an electrochemical cell, and sealing the electrochemical cell in a pouch in step 23.

[0015] In step 11, a drying process can be used to remove excess moisture from any of the materials used to fabricate the semi-solid electrode. In some embodiments, a powder is subjected to the drying process. In some embodiments, the powder can include an active material. In some embodiments, the powder can include a conductive material. In some embodiments, the powder can include both an active material and a conductive material. In some embodiments, step 11 can include a gravity drying process. In some embodiments, gravity drying can include dropping the powder through a drying container (i.e., via gravity). In some embodiments, a drying gas can flow through the drying container while the powder falls vertically through the drying container. The use of a gravity drying process can be more effective and efficient than a simple drying oven or a drying oven with a conveyor. One advantage is that the powder can move in three dimensions as it falls through the container. In other words, the powder can move downward due to gravity, spread back and forth, and spread left and right. This is in contrast to a simple drying oven with a conveyor, where the powder simply moves in one dimension along the conveyor, and the powder does not move. This freedom of movement can help the powder spread out and have a larger surface area exposed to the drying gas. Also, using gravity to move the powder can be more energy efficient than using a pneumatic stream. Additionally, the drying gas can flow perpendicular or countercurrent to the powder movement, thus increasing the efficiency of heat exchange (i.e., countercurrent heat exchange is more effective than parallel heat exchange). In some embodiments, the drying gas can include air, argon, helium, nitrogen, or any non-reactive gas, or a combination thereof. In some embodiments, the dry gas may have a moisture content of less than about 1 ppm, less than about 0.9 ppm, less than about 0.8 ppm, less than about 0.7 ppm, less than about 0.6 ppm, less than about 0.5 ppm, less than about 0.4 ppm, less than about 0.3 ppm, less than about 0.2 ppm, less than about 0.1 ppm, less than about 0.09 ppm, less than about 0.08 ppm, less than about 0.07 ppm, less than about 0.06 ppm, less than about 0.05 ppm, less than about 0.04 ppm, less than about 0.03 ppm, less than about 0.02 ppm, or less than about 0.01 ppm (including all values ​​and ranges therebetween).

[0016] In some embodiments, step 11 can be performed at ambient temperature. In some embodiments, step 11 can include the application of heat. In some embodiments, the drying vessel in step 11 can be maintained at a temperature of at least about 25°C, at least about 30°C, at least about 35°C, at least about 40°C, at least about 45°C, at least about 50°C, at least about 55°C, at least about 60°C, at least about 65°C, at least about 70°C, at least about 75°C, at least about 80°C, at least about 85°C, at least about 90°C, or at least about 95°C. In some embodiments, the drying vessel in step 11 can be maintained at a temperature of about 100°C or less, about 95°C or less, about 90°C or less, about 85°C or less, about 80°C or less, about 75°C or less, about 70°C or less, about 65°C or less, about 60°C or less, about 55°C or less, about 50°C or less, about 45°C or less, about 40°C or less, about 35°C or less, or about 30°C or less. Combinations of the above temperatures for the drying vessel in step 11 are also possible (e.g., at least about 25°C and not more than about 100°C, or at least about 50°C and not more than about 75°C), including all values ​​and ranges therebetween. In some embodiments, the drying vessel in step 11 can be maintained at a temperature of about 25°C, about 30°C, about 35°C, about 40°C, about 45°C, about 50°C, about 55°C, about 60°C, about 65°C, about 70°C, about 75°C, about 80°C, about 85°C, about 90°C, about 95°C, or about 100°C.

[0017] In some embodiments, the powder after step 11 can have a moisture content of less than about 10 ppm by weight, less than about 9 ppm by weight, less than about 8 ppm by weight, less than about 7 ppm by weight, less than about 6 ppm by weight, less than about 5 ppm by weight, less than about 4 ppm by weight, less than about 3 ppm by weight, less than about 2 ppm by weight, less than about 1 ppm by weight, less than about 0.9 ppm by weight, less than about 0.8 ppm by weight, less than about 0.7 ppm by weight, less than about 0.6 ppm by weight, less than about 0.5 ppm by weight, less than about 0.4 ppm by weight, less than about 0.3 ppm by weight, less than about 0.2 ppm by weight, or less than about 0.1 ppm by weight (including all values ​​and ranges therebetween).

[0018] In step 12, the active material, conductive material, and electrolyte are mixed together to form a semi-solid electrode material. In some embodiments, the active material, conductive material, and electrolyte are mixed without a binder. In some embodiments, the semi-solid electrode material can be binderless or substantially binderless. In some embodiments, the mixing can be via a continuous process. In some embodiments, the mixing can be in a continuous mixer. In some embodiments, the mixing can be in a twin-screw extruder. Further examples of mixing methods and compositions are described in U.S. Pat. No. 9,484,569 (the '569 patent), entitled "Electrochemical Slurry Compositions and Methods for Preparing the Same," filed March 15, 2013, the entire disclosure of which is incorporated herein by reference in its entirety. In some embodiments, the electrolyte can be incorporated into the active material and conductive material via an infusion process. In some embodiments, the infusion process can include drawing a vacuum. In some embodiments, the semi-solid electrode can be substantially mixed such that the semi-solid electrode material has a high level of homogeneity. Further examples of injection processes are described in the '087 patent. In some embodiments, the electrochemical cells described herein can include a separator having a separator seal. Further examples of separators having a separator seal are described in more detail in International Application No. PCT / US2020 / 058564 (the '564 application), entitled "Electrochemical Cells with Separator Seals, and Methods of Manufacturing The Same," filed November 2, 2020, the entire disclosure of which is incorporated herein by reference in its entirety.

[0019] In some embodiments, the amount of semi-solid electrode material mixed together may be sufficient to form a large number of semi-solid electrodes. Mixing large amounts of material together may facilitate a more continuous fabrication process because the semi-solid electrode material does not need to be refilled as frequently. In some embodiments, the amount of semi-solid electrode material mixed together may be at least about 50 semi-solid electrodes, at least about 60 semi-solid electrodes, at least about 70 semi-solid electrodes, at least about 80 semi-solid electrodes, at least about 90 semi-solid electrodes, at least about 100 semi-solid electrodes, at least about 150 semi-solid electrodes, at least about 200 semi-solid electrodes, at least about 250 semi-solid electrodes, at least about 300 semi-solid electrodes, at least about 350 semi-solid electrodes, at least about 400 semi-solid electrodes, at least about 500 semi-solid electrodes, at least about 600 semi-solid electrodes, at least about 700 semi-solid electrodes, at least about 800 semi-solid electrodes, at least about 900 semi-solid electrodes, at least about 1000 semi-solid electrodes, at least about 1500 semi-solid electrodes, at least about 2000 semi-solid electrodes, at least about 2500 semi-solid electrodes, at least about 3000 semi-solid electrodes, at least about 3500 semi-solid electrodes, at least about 4000 semi-solid electrodes, at least about 5000 semi-solid electrodes, at least about 6000 semi-solid electrodes, at least about 7000 semi-solid electrodes, at least about 8000 semi-solid electrodes, at least about 9000 semi-solid electrodes, at least about 10000 semi-solid electrodes, at least about 1500 semi-solid electrodes, at least about 2000 semi-solid electrodes, at least about 2500 semi-solid electrodes, at least about 3000 semi-solid electrodes, at least about 3500 semi-solid electrodes, It may be sufficient to form about 450 semi-solid electrodes, at least about 500 semi-solid electrodes, at least about 550 semi-solid electrodes, at least about 600 semi-solid electrodes, at least about 650 semi-solid electrodes, at least about 700 semi-solid electrodes, at least about 750 semi-solid electrodes, at least about 800 semi-solid electrodes, at least about 850 semi-solid electrodes, at least about 900 semi-solid electrodes, at least about 950 semi-solid electrodes, or at least about 1,000 semi-solid electrodes (including all values ​​and ranges therebetween).

[0020] In optional step 13, a vacuum can be applied to the semi-solid electrode material to degas the semi-solid electrode material. In some embodiments, the vacuum can be applied before the addition of the electrolyte. In some embodiments, the vacuum can be applied after the addition of the electrolyte. In some embodiments, the vacuum can be applied simultaneously with mixing (i.e., in step 12). In some embodiments, the vacuum can occur in the same vessel as the mixing. In some embodiments, the vacuum can occur in a vessel different from the mixer. In some embodiments, the vacuum may reduce the pressure within the vessel housing the semi-solid electrode material by at least about 0.05 bar, at least about 0.1 bar, at least about 0.15 bar, at least about 0.2 bar, at least about 0.25 bar, at least about 0.3 bar, at least about 0.35 bar, at least about 0.4 bar, at least about 0.45 bar, at least about 0.5 bar, at least about 0.55 bar, at least about 0.6 bar, at least about 0.65 bar, at least about 0.7 bar, at least about 0.75 bar, at least about 0.80 bar, at least about 0.85 bar, at least about 0.90 bar, at least about 0.95 bar, or at least about 1 bar (including all values ​​and ranges therebetween).

[0021] In step 14, the semi-solid electrode material is compressed to form a semi-solid electrode brick. In some embodiments, the compressing can be in the same container as the mixing (i.e., step 12). In some embodiments, the compressing can be in the same container as the vacuum (i.e., step 13). In some embodiments, the compressing can be in a different container from the mixing. In some embodiments, the compressing can be in a different container from the vacuum. In some embodiments, the compressing can increase the density of the semi-solid electrode material by at least about 1-fold, at least about 1.1-fold, at least about 1.2-fold, at least about 1.3-fold, at least about 1.4-fold, at least about 1.5-fold, at least about 1.6-fold, at least about 1.7-fold, at least about 1.8-fold, at least about 1.9-fold, or at least about 2-fold (including all values ​​and ranges therebetween). In some embodiments, the compressing may reduce the electrolyte content in the semi-solid electrode material by at least about 1-fold, at least about 1.1-fold, at least about 1.2-fold, at least about 1.3-fold, at least about 1.4-fold, at least about 1.5-fold, at least about 1.6-fold, at least about 1.7-fold, at least about 1.8-fold, at least about 1.9-fold, or at least about 2-fold (including all values ​​and ranges therebetween). In some embodiments, the compressing may include any of the methods described in the '192 publication.

[0022] In some embodiments, the semi-solid electrode brick formed in step 14 comprises at least about 50 semi-solid electrodes, at least about 60 semi-solid electrodes, at least about 70 semi-solid electrodes, at least about 80 semi-solid electrodes, at least about 90 semi-solid electrodes, at least about 100 semi-solid electrodes, at least about 150 semi-solid electrodes, at least about 200 semi-solid electrodes, at least about 250 semi-solid electrodes, at least about 300 semi-solid electrodes, at least about 350 semi-solid electrodes, at least about 400 semi-solid electrodes, at least about 45 The electrode material may comprise a sufficient amount of semi-solid electrode material to form 0 semi-solid electrodes, at least about 500 semi-solid electrodes, at least about 550 semi-solid electrodes, at least about 600 semi-solid electrodes, at least about 650 semi-solid electrodes, at least about 700 semi-solid electrodes, at least about 750 semi-solid electrodes, at least about 800 semi-solid electrodes, at least about 850 semi-solid electrodes, at least about 900 semi-solid electrodes, at least about 950 semi-solid electrodes, or at least about 1,000 semi-solid electrodes (including all values ​​and ranges therebetween).

[0023] In some embodiments, the electrode brick can be self-supporting without collapsing. In other words, the electrode brick can have sufficient cohesive properties and / or structural stability to stand on a surface without a support and without collapsing. In some embodiments, the electrode brick can stand with its longest dimension vertical without a support and without collapsing. In some embodiments, the electrode brick can have a length of at least about 10 cm, at least about 15 cm, at least about 20 cm, at least about 25 cm, at least about 30 cm, at least about 35 cm, at least about 40 cm, at least about 45 cm, at least about 50 cm, at least about 55 cm, at least about 60 cm, at least about 65 cm, at least about 70 cm, at least about 75 cm, or at least about 80 cm. In some embodiments, the electrode brick can have a width of at least about 5 cm, at least about 10 cm, at least about 15 cm, at least about 20 cm, at least about 25 cm, at least about 30 cm, at least about 35 cm, at least about 40 cm, at least about 45 cm, at least about 50 cm, at least about 55 cm, or at least about 60 cm. In some embodiments, the electrode brick can have a thickness of at least about 0.5 cm, at least about 1 cm, at least about 1.5 cm, at least about 2 cm, at least about 2.5 cm, at least about 3 cm, at least about 3.5 cm, at least about 4 cm, at least about 4.5 cm, or at least about 5 cm.

[0024] In some embodiments, the electrode brick has a mass of at least about 1 g / cm 3 , at least about 1.5 g / cm 3 , at least about 2 g / cm 3 , at least about 2.5 g / cm 3 , at least about 3 g / cm 3 , at least about 3.5 g / cm 3 , at least about 4 g / cm 3 , or at least about 4.5 g / cm 3 In some embodiments, the electrode brick may have a density of about 5 g / cm 3 Below, about 4.5g / cm 3Below, about 4g / cm 3 Below, about 3.5g / cm 3 Below, about 3g / cm 3 Below, about 2.5g / cm 3 Below, about 2g / cm 3 or less, or about 1.5 g / cm 3 Combinations of the above densities of the electrode brick (e.g., at least about 1 g / cm 3 and approximately 5g / cm 3 or less, or at least about 2 g / cm 3 and approximately 4 g / cm 3 In some embodiments, the electrode brick has a density of at least about 1 g / cm 3 , at least about 1.5 g / cm 3 , at least about 2 g / cm 3 , at least about 2.5 g / cm 3 , at least about 3 g / cm 3 , at least about 3.5 g / cm 3 , at least about 4 g / cm 3 , at least about 4.5 g / cm 3 , or about 5 g / cm 3 The density may be

[0025] Method 10 optionally includes step 15, in which a metal foil is laser cut to form a current collector. In some embodiments, step 15 occurs as part of a different process than steps 12, 13, and 14. In some embodiments, step 15 occurs on a different conveyor or transport system than the other steps of method 10. Because blades and rotary tools can often wear over time, laser cutting is a beneficial method of current collector formation. In step 15, a foil is applied to a pouch or film material. A laser cutting process is then applied to the foil to form the current collector. In some embodiments, the laser cutting process can include a kiss-cut process. In some embodiments, the precision of the laser cutting process can minimize any cutting of the pouch material. In other words, the margin of error of the laser cutting process can be small enough so that the foil is completely cut without any significant cutting of the pouch material. In some embodiments, the laser cutting can be accurate (i.e., within a margin of error) to less than about 500 nm, less than about 450 nm, less than about 400 nm, less than about 350 nm, less than about 300 nm, less than about 250 nm, less than about 200 nm, less than about 150 nm, less than about 100 nm, less than about 90 nm, less than about 80 nm, less than about 70 nm, less than about 60 nm, less than about 50 nm, less than about 40 nm, less than about 30 nm, less than about 20 nm, or less than about 10 nm.

[0026] In some embodiments, the foil (and subsequent current collector) can have a thickness of at least about 500 nm, at least about 1 μm, at least about 1.5 μm, at least about 2 μm, at least about 2.5 μm, at least about 3 μm, at least about 3.5 μm, at least about 4 μm, at least about 4.5 μm, at least about 5 μm, at least about 5.5 μm, at least about 6 μm, at least about 6.5 μm, at least about 7 μm, at least about 7.5 μm, at least about 8 μm, at least about 8.5 μm, at least about 9 μm, or at least about 9.5 μm. In some embodiments, the foil can have a thickness of about 10 μm or less, about 9.5 μm or less, about 9 μm or less, about 8.5 μm or less, about 8 μm or less, about 7.5 μm or less, about 7 μm or less, about 6.5 μm or less, about 6 μm or less, about 5.5 μm or less, about 5 μm or less, about 4.5 μm or less, about 4 μm or less, about 3.5 μm or less, about 3 μm or less, about 2.5 μm or less, about 2 μm or less, about 1.5 μm or less, or about 1 μm or less. Combinations of the above ranges for foil thickness (e.g., at least about 500 nm and about 10 μm or less, or at least about 1 μm and about 5 μm or less) are also possible, including all values ​​and ranges therebetween. In some embodiments, the foil can have a thickness of about 500 nm, about 1 μm, about 1.5 μm, about 2 μm, about 2.5 μm, about 3 μm, about 3.5 μm, about 4 μm, about 4.5 μm, about 5 μm, about 5.5 μm, about 6 μm, about 6.5 μm, about 7 μm, about 7.5 μm, about 8 μm, about 8.5 μm, about 9 μm, about 9.5 μm, or about 10 μm.

[0027] In step 16, a portion of the semi-solid electrode brick is dispensed onto a current collector to form a semi-solid electrode. In some embodiments, the dispensing of the portion of the semi-solid electrode brick can be from the same container in which the compaction took place (i.e., step 14). In some embodiments, the dispensing can be from a different container than the one in which the compaction took place. In some embodiments, the dispensing can be from a cartridge having a nozzle. In some embodiments, the dispensing can be onto a conveyor or transport system.

[0028] In step 17, the semi-solid electrode is transported through a former (e.g., via a conveyor belt). In some embodiments, the former can be attached to the same device that performs dispensing in step 16. In some embodiments, the former can include an upper blade to control the thickness of the semi-solid electrode. In some embodiments, the former can include one or more side plates to control the width of the semi-solid electrode. Tight control of the edges of the semi-solid electrode can enhance edge integrity and reduce collapse. In some embodiments, the side plates can form a seal with the conveyor, pouch material, or current collector to prevent the semi-solid electrode material from leaking or extruding through the bottom region of the semi-solid electrode. In some embodiments, the lateral edges of the semi-solid electrode can be controlled by sandwiching the pouch material between adjacent plates on the conveyor. In some embodiments, step 17 can include high-speed, micron-level adjustment of the upper blade in the z-direction (i.e., toward and away from the conveyor). In some embodiments, an x-ray gauge and / or a beta gauge can be used to monitor the electrode thickness for consistency. In some embodiments, a closed-loop algorithm can be used in conjunction with an x-ray gauge and / or a beta gauge to narrow the margin of error in the semi-solid electrode thickness from one semi-solid electrode to the next, i.e., narrow the margin of error in the electrode thickness in situ. In some embodiments, an algorithm can be applied to smooth the movement of the upper blade in the z-direction (i.e., making gradual adjustments to avoid creating an uneven surface on the semi-solid electrode).

[0029] Method 10 optionally includes wetting the semi-solid electrode with a solvent in step 18. The solvent (i.e., electrolyte solvent) may evaporate during any portion of method 10. This may reduce the transport of electroactive species through the semi-solid electrode and subsequent electrochemical cell. Therefore, replacing the solvent may help reduce the likelihood of such an occurrence. In some embodiments, wetting in step 18 may include spraying. In some embodiments, step 18 may include spraying the solvent. In some embodiments, step 18 may include spraying the electrolyte. In some embodiments, step 18 may include spraying the solvent and spraying the electrolyte. In some embodiments, step 18 may include spraying the solvent onto the semi-solid electrode. In some embodiments, step 18 may include spraying the electrolyte onto the semi-solid electrode. In some embodiments, step 18 may include spraying both the solvent and the electrolyte onto the semi-solid electrode. In some embodiments, step 18 may include inkjet printing the solvent for high-precision application. Inkjet printing may limit or completely eliminate overspray. In some embodiments, a separator may be disposed on the semi-solid electrode prior to step 18, and spraying may be performed on the separator. In some embodiments, step 18 may include spraying a solvent onto the separator. In some embodiments, step 18 may include spraying an electrolyte onto the separator. In some embodiments, step 18 may include spraying both a solvent and an electrolyte onto the separator. In some embodiments, step 18 may include inkjet printing the solvent for high precision application.

[0030] In some embodiments, step 18 may include spraying the hard carbon. In some embodiments, step 18 may include spraying a hard carbon suspension. In some embodiments, step 18 may include applying the hard carbon suspension onto a semi-solid electrode. In some embodiments, step 18 may include spraying the hard carbon suspension onto a semi-solid electrode. In some embodiments, step 18 may include applying the hard carbon suspension onto a separator. In some embodiments, step 18 may include spraying the hard carbon suspension onto a separator. Examples of electrodes, separators, and electrochemical cells incorporating hard carbon are described in International Application No. PCT / US2021 / 038921, entitled "Electrochemical Cells with Multi-Layered Electrodes and Coated Separators and Methods of Making the Same," filed June 24, 2021 (the '921 application), the entire disclosure of which is incorporated herein by reference in its entirety. In some embodiments, spraying the solvent onto the separator can allow the solvent to more easily adhere to the semi-solid electrode. In some embodiments, the spraying can be done on the semi-solid electrode. In some embodiments, the solvent can include an electrolyte salt. In some embodiments, the solvent can be free of an electrolyte salt. In some embodiments, the solvent can be added (e.g., via spraying) to a conventional electrode (i.e., a solid electrode) with an electrolyte salt. Wetting large-format conventional electrodes can be difficult. Wetting a large area of ​​a conventional electrochemical cell with electrolyte and / or solvent prior to assembly can be beneficial in conventional electrochemical cell manufacturing (e.g., conventional Li-ion electrochemical cell manufacturing).

[0031] In step 19, the semi-solid electrode may optionally be transported through a tunnel. The tunnel may help prevent evaporation of the solvent. In other words, the tunnel may reduce the vent effect in which the semi-solid electrode is exposed to the ambient environment. Any portion of the conveyor or transport system may include a tunnel overhead. In other words, a tunnel may be deployed during any portion of method 10 (e.g., before step 18).

[0032] In step 21, the semi-solid electrode may be adjacent to an additional electrode (i.e., an adjacent electrode), optionally separated by a separator, to form an electrochemical cell. In some embodiments, the adjacent electrode may come from a different conveyor or transport system than the semi-solid electrode. In some embodiments, the adjacent electrode may be placed on the semi-solid electrode from above. In some embodiments, the adjacent electrode may be a conventional electrode. In some embodiments, the adjacent electrode may be an additional semi-solid electrode. Further examples of adjacent methods and adjacent systems are described in the '025 publication.

[0033] In step 23, the electrochemical cell may optionally be sealed in a pouch. In some embodiments, the pouch sealing may be via impulse heating. Pouch sealing methods often use a sealing device in which constant heat is applied to the sealing device. In the presence of such heat, the pouch material may warp and wrinkle. Additionally, electrolyte from the semi-solid electrode may evaporate from such heat. With the use of impulse heating, the application of heat is very rapid, so that the surrounding environment does not significantly increase in temperature. Additionally, the sealing in step 23 may be via a single sealing device. In other words, a single device may seal the entire perimeter of the pouch in one operation, rather than sealing only one side at a time through multiple passes or multiple sealing devices.

[0034] 2 is a schematic diagram of a system 100 for semi-continuous or continuous manufacturing of semi-solid electrodes, according to one embodiment. As shown, system 100 includes a compactor 120, a cartridge 130, a conveyor 148, and a molding device 150. In some embodiments, system 100 may include a gravity dryer 110, a mixer 118, a laser cutting device 140, a wetting device 160, a tunnel 168, an adjoining system 170, and a pouch sealer 180. In some embodiments, system 100 may be used to perform method 10, as described above with reference to FIG. 1.

[0035] In some embodiments, the gravity dryer 110 can include a container through which the powder can be conveyed via gravity. In some embodiments, the gravity dryer can include a gas inlet and a gas outlet for drying gas. In some embodiments, the gravity dryer 110 can maintain a moisture content of less than about 1 ppm, less than about 0.9 ppm, less than about 0.8 ppm, less than about 0.7 ppm, less than about 0.6 ppm, less than about 0.5 ppm, less than about 0.4 ppm, less than about 0.3 ppm, less than about 0.2 ppm, less than about 0.1 ppm, less than about 0.09 ppm, less than about 0.08 ppm, less than about 0.07 ppm, less than about 0.06 ppm, less than about 0.05 ppm, less than about 0.04 ppm, less than about 0.03 ppm, less than about 0.02 ppm, or less than about 0.01 ppm (including all values ​​and ranges therebetween).

[0036] The mixer 118 mixes the active material, the conductive material, and the electrolyte to form the semi-solid electrode material. In some embodiments, the mixer 118 can include a twin-screw extruder. In some embodiments, the mixer 118 can include a twin-screw kneader. In some embodiments, the mixer can include any of the mixers mentioned in the '569 patent. In some embodiments, the mixer 118 can be fluidly coupled to the gravity dryer 110 such that material can flow continuously from the gravity dryer 110 to the mixer 118.

[0037] The compressor 120 forms the semi-solid electrode material into semi-solid electrode bricks. In some embodiments, the compressor 120 may be fluidly coupled to the mixer 118 such that the semi-solid electrode material can continuously flow from the mixer 118 to the compressor 120. In some embodiments, the compressor 120 may be fluidly coupled to a vacuum. In some embodiments, the compressor 120 may include a piston for compression. In some embodiments, the compressor 120 may be part of the same device as the mixer 118. In other words, the same device may both mix and compress the electrode material.

[0038] The cartridge 130 contains a semi-solid electrode brick and dispenses portions of the semi-solid electrode brick onto a current collector to form a semi-solid electrode. In some embodiments, the cartridge 130 may include a nozzle for dispensing. In some embodiments, the cartridge 130 may be part of the same structure or device as the compressor 120 and / or the mixer 118.

[0039] The laser cutting device 140 cuts the foil to form the current collector. In some embodiments, the laser cutting device 140 can perform a kiss cut. In some embodiments, the laser cutting device 140 can have an accuracy (i.e., margin of error) of less than about 500 nm, less than about 450 nm, less than about 400 nm, less than about 350 nm, less than about 300 nm, less than about 250 nm, less than about 200 nm, less than about 150 nm, less than about 100 nm, less than about 90 nm, less than about 80 nm, less than about 70 nm, less than about 60 nm, less than about 50 nm, less than about 40 nm, less than about 30 nm, less than about 20 nm, or less than about 10 nm.

[0040] A conveyor 148 moves the semi-solid electrodes through additional process units of the system 100. In some embodiments, the system may include multiple conveyors (not shown). In some embodiments, multiple conveyors may be used to bring multiple electrodes together, as described in the '025 publication.

[0041] The shaping device 150 shapes the edges of the semi-solid electrode. In other words, the shaping device 150 controls the edges of the semi-solid electrode. In some embodiments, the shaping device 150 may include a single frame for shaping the outer edges of the semi-solid electrode. In some embodiments, the shaping device 150 may include an upper blade for controlling the thickness of the semi-solid electrode and a side plate for controlling the width of the semi-solid electrode. In some embodiments, the shaping device 150 may be adjusted with micron-level precision. In some embodiments, the shaping device 150 may be trained with a closed-loop process algorithm. In some embodiments, the shaping device 150 may be part of the same structure as the cartridge 130. That is, the upper blade and the side plate may be attached to the cartridge 130.

[0042] The wetting device 160 wets the semi-solid electrode with electrolyte solvent to replace electrolyte solvent lost during fabrication. In some embodiments, the wetting device may include a sprayer. In some embodiments, a tunnel 168 may be disposed throughout the conveyor 148. In some embodiments, the tunnel 168 may be disposed adjacent to the wetting device 160 to reduce evaporation of electrolyte from the semi-solid electrode.

[0043] In some embodiments, the adjacency system 170 may combine additional electrodes with the semi-solid electrodes to form an electrochemical cell. In some embodiments, the adjacency system 170 may include a second conveyor. Further examples of adjacency systems are described in the '025 publication.

[0044] In some embodiments, pouch sealer 180 seals the pouch around the outer edge of the electrochemical cell. In some embodiments, pouch sealer 180 may include an impulse heater. In some embodiments, pouch sealer 180 may be shaped such that it can seal around the outer edge of the electrochemical cell in a single step.

[0045] In some embodiments, system 100 may be enclosed within a main enclosure that controls the environment in which each of the electrodes is fabricated and the electrochemical cell is assembled. In some embodiments, system 100 may include multiple conveyors 148. In some embodiments, system 100 may include an anode casting station and a cathode casting station. In some embodiments, the anode casting station may include a first conveyor, and the cathode casting station may include a second conveyor. In some embodiments, the anode casting station and / or the cathode casting station may include cartridges that dispense material onto a lateral steering platform. In some embodiments, the cartridges at the anode casting station dispense anode material, while the cartridges at the cathode casting station dispense cathode material. In some embodiments, the cartridges may dispense portions of semi-solid electrode bricks. In some embodiments, each of the anode casting station and the cathode casting station may include an optical measurement device and an X-ray. Optical measurement devices and x-rays can be used for quality control to verify the thickness of the semi-solid electrode after it has been formed. In some embodiments, the anode can be formed at an anode casting station, with the anode material disposed on a current collector and / or pouch material. In some embodiments, the cathode can be formed at a cathode casting station, with the cathode material disposed on a current collector and / or pouch material.

[0046] After being formed at the cathode forming station, the cathode material may be passed through a spray enclosure. In some embodiments, the wetting device 160 and / or the tunnel 168 may be inside the spray enclosure. In some embodiments, a solvent may be sprayed onto the anode material and / or cathode material within the spray enclosure. In some embodiments, the solvent sprayed onto the cathode material may be flammable. The use of a spray enclosure may help prevent ignition by keeping the concentration level of the flammable material outside of an ignitable range. In some embodiments, the spray enclosure includes a vent to vent the spray enclosure to the surrounding environment to keep the concentration of the flammable material below flammable limits. In some embodiments, the spray enclosure may be explosion-proof. In some embodiments, the cathode material may be passed through the spray enclosure. In some embodiments, the anodic material may be passed through the spray enclosure. In some embodiments, the anodic material may be passed through a first spray enclosure and the cathode material may be passed through a second spray enclosure. In some embodiments, the anodic and cathodic materials may pass through the same spray enclosure.

[0047] In some embodiments, the spray enclosure may be purged of oxygen to reduce the risk of fire within the enclosure. In some embodiments, purging of oxygen may be via drawing a vacuum on the spray enclosure. In some embodiments, purging of oxygen may be via flowing an inert gas (e.g., nitrogen, argon) into the spray enclosure. In some embodiments, purging of oxygen may be via drawing a vacuum on the spray enclosure and flowing an inert gas into the spray enclosure.

[0048] In some embodiments, the formed anode material, the formed cathode material, and the separator material may all be fed into a vacuum drum (not shown), where the anode material, the cathode material, and the separator are combined. In some embodiments, the anode material, the cathode material, and the separator may each be wrapped around the vacuum drum at different points along the vacuum drum to form layers of the electrochemical cell. In some embodiments, the vacuum drum may apply a force to the electrodes to increase their density. In some embodiments, the vacuum drum may apply a downward force to the electrodes such that the electrodes are subjected to a pressure of at least about 1 MPa, at least about 2 MPa, at least about 3 MPa, at least about 4 MPa, at least about 5 MPa, at least about 6 MPa, at least about 7 MPa, at least about 8 MPa, or at least about 9 MPa. In some embodiments, the vacuum drum may apply a downward force to the electrode such that the electrode experiences a pressure of about 10 MPa or less, about 9 MPa or less, about 8 MPa or less, about 7 MPa or less, about 6 MPa or less, about 5 MPa or less, about 4 MPa or less, about 3 MPa or less, or about 2 MPa or less. Combinations of the above pressures experienced by the electrode due to the downward force of the vacuum drum (e.g., at least about 1 MPa and about 10 MPa or less, or at least about 3 MPa and about 7 MPa or less) are also possible, including all values ​​and ranges therebetween. In some embodiments, the vacuum drum may apply a downward force to the electrode such that the electrode experiences a pressure of about 1 MPa, about 2 MPa, about 3 MPa, about 4 MPa, about 5 MPa, about 6 MPa, about 7 MPa, about 8 MPa, about 9 MPa, or about 10 MPa.

[0049] In some embodiments, the vacuum drum can have a diameter of at least about 1 cm, at least about 5 cm, at least about 10 cm, at least about 20 cm, at least about 30 cm, at least about 40 cm, at least about 50 cm, at least about 60 cm, at least about 70 cm, at least about 80 cm, or at least about 90 cm. In some embodiments, the vacuum drum can have a diameter of about 1 meter or less, about 90 cm or less, about 80 cm or less, about 70 cm or less, about 60 cm or less, about 50 cm or less, about 40 cm or less, about 30 cm or less, about 20 cm or less, about 10 cm or less, or about 5 cm or less. Combinations of the above diameters for the vacuum drum (e.g., at least about 1 cm and about 1 meter or less, or at least about 10 cm and about 50 cm or less) are also possible, including all values ​​and ranges therebetween. In some embodiments, the vacuum drum can have a diameter of about 1 cm, about 5 cm, about 10 cm, about 20 cm, about 30 cm, about 40 cm, about 50 cm, about 60 cm, about 70 cm, about 80 cm, about 90 cm, or about 1 m.

[0050] In some embodiments, the vacuum drum may be held in place using tacks. In some embodiments, the vacuum drum may include multiple members arranged around the vacuum drum. In some embodiments, the members may include a pallet. In some embodiments, the vacuum drum may include a central duct with a vacuum to remove liquid from the material outside the vacuum drum. Once merged, a laser cutter may cut the anode material, cathode material, and separator to form individual electrochemical cells. As shown, the individual electrochemical cells may be transported across a vacuum conveyor. In some embodiments, the vacuum conveyor may remove stray particles from the electrochemical cells. The individual electrochemical cells may be measured via optical measurement for quality control. The individual electrochemical cells may then be selectively slid off the vacuum conveyor depending on whether they pass quality control testing.

[0051] In some embodiments, system 100 can include a first vacuum drum that receives a supply of cathode and separator material and a second vacuum drum that receives a supply of anode material. In some embodiments, the first vacuum drum presses the separator and cathode material onto a conveyor, and then the second vacuum drum presses the anode material onto the cathode material and separator.

[0052] In some embodiments, the anode casting station and / or the cathode casting station may include a densification station (not shown), which may use any of the electrode densification methods described in the '192 publication.

[0053] In some embodiments, the system 100 can produce at least about 100, at least about 150, at least about 200, at least about 250, at least about 300, at least about 350, at least about 400, at least about 450, at least about 500, at least about 550, at least about 600, at least about 650, at least about 700, at least about 750, at least about 800, at least about 850, at least about 900, at least about 950, or at least about 1,000 electrodes per minute (including all values ​​and ranges therebetween). In some embodiments, system 100 can produce at least about 100, at least about 150, at least about 200, at least about 250, at least about 300, at least about 350, at least about 400, at least about 450, at least about 500, at least about 550, at least about 600, at least about 650, at least about 700, at least about 750, at least about 800, at least about 850, at least about 900, at least about 950, or at least about 1,000 electrochemical cells per minute (including all values ​​and ranges therebetween).

[0054] FIG. 3 illustrates a gravity dryer 210, according to one embodiment. In some embodiments, gravity dryer 210 can be the same as or substantially similar to gravity dryer 110 described above with reference to FIG. 2 . Accordingly, certain aspects of gravity dryer 210 will not be described in further detail herein. As shown, gravity dryer 210 includes a powder loading port 212, a powder discharge port 213, a gas inlet 214, and a gas outlet 215. As shown, powder includes active material AM and conductive material CM that are fed into gravity dryer 210. The powder falls through gravity dryer 210 while gas G is fed through gravity dryer 210.

[0055] In some embodiments, powder loading port 212 may include a mesh to filter out larger particles. In some embodiments, powder loading port 212 may include a funnel-shaped opening to facilitate pouring. Exit port 213 discharges the powder from the gravity dryer. In some embodiments, exit port 213 may be fluidly coupled to another process unit (e.g., a mixer). Gas G is supplied to gravity dryer 210 via a gas inlet. In some embodiments, gas G may be supplied at positive pressure. In some embodiments, the gas G may be supplied at a pressure of at least about 1 bar, at least about 1.5 bar, at least about 2 bar, at least about 2.5 bar, at least about 3 bar, at least about 3.5 bar, at least about 4 bar, at least about 4.5 bar, at least about 5 bar, at least about 5.5 bar, at least about 6 bar, at least about 6.5 bar, at least about 7 bar, at least about 7.5 bar, at least about 8 bar, at least about 8.5 bar, at least about 9 bar, or at least about 9.5 bar. In some embodiments, gas G can be supplied at a pressure of about 10 bar or less, about 9.5 bar or less, about 9 bar or less, about 8.5 bar or less, about 8 bar or less, about 7.5 bar or less, about 7 bar or less, about 6.5 bar or less, about 6 bar or less, about 5.5 bar or less, about 5 bar or less, about 4.5 bar or less, about 4 bar or less, about 3.5 bar or less, about 3 bar or less, about 2.5 bar or less, about 2 bar or less, or about 1.5 bar or less. Combinations of the above pressures of gas G supplied to gravity dryer 210 are also possible (e.g., at least about 1 bar and about 10 bar or less, or at least about 2 bar and about 5 bar or less), including all values ​​and ranges therebetween. In some embodiments, the gas G may be supplied at a pressure of about 1 bar, about 1.5 bar, about 2 bar, about 2.5 bar, about 3 bar, about 3.5 bar, about 4 bar, about 4.5 bar, about 5 bar, about 5.5 bar, about 6 bar, about 6.5 bar, about 7 bar, about 7.5 bar, about 8 bar, about 8.5 bar, about 9 bar, about 9.5 bar, or about 10 bar.

[0056] As shown, gravity dryer 210 includes a single gas inlet 214 and a single gas outlet 215. In some embodiments, gravity dryer 210 can include multiple gas inlets 214 and / or gas outlets 215. In some embodiments, gravity dryer 210 can include at least about 2, at least about 3, at least about 4, at least about 5, at least about 6, at least about 7, at least about 8, at least about 9, or at least about 10 gas inlets 214 and / or gas outlets 215. As shown, gas G flows perpendicular to the powder flow. In some embodiments, gas G can flow countercurrent to the powder flow. In some embodiments, gas G can flow parallel to the powder flow.

[0057] FIG. 4 is a diagram of a compressor 220, according to one embodiment. In some embodiments, the compressor 220 can be the same as or substantially similar to the compressor 120 described above with reference to FIG. 2 . Accordingly, certain aspects of the compressor 220 will not be described in further detail herein. The compressor 220 forms the semi-solid electrode material into a semi-solid electrode brick. As shown, the compressor 220 includes a container 222, a piston 224, and a pump 226. The conductive material CM and the active material AM are shown in a compressed state. In some embodiments, an electrolyte can be included in the material being compressed (i.e., the material in the compressor 220 can be a semi-solid electrode). In some embodiments, the electrolyte can be added to the compressor 220. In some embodiments, the electrolyte can be injected into the compressor 220. Methods and apparatus for injection are described in more detail in the '087 patent.

[0058] The container 222 holds the semi-solid electrode material in place during compression. In some embodiments, the container 222 can have a cylindrical shape, a cubic shape, a rectangular prism shape, or any other suitable shape. In some embodiments, the container 222 has a volume of at least about 0.1 L, at least about 0.5 L, at least about 1 L, at least about 5 L, at least about 10 L, at least about 50 L, at least about 100 L, at least about 500 L, at least about 1 m 3 , or at least about 5 m3 In some embodiments, the vessel 222 may have a volume of about 10 m 3 Below, approximately 5m 3 Below, approximately 1m 3 The vessel 222 may have a volume of about 500 L or less, about 100 L or less, about 50 L or less, about 10 L or less, about 5 L or less, about 1 L or less, or about 0.5 L or less. Combinations of the above volumes of the vessel 222 (e.g., at least about 0.1 L and about 10 m 3 In some embodiments, the container 222 may have a volume of about 0.1 L, about 0.5 L, about 1 L, about 5 L, about 10 L, about 50 L, about 100 L, about 500 L, about 1 m 3 , about 5m 3 , or about 10 m 3 The volume of the suction pipe may be 1000 vol.

[0059] Piston 224 compresses the semi-solid electrode material (i.e., by moving along line AA) to form a semi-solid electrode brick. In some embodiments, piston 224 may include a gasket around its edge to form a seal with container 222. In some embodiments, vacuum pump 226 may remove gas and / or electrolyte from the semi-solid electrode material in container 222. In some embodiments, the vacuum pump may draw a vacuum of at least about 0.1 bar, at least about 0.2 bar, at least about 0.3 bar, at least about 0.4 bar, at least about 0.5 bar, at least about 0.6 bar, at least about 0.7 bar, at least about 0.8 bar, or at least about 0.9 bar (including all values ​​and ranges therebetween).

[0060] FIG. 5 is a diagram of a cartridge 230 having a molding device 250, according to one embodiment. In some embodiments, the cartridge 230 and molding device 250 can be the same as or substantially similar to the cartridge 130 and molding device 150 described above with reference to FIG. 2 . Accordingly, certain aspects of the cartridge 230 and molding device 250 will not be described in further detail herein. In some embodiments, the cartridge 230 can be part of the same structure as the compressor 220, as described above with reference to FIG. 4 . In other words, a single device can perform all of the functions of the compressor 230 and the cartridge 230. As shown, the cartridge 230 includes a container 232, a piston 234, and a nozzle opening 237, while the molding device 250 (attached to the cartridge 230) includes an upper blade 252 and side plates 254 a, 254 b (collectively referred to as side plates 254). As shown, the nozzle opening 237 is a wide opening obstructed by the upper blade 252 and is therefore shown with a dotted line. The cartridge 230 may dispense portions of the semi-solid electrode brick SSEB onto the conveyor 248a.

[0061] The container 232 contains the semi-solid electrode brick SSEB. In some embodiments, the container 232 can have a cylindrical shape, a cubic shape, a rectangular prism shape, or any other suitable shape. In some embodiments, the container 232 has a volume of at least about 0.1 L, at least about 0.5 L, at least about 1 L, at least about 5 L, at least about 10 L, at least about 50 L, at least about 100 L, at least about 500 L, at least about 1 m 3 , or at least about 5 m 3 In some embodiments, the vessel 232 may have a volume of about 10 m 3 Below, approximately 5m 3 Below, approximately 1m 3 The vessel 232 may have a volume of about 500 L or less, about 100 L or less, about 50 L or less, about 10 L or less, about 5 L or less, about 1 L or less, or about 0.5 L or less. Combinations of the above volumes of the vessel 232 (e.g., at least about 0.1 L and about 10 m 3In some embodiments, the container 232 may have a volume of about 0.1 L, about 0.5 L, about 1 L, about 5 L, about 10 L, about 50 L, about 100 L, about 500 L, about 1 m 3 , about 5m 3 , or about 10 m 3 The piston 234 pushes the semi-solid electrode brick SSEB such that a portion of the semi-solid electrode brick SSEB exits the cartridge 230 through a nozzle opening 237.

[0062] As shown, the top blade 252 controls the thickness of the semi-solid electrode, while the side plate 254 controls the width of the semi-solid electrode. In some embodiments, the top blade 252 and / or the side plate 254 can be adjusted with micron-level precision. In some embodiments, the top blade 252 and / or the side plate 254 can be controlled by an algorithm that can train a closed-loop process algorithm. In some embodiments, the side plate 254 can create a seal with the conveyor 248a to prevent portions of the semi-solid electrode from flowing sideways out of the nozzle. In some embodiments, the side plate 254 can be clamped to the cartridge 230 via a clamp plate. In some embodiments, the side plate can be made of polyethylene terephthalate (PET). In some embodiments, the side plate can have a thickness of about 0.15 mm, about 0.2 mm, or about 0.25 mm (including all values ​​and ranges therebetween).

[0063] In some embodiments, supports may be placed below the conveyor 248a to prevent deflection of the conveyor 248a due to forces exerted on the conveyor 248a from the casting of the semi-solid electrode bricks SSEBs. In some embodiments, the conveyor 248a may be supported from above (e.g., via beams suspended from the ceiling) to prevent deflection of the conveyor 248a due to forces exerted on the conveyor 248a from the casting of the semi-solid electrode bricks SSEBs.

[0064] FIG. 6 illustrates a laser cutter 240, according to one embodiment. The laser cutter 240 cuts the current collector material CCM being transported along a conveyor 248b. In some embodiments, the laser cutter 240 may be the same as or substantially similar to the laser cutter 140 described above with reference to FIG. 2 . Accordingly, certain aspects of the laser cutter 240 will not be described in further detail herein. The current collector material CCM is applied to the pouch material PM and cut via the laser cutter 240. In some embodiments, portions of the current collector material CCM are removed to create an area of ​​pouch material PM around the edges of the current collector material CCM for sealing. In some embodiments, the laser cutter 240 may have an accuracy (i.e., margin of error) of less than about 500 nm, less than about 450 nm, less than about 400 nm, less than about 350 nm, less than about 300 nm, less than about 250 nm, less than about 200 nm, less than about 150 nm, less than about 100 nm, less than about 90 nm, less than about 80 nm, less than about 70 nm, less than about 60 nm, less than about 50 nm, less than about 40 nm, less than about 30 nm, less than about 20 nm, or less than about 10 nm.

[0065] In some embodiments, the conveyor 248a can advance horizontally. In some embodiments, the conveyor 248a can include multiple members or pallets (not shown) arranged side by side that advance horizontally. In some embodiments, rotating wheels or drums on either side of the conveyor 248a can facilitate movement of the conveyor 248a. In some embodiments, one or more pusher fingers can be housed within the conveyor 248a to push portions of the current collector material CCM into the gaps between the pallets. In some embodiments, the pusher fingers housed within the conveyor 248a can include a vacuum within the pusher fingers so that the pusher fingers can contact the current collector material CCM (or the conveyor belt on which the current collector material CCM is resting) and pull the current collector material CCM into the gaps between the pallets. In some embodiments, the pallets can come together to sandwich the pushed portions of the current collector material CCM. Pressing / squeezing portions of the current collector material CCM before casting the electrode material onto the conveyor 248a can help create space between the electrode material when the pallets are later released and spaced apart from each other again, so that the electrode material can separate into separate electrodes.

[0066] FIG. 7 is a diagram of a wetting device 260 and tunnel 268, according to one embodiment. In some embodiments, the wetting device 260 and tunnel 268 can be the same as or substantially similar to the wetting device 160 and tunnel 168 described above with reference to FIG. 2 . Accordingly, certain aspects of the wetting device 160 and tunnel 168 will not be described in further detail herein. As shown, the wetting device 260 is a sprayer. In some embodiments, other wetting devices, such as a hose or inkjet, may be used. The wetting device 260 may dispense an electrolyte or electrolyte solvent onto the semi-solid electrode being transported along the conveyor 248a. In some embodiments, the sprayed electrolyte or electrolyte solvent may replace solvent lost during other parts of the manufacturing process. Wetting with the electrolyte or electrolyte solvent may improve the electrochemical performance of the semi-solid electrode SSE and / or diffusivity within the SSE. The tunnel 268 may reduce solvent evaporation by limiting exposure to the external atmosphere.

[0067] In some embodiments, the wetting device 260 has a density of at least about 0.5 mg / cm 2 , at least about 1 mg / cm 2 , at least about 1.5 mg / cm 2 , at least about 2 mg / cm 2 , or at least about 2.5 mg / cm 2 In some embodiments, the liquid may be applied to the semi-solid electrode and / or separator at a rate of about 3 mg / cm. 2 Below, about 2.5mg / cm 2 Below, about 2mg / cm 2 Below, about 1.5mg / cm 2 or less, or about 1 mg / cm 2 The liquid may be applied to the semi-solid electrode and / or separator at the following rates: A combination of the above amounts of liquid applied to the electrode and / or separator (e.g., at least about 0.5 mg / cm 2 and approximately 3 mg / cm 2 or less, or at least about 1 mg / cm 2 and approximately 2 mg / cm 2In some embodiments, the wetting device 260 has a density of about 0.5 mg / cm 2 , about 1mg / cm 2 , about 1.5mg / cm 2 , about 2mg / cm 2 , about 2.5mg / cm 2 , or about 3 mg / cm 2 The liquid may be applied to the semi-solid electrode and / or separator at a rate of

[0068] In some embodiments, the wetting device 260 has a volume of at least about 0.5 μL / cm 2 , at least about 1 μL / cm 2 , at least about 1.5 μL / cm 2 , at least about 2 μL / cm 2 , or at least about 2.5 μL / cm 2 In some embodiments, the wetting device may apply liquid to the semi-solid electrode and / or separator at a rate of about 3 μL / cm 2 Below, approximately 2.5μL / cm 2 Below, approximately 2μL / cm 2 Below, approximately 1.5μL / cm 2 or less, or about 1 μL / cm 2 The liquid may be applied to the semi-solid electrode and / or separator at the following rates: A combination of the above amounts of liquid applied to the electrode and / or separator (e.g., at least about 0.5 μL / cm 2 and approximately 3 μL / cm 2 or less, or at least about 1 μL / cm 2 and approximately 2 μL / cm 2 In some embodiments, the wetting device 260 has a flow rate of about 0.5 μL / cm 2 , about 1μL / cm 2 , about 1.5μL / cm 2 , about 2μL / cm 2 , about 2.5μL / cm 2 , or about 3 μL / cm 2 The liquid may be applied to the semi-solid electrode and / or separator at a rate of

[0069] 8A and 8B illustrate a pouch sealer 280, according to one embodiment. FIG. 8A illustrates a side view of the pouch sealer 280, while FIG. 8B illustrates a bottom view of the pouch sealer 280. In some embodiments, the pouch sealer 280 can be the same as or substantially similar to the pouch sealer 180 described above with reference to FIG. 2. Accordingly, certain aspects of the pouch sealer 280 will not be described in further detail herein. As shown, the pouch sealer 280 includes a base 282, a heater frame 284, and a wire cartridge 285. In use, the base 282 moves toward the electrochemical cell EC while the electrochemical cell EC is transported along the conveyor 248a. The heater frame 284 contacts the outer edge of the pouch material of the electrochemical cell EC while being heated via an impulse heater. This application of heat seals the outer edge of the pouch material in a single step. The base 282 is then lifted and the heater frame 284 is removed from contact with the electrochemical cell EC. Due to the design of the heater frame 284 extending around the periphery of the electrochemical cell EC, heat sealing of the pouch material can be performed in a single step.

[0070] The heater frame 284 includes a heating wire lining the outer periphery of the heater frame 284. After numerous heating cycles, the wire can become fatigued and unusable. The wire cartridge 285 allows for the deployment of new wire to replace the worn wire. When the wire becomes fatigued, the wire cartridge can dispense a length of new wire from a first portion of the wire cartridge 285 (e.g., via one or more wheels in contact with the new wire), and the worn wire can be placed back into the wire cartridge 285 in a second portion of the wire cartridge. This mechanism is similar to an automatic plastic toilet seat changer.

[0071] Impulse heating of the wires of heater frame 284 can cause heater frame 284 to expand and / or move. In some embodiments, restraints 286 can be placed at various locations around heater frame 284 to minimize movement of heater frame 284 during impulse heating. In some embodiments, restraints 286 can include pins welded to heater frame 284 and / or base 282.

[0072] 9 is a diagram of a gravity dryer 310, according to one embodiment. As shown, gravity dryer 310 includes a container 311, a powder load port 312, a powder discharge port 313, a gas inlet 314, a gas outlet 315, a vertical plate 316, a feeder tray 317, and a gas-permeable bed 318. In some embodiments, powder load port 312, powder discharge port 313, gas inlet 314, and gas outlet 315 can be the same as or substantially similar to powder load port 212, powder discharge port 231, gas inlet 214, and gas outlet 215 described above with reference to FIG. 3 . Accordingly, certain aspects of powder load port 312, powder discharge port 313, gas inlet 314, and gas outlet 315 will not be described in further detail herein. Active material AM and conductive material CM are shown passing through gravity dryer 310, as is gas G.

[0073] In some embodiments, the container 311 may have a cylindrical shape. The cylindrical shape and / or the inclusion of the vertical plates 316 may maintain a low, but non-zero, vertical solid stress on the powder within the gravity dryer 310. Maintaining a low, non-zero vertical solid stress on the powder within the gravity dryer 310 may prevent the gas G from channeling. In other words, the gas G may begin to channel around the powder and not contribute to drying the powder clusters. The cylindrical shape of the container 311 and / or the inclusion of the vertical plates 316 within the container 311 may help distribute the flow of the gas G, preventing the channeling of the gas G and the clustering of the powder.

[0074] Feed tray 317 may be porous so that gas G flows into vessel 311 through many pores on feed tray 317 rather than through a single orifice. The combination of feed tray 317 and gas permeable bed 318 may help distribute gas G throughout vessel 311. In some embodiments, feed tray 317 may have a circular shape.

[0075] 10A and 10B are diagrams of components of a brick formation system, according to one embodiment. FIG. 10A is a side view, while FIG. 10B is a top view of the components. As shown, the active material AM, the conductive material CM, and the electrolyte (not shown) are mixed and then proceed from mixer 318 to hopper 317. In some embodiments, mixer 318 can include a twin-screw extruder. In some embodiments, mixer 318 can include a twin-screw kneader. From hopper 317, the active material AM, the conductive material CM, and the electrolyte (herein, the active material AM, the conductive material CM, and the electrolyte are collectively referred to as "semi-solid electrode materials") proceed through feeder 319a and / or feeder 319b (collectively referred to as feeders 319) to compressor 320a and / or compressor 320b (collectively referred to as compressors 320). In some embodiments, the compactor 320 can be a brick-forming chamber, where the semi-solid electrode material can be pressed to form semi-solid electrode bricks. Once the semi-solid electrode material is in the compactor 320, brick-forming presses 324a, 324b (collectively referred to as brick-forming presses 324) are inserted. As shown, the feeder 319 is adjustable and can move along line P to align either feeder 319a or feeder 319b with the hopper 317. The semi-solid electrode material flows through feeder 319a to compactor 320a and / or through feeder 319b to compactor 320b. In some embodiments, the semi-solid electrode material in compactor 320a can be pressed by brick-forming press 324a. In some embodiments, the semi-solid electrode material in compactor 320b can be pressed by brick-forming press 324b.

[0076] In some embodiments, the semi-solid electrode material may undergo a conductivity test at conductivity testing stations 325a, 325b (collectively referred to as conductivity testing stations 325). In some embodiments, the conductivity test may be performed with the semi-solid electrode material in the compactor 320. In some embodiments, the semi-solid electrode material may be removed from the compactor 320 prior to the conductivity test. After undergoing the conductivity test, the semi-solid electrode material may be provided in cartridges 330a, 330b (collectively referred to as cartridges 330). In some embodiments, cartridges 330 may be the same as or substantially similar to cartridge 230 described above with reference to FIG. 5 . Accordingly, certain aspects of cartridge 330 will not be described in greater detail herein.

[0077] 11A-11F are diagrams of a compressor 420, according to one embodiment. Each of FIGS. 11A-11F illustrates a different portion of the brick formation process. As shown, compressor 420 includes a vessel base 421, a vessel jacket 422, a sliding platform 423, and a piston 424. In some embodiments, vessel jacket 422 and piston 424 may be the same as or substantially similar to vessel 222 and piston 224 described above with reference to FIG. 4. Accordingly, certain aspects of vessel jacket 422 and piston 424 will not be described in further detail herein.

[0078] In use, the vessel jacket 422 is raised, as shown in FIG. 11A . The vessel base 421 and vessel jacket 422 are moved along the sliding platform 423 to a forward position. While the vessel base 421 and vessel jacket 422 are in the forward position, semi-solid electrode material can be loaded into the vessel jacket 422. In some embodiments, the forward position can be away from the piston 424 so that the piston 424 does not interfere with the loading of the semi-solid electrode material. The semi-solid electrode material is then loaded into the vessel jacket 422. After the semi-solid electrode material is loaded into the vessel jacket 422, the vessel base 421 and vessel jacket 422 are slid along the sliding platform 423 to a rearward position, as shown in FIG. 11B . In some embodiments, the rearward position can position the vessel base 421 and vessel jacket 422 such that they are directly below the piston 424. After the vessel base 421 and vessel jacket 422 are positioned under the piston 424, the piston 424 is lowered, as shown in Figure 11C. The piston 424 compresses the semi-solid electrode material to form a semi-solid electrode brick SSEB.

[0079] After the piston 424 compresses the semi-solid electrode material to form the semi-solid electrode brick SSEB, the piston 424 is raised, as shown in FIG. 11D. After the piston 424 is raised, the container base 421 and container jacket 422 are moved along the sliding platform 423 to a forward position, as shown in FIG. 11E. Then, as shown in FIG. 11F, the container jacket 422 is lowered along the outer periphery of the container base 421 to expose the semi-solid electrode brick SSEB. The semi-solid electrode brick SSEB may then be removed from the compressor 420 and placed into a cartridge (not shown).

[0080] 12A-12E are diagrams of an extrusion system 430, according to one embodiment. As shown, the extrusion system 430 includes a dispenser 436 (e.g., a nozzle) and a rotating drum 441. The rotating drum 441 includes a plurality of pallets 442. The pallets 442 are coupled to a plate cam 443 via a cam lever 445. In some embodiments, the plate cam 443 and cam lever 445 rotate around a stationary anvil drum. The stationary anvil drum can be at or near the center of the rotating drum 441. A conveyor 448 is shown in contact with one or more of the pallets 442. FIG. 12A shows the pallets 442 near the dispenser 436 in an open position, while FIG. 12B shows the pallets 442 near the dispenser 436 in a closed position. In use, a film and / or current collector material (not shown) can be placed on the conveyor 448 and advanced along the pallets 442 through the rotating drum 441. In some embodiments, the film and / or current collector material may function as a conveyor 448. In other words, the film and / or current collector material may move around the outer edge of the rotating drum 441 without a conveyor belt or other transport device underneath the film and / or current collector. In some embodiments, the film may be conveyed around the outer edge of the rotating drum 441. In some embodiments, the current collector material may be conveyed around the outer edge of the rotating drum 441. In some embodiments, the film and current collector material may be conveyed around the outer edge of the rotating drum 441. By adjusting the pallets 442 from an open position to a closed position, the current collector can be sandwiched such that a portion of the film and / or current collector material is sandwiched between the pallets 442. Semi-solid electrode material (not shown) can be dispensed onto the current collector material from a dispenser 436. Upon advancing through the rotating drum 441, the pallets 442 can again separate, leaving the current collector material with the semi-solid electrodes separated from one another. In some embodiments, the pallets 442 may be attached or keyed together to absorb moments, in other words, rather than one pallet absorbing an impact, the pallets 442 may absorb an impact collectively.In some embodiments, the exterior surface of the pallet 442 may be precision ground to a cylindrical shape.

[0081] In some embodiments, cam lever 445 may control the positioning and timing of pallets 442. In some embodiments, pallet vacuum and / or chilled water may be supplied through a multi-pass rotary union in rotating drum 441. In some embodiments, pallets 442 may be polished on rotating drum 441 to ensure height accuracy. In some embodiments, the position of each pallet 442 may be controlled by plate cam 445 and cam lever 443 to eliminate cumulative stacking errors. In some embodiments, a film pushing mechanism may be included to synchronously push current collector material and / or film between pallets 442. In some embodiments, a cylindrical support provides rigidity to pallets 442.

[0082] The size and width of the rotating drum 441 may make it more sturdy than a linear conveying device (e.g., a flat belt) and more resistant to shifting and deflection due to external forces (e.g., from casting or densification equipment). Additionally, the arch shape formed by adjacent pallets 442 may create structural stability within the rotating drum 441 that may resist deflection. The anvil drum at the center of the rotating drum 441 has a cylindrical shape and may provide additional resistance to external forces. Castings from the dispenser 436 may exert significant forces (e.g., about 10 kN, about 20 kN, about 30 kN, about 40 kN, about 50 kN, about 60 kN, about 70 kN, about 80 kN, about 90 kN, or about 100 kN, including all values ​​and ranges therebetween), and a conveying device with a wide base may withstand greater forces. In some embodiments, the rotating drum 441 can have a diameter of at least about 5 cm, at least about 10 cm, at least about 15 cm, at least about 20 cm, at least about 25 cm, at least about 30 cm, at least about 35 cm, at least about 40 cm, at least about 45 cm, at least about 50 cm, at least about 55 cm, at least about 60 cm, at least about 65 cm, at least about 70 cm, at least about 75 cm, at least about 80 cm, at least about 85 cm, at least about 90 cm, at least about 95 cm, at least about 1 m, at least about 2 m, at least about 3 m, at least about 4 m, at least about 5 m, at least about 6 m, at least about 7 m, at least about 8 m, or at least about 9 m. In some embodiments, the rotating drum 441 can have a diameter of about 10 m or less, about 9 m or less, about 8 m or less, about 7 m or less, about 6 m or less, about 5 m or less, about 4 m or less, about 3 m or less, about 2 m or less, about 1 m or less, about 95 cm or less, about 90 cm or less, about 85 cm or less, about 80 cm or less, about 75 cm or less, about 70 cm or less, about 65 cm or less, about 60 cm or less, about 55 cm or less, about 50 cm or less, about 45 cm or less, about 40 cm or less, about 35 cm or less, about 30 cm or less, about 25 cm or less, about 20 cm or less, about 15 cm or less, or about 10 cm or less.

[0083] Combinations of the above diameters (e.g., at least about 5 cm and not more than about 10 cm, or at least about 20 cm and not more than about 40 cm) are also possible for the rotating drum 441, including all values ​​and ranges therebetween. In some embodiments, the rotating drum 441 can have a diameter of about 5 cm, about 10 cm, about 15 cm, about 20 cm, about 25 cm, about 30 cm, about 35 cm, about 40 cm, about 45 cm, about 50 cm, about 55 cm, about 60 cm, about 65 cm, about 70 cm, about 75 cm, about 80 cm, about 85 cm, about 90 cm, about 95 cm, about 1 m, about 2 m, about 3 m, about 4 m, about 5 m, about 6 m, about 7 m, about 8 m, about 9 m, or about 10 m.

[0084] The robustness of the rotating drum 441 can help improve uniformity among the fabricated electrodes. More specifically, the rotating drum 441 resists movement due to casting forces. This resistance to movement can reduce the margin of error in the thickness of the electrode material as it is cast onto the conveyor 448. In other words, thickness variations from one electrode to the next can be minimized. In some embodiments, the robustness of the rotating drum 441 and the uniformity of electrode thickness it provides can eliminate thickness inspection methods (e.g., X-ray inspection) from the electrode fabrication process. This robustness can also be improved by keying or connecting the pallets 442 to each other. In some embodiments, the pallets 442 can be ground cylindrically to form the rotating drum 441. During manufacturing, the pallets 442 can have slight size variations from pallet to pallet. The pallets 442 can be placed on the plate cam 445, and then the rotating drum 441 can be ground cylindrically to smooth the outer surface of the pallets 442. The smoothness of the exterior surface of the pallet 442 may further improve the uniformity of the electrodes cast onto the conveyor 448 .

[0085] As shown, the gap G can be measured between the edges of adjacent pallets 442. In some embodiments, when adjacent pallets 442 are not pressed together, the gap G is at least about 10 μm, at least about 20 μm, at least about 30 μm, at least about 40 μm, at least about 50 μm, at least about 60 μm, at least about 70 μm, at least about 80 μm, at least about 90 μm, at least about 100 μm, at least about 150 μm, at least about 200 μm, at least about 250 μm, at least about 300 μm, at least about 350 μm, at least about 400 μm, at least about 500 μm, at least about 600 μm, at least about 700 μm, at least about 800 μm, at least about 90 ... It can be at least about 450 μm, at least about 500 μm, at least about 550 μm, at least about 600 μm, at least about 650 μm, at least about 700 μm, at least about 750 μm, at least about 800 μm, at least about 850 μm, at least about 900 μm, at least about 950 μm, at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, or at least about 9 mm. In some embodiments, when adjacent pallets 442 are not pressed together, the gap G is about 1 cm or less, about 9 mm or less, about 8 mm or less, about 7 mm or less, about 6 mm or less, about 5 mm or less, about 4 mm or less, about 3 mm or less, about 2 mm or less, about 1 mm or less, about 950 μm or less, about 900 μm or less, about 850 μm or less, about 800 μm or less, about 750 μm or less, about 700 μm or less, about 650 μm or less. The gap G may be about 600 μm or less, about 550 μm or less, about 500 μm or less, about 450 μm or less, about 400 μm or less, about 350 μm or less, about 300 μm or less, about 250 μm or less, about 200 μm or less, about 150 μm or less, about 100 μm or less, about 90 μm or less, about 80 μm or less, about 70 μm or less, about 60 μm or less, about 50 μm or less, about 40 μm or less, about 30 μm or less, or about 20 μm or less. Combinations of the above values ​​for the gap G when adjacent pallets 442 are not pressed together are also possible (e.g., at least about 10 μm and about 1 cm or less, or at least about 100 μm and about 1 mm or less), including all values ​​and ranges therebetween.In some embodiments, when adjacent pallets 442 are not pressed together, the gap G can be about 10 μm, about 20 μm, about 30 μm, about 40 μm, about 50 μm, about 60 μm, about 70 μm, about 80 μm, about 90 μm, about 100 μm, about 150 μm, about 200 μm, about 250 μm, about 300 μm, about 350 μm, about 400 μm, about 450 μm, about 500 μm, about 550 μm, about 600 μm, about 650 μm, about 700 μm, about 750 μm, about 800 μm, about 850 μm, about 900 μm, about 950 μm, about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, or about 1 cm.

[0086] In some embodiments, when adjacent pallets 442 are pressed together, the gap G is about 2 mm or less, about 1 mm or less, about 950 μm or less, about 900 μm or less, about 850 μm or less, about 800 μm or less, about 750 μm or less, about 700 μm or less, about 650 μm or less, about 600 μm or less, about 550 μm or less, about 500 μm or less, about 450 μm or less, about 400 μm or less, about 350 μm or less, about 300 μm or less , about 250 μm or less, about 200 μm or less, about 150 μm or less, about 100 μm or less, about 90 μm or less, about 80 μm or less, about 70 μm or less, about 60 μm or less, about 50 μm or less, about 40 μm or less, about 30 μm or less, about 20 μm or less, about 10 μm or less, about 9 μm or less, about 8 μm or less, about 7 μm or less, about 6 μm or less, about 5 μm or less, about 4 μm or less, about 3 μm or less, about 2 μm or less, or about 1 μm or less.

[0087] In some embodiments, the rotating drum 441 may rotate at a rotational speed of at least about 10 rpm, at least about 20 rpm, at least about 30 rpm, at least about 40 rpm, at least about 50 rpm, at least about 60 rpm, at least about 70 rpm, at least about 80 rpm, at least about 90 rpm, at least about 100 rpm, at least about 150 rpm, at least about 200 rpm, at least about 250 rpm, at least about 300 rpm, at least about 350 rpm, at least about 400 rpm, at least about 450 rpm, or at least about 500 rpm (including all values ​​and ranges therebetween).

[0088] In some embodiments, the rotating drum 441 can include a vacuum within the rotating drum 441 so that the vacuum can draw and push portions of the conveyor 448 (and the current collector material disposed thereon) into the rotating drum 441, as shown in FIG. 12C . Vacuum tacking can pull the conveyor 448 and the portions of the current collector material thereon inward, facilitating pushing of the current collector. Inducing pushing from within the rotating drum 441 can help prevent contamination of the electrode material dispensed on the current collector material. More specifically, the tacking arm or tacking finger, if not timed properly, can contact the electrode material disposed on the current collector material. This electrode material can become deposited on the tacking arm or tacking finger. This deposited electrode material can subsequently contaminate electrode material passing over the rotating drum 441. Including a vacuum within the rotating drum 441 can prevent pieces of material from contacting and contaminating other materials. Additionally, the vacuum within the rotating drum 441 can help push the conveyor 448 and current collector material deeper than the tacking arms or fingers. The rotating drum 441 can move at high speeds (e.g., about 30 rpm, about 40 rpm, about 50 rpm, about 60 rpm, about 70 rpm, about 80 rpm, about 90 rpm, or about 100 rpm, including all values ​​and ranges therebetween). These high speeds can make it difficult for the tacking arms or fingers to accurately target and penetrate deep enough into the spaces between the pallets 442 so that the conveyor 448 and current collector material are fully pushed between the pallets.

[0089] In some embodiments, the conveyor 448 may push with a stagger. In other words, the plate cam 445 may open and close the gap between the pallets 442 over a relatively long period of time. More specifically, two adjacent pallets 442 may separate from each other after moving around a significant portion of the outer edge of the rotating drum 441 while coupled together. This staggered approach may allow the electrode material to be distributed onto the urged current collector material for a longer period of time than if the pallets were simply pushed for a short period of time (e.g., the amount of time required for the rotating drum 441 to move the distance of one pallet 442's width). In some embodiments, adjacent pallets 442 may be coupled together for at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, or at least about 50% of one rotation around the center of the rotating drum 441. In some embodiments, one or more barrel cams may be used to perform the staggered pushing of the conveyor 448.

[0090] As shown in Figures 12A-12C, the dispenser 436 casts the electrode material vertically. In other words, the dispenser 436 casts in a direction perpendicular to the ground when the conveyor 448 is near its highest point on the rotating drum. In some embodiments, the dispenser 436 can cast horizontally (i.e., in a direction parallel to the ground). In some embodiments, the dispenser 436 can cast horizontally onto the side of the conveyor 448, as shown in Figure 12D. For reference, FIG. 12D shows angles relative to the vertical plane at the top of the rotating drum 441 (0 degrees, 90 degrees, 180 degrees, 270 degrees. In some embodiments, the dispenser 436 is angled at about 5 degrees, about 10 degrees, about 15 degrees, about 20 degrees, about 25 degrees, about 30 degrees, about 35 degrees, about 40 degrees, about 45 degrees, about 50 degrees, about 55 degrees, about 60 degrees, about 65 degrees, about 70 degrees, about 75 degrees, about 80 degrees, about 85 degrees, about 90 degrees, about 95 degrees, about 100 degrees, about 105 degrees, about 110 degrees, about 115 degrees, about 120 degrees, about 125 degrees, about 130 degrees, about 135 degrees, about 140 degrees, about 145 degrees, about 150 degrees, about 155 degrees, about 160 degrees, Approximately 165 degrees, approximately 170 degrees, approximately 175 degrees, approximately 180 degrees, approximately 185 degrees, approximately 190 degrees, approximately 195 degrees, approximately 200 degrees, approximately 205 degrees, approximately 210 degrees, approximately 215 degrees, approximately 220 degrees, approximately 225 degrees, approximately 230 degrees, approximately 235 degrees, approximately 240 degrees, approximately 245 degrees, approximately 250 degrees, approximately 255 degrees, approximately 260 degrees, approximately 265 degrees, approximately 270 degrees, approximately 275 degrees , about 280 degrees, about 285 degrees, about 290 degrees, about 295 degrees, about 300 degrees, about 305 degrees, about 310 degrees, about 315 degrees, about 320 degrees, about 325 degrees, about 330 degrees, about 335 degrees, about 340 degrees, about 345 degrees, about 350 degrees, or about 355 degrees (including all values ​​and ranges therebetween).

[0091] In some embodiments, the dispenser 436 may be moved to control the casting gap between the dispenser 436 and the conveyor 448 to an accuracy of less than 10 μm, less than 9 μm, less than 8 μm, less than 7 μm, less than 6 μm, less than 5 μm, less than 4 μm, less than 3 μm, less than 2 μm, or less than 1 μm. In some embodiments, the gap between the dispenser 436 and the conveyor 448 may be adjusted (e.g., via a computer algorithm controlling the movement of the dispenser 436) at intervals of the distance traveled by the conveyor 448. For example, the dispenser 436 may be adjusted once every 10 mm that the conveyor 448 travels. These rapid adjustments may help create uniformity in the thickness of the resulting electrode. In some embodiments, the position of the dispenser 448 relative thereto may be adjusted once about every 1 mm, about every 2 mm, about every 3 mm, about every 4 mm, about every 5 mm, about every 6 mm, about every 7 mm, about every 8 mm, about every 9 mm, about every 10 mm, about every 11 mm, about every 12 mm, about every 13 mm, about every 14 mm, about every 15 mm, about every 16 mm, about every 17 mm, about every 18 mm, about every 19 mm, about every 20 mm, about every 25 mm, about every 25 mm, about every 30 mm, about every 35 mm, about every 40 mm, about every 45 mm, or about every 50 mm (including all values ​​and ranges therebetween) that the conveyor 448 moves.

[0092] 12D, a conveyor 448 travels around the outer periphery of the rotating drum 441. In some embodiments, the conveyor 448 may have a current collector material (not shown) disposed thereon. In some embodiments, the current collector material may travel around the outer periphery of the rotating drum 441 without the conveyor 448.

[0093] As shown in FIG. 12D, the conveyor 448 enters the rotating drum 441 at the bottom of the drum (ie, at approximately 180 degrees relative to the vertical plane at the top of the rotating drum 441). In some embodiments, the conveyor 448 is angled at about 5 degrees, about 10 degrees, about 15 degrees, about 20 degrees, about 25 degrees, about 30 degrees, about 35 degrees, about 40 degrees, about 45 degrees, about 50 degrees, about 55 degrees, about 60 degrees, about 65 degrees, about 70 degrees, about 75 degrees, about 80 degrees, about 85 degrees, about 90 degrees, about 95 degrees, about 100 degrees, about 105 degrees, about 110 degrees, about 115 degrees, about 120 degrees, about 125 degrees, about 130 degrees, about 135 degrees, about 140 degrees, about 145 degrees, about 150 degrees, about 155 degrees, about 160 degrees, about 165 degrees, about 170 degrees, about 175 degrees, about 180 degrees, about 185 degrees, about The rotating drum 441 may be entered at an angle of 190 degrees, about 195 degrees, about 200 degrees, about 205 degrees, about 210 degrees, about 215 degrees, about 220 degrees, about 225 degrees, about 230 degrees, about 235 degrees, about 240 degrees, about 245 degrees, about 250 degrees, about 255 degrees, about 260 degrees, about 265 degrees, about 270 degrees, about 275 degrees, about 280 degrees, about 285 degrees, about 290 degrees, about 295 degrees, about 300 degrees, about 305 degrees, about 310 degrees, about 315 degrees, about 320 degrees, about 325 degrees, about 330 degrees, about 335 degrees, about 340 degrees, about 345 degrees, about 350 degrees, or about 355 degrees (including all values ​​and ranges therebetween).

[0094] As shown in FIG. 12D, the conveyor 448 exits the rotating drum 441 at the top of the drum (ie, at approximately 0 degrees relative to the vertical at the top of the rotating drum 441). In some embodiments, the conveyor 448 is angled at about 5 degrees, about 10 degrees, about 15 degrees, about 20 degrees, about 25 degrees, about 30 degrees, about 35 degrees, about 40 degrees, about 45 degrees, about 50 degrees, about 55 degrees, about 60 degrees, about 65 degrees, about 70 degrees, about 75 degrees, about 80 degrees, about 85 degrees, about 90 degrees, about 95 degrees, about 100 degrees, about 105 degrees, about 110 degrees, about 115 degrees, about 120 degrees, about 125 degrees, about 130 degrees, about 135 degrees, about 140 degrees, about 145 degrees, about 150 degrees, about 155 degrees, about 160 degrees, about 165 degrees, about 170 degrees, about 175 degrees, about 180 degrees, about 185 degrees, about The rotating drum 441 may exit at an angle of 190 degrees, about 195 degrees, about 200 degrees, about 205 degrees, about 210 degrees, about 215 degrees, about 220 degrees, about 225 degrees, about 230 degrees, about 235 degrees, about 240 degrees, about 245 degrees, about 250 degrees, about 255 degrees, about 260 degrees, about 265 degrees, about 270 degrees, about 275 degrees, about 280 degrees, about 285 degrees, about 290 degrees, about 295 degrees, about 300 degrees, about 305 degrees, about 310 degrees, about 315 degrees, about 320 degrees, about 325 degrees, about 330 degrees, about 335 degrees, about 340 degrees, about 345 degrees, about 350 degrees, or about 355 degrees (including all values ​​and ranges therebetween).

[0095] 12D, the conveyor 448 exits the rotating drum 441 at approximately 180 degrees from where it entered the rotating drum 441. In other words, the conveyor 448 contacts or osculates with the rotating drum 441 over approximately 180 degrees. In some embodiments, the conveyor 448 may contact or osculate with the rotating drum 441 at an angle of approximately 5 degrees, 10 degrees, 15 degrees, 20 degrees, 25 degrees, 30 degrees, 35 degrees, 40 degrees, 45 degrees, 50 degrees, 55 degrees, 60 degrees, 65 degrees, 70 degrees, 75 degrees, 80 degrees, 85 degrees, 90 degrees, 95 degrees, 100 degrees, 105 degrees, 110 degrees, 115 degrees, 120 degrees, 125 degrees, 130 degrees, 135 degrees, 140 degrees, 145 degrees, 150 degrees, 155 degrees, 160 degrees, 165 degrees, 170 degrees, 175 degrees, 180 degrees, 185 degrees, 190 degrees, 200 degrees, 210 degrees, 215 degrees, 220 degrees, 225 degrees, 230 degrees, 230 degrees, 240 degrees, 245 degrees, 250 degrees, 250 degrees, 260 degrees, 265 degrees, 270 degrees, 275 degrees, 280 degrees, 285 degrees, 290 degrees, 300 degrees, 310 degrees, 315 degrees, 320 degrees, 325 degrees, 330 degrees, 330 degrees, 340 degrees, 345 degrees, 350 degrees, 350 degrees, 360 degrees, 365 degrees, 370 degrees, 375 degrees The rotating drum 441 may be contacted over an angle of 20 degrees, about 125 degrees, about 130 degrees, about 135 degrees, about 140 degrees, about 145 degrees, about 150 degrees, about 155 degrees, about 160 degrees, about 165 degrees, about 170 degrees, about 175 degrees, about 180 degrees, about 185 degrees, about 190 degrees, about 195 degrees, or about 200 degrees (including all values ​​and ranges therebetween).

[0096] The entry point of the conveyor 448 may be selected so that the conveyor 448 has enough space to lie flat on the outer surface of the pallet 442. Additionally, the greater the angle between the entry and exit points of the conveyor 448, the greater the space (and therefore the time) that the dispenser 436 has to cast the electrode material onto the conveyor 448. As shown, one dispenser 436 is casting the electrode material onto the conveyor 448. In some embodiments, the extrusion system 430 may include multiple dispensers that cast the electrode material onto the conveyor 448.

[0097] FIG. 12D includes section E, which is shown in more detail in FIG. 12E. FIG. 12E shows a close-up view of two pallets 442 pressed together, sandwiching a conveyor 448. As shown, the conveyor 448 is wedged between the pallets 442. Each of the pallets 442 includes a gasket or deformable member 444 disposed on the outer edge of the pallet 442. The gasket 444 may increase friction between adjacent pallets 442 to prevent the pallets 442 from sliding relative to one another. In some embodiments, the pallets 442 may be constructed of stainless steel, aluminum, or a similar metal or material with a smooth surface. When the smooth surfaces of the pallets 442 contact each other, these smooth surfaces may move laterally relative to one another (i.e., toward and away from the center of the rotating drum 441). In other words, the gasket 444 prevents metal-to-metal contact and the resulting sliding. Additionally, gasket 444 may ensure that pallet 442 grips conveyor 448, current collectors, and / or any film material being transported around rotating drum 441 along the entire depth of pallet 444. In some embodiments, gasket 444 may include an O-ring. In some embodiments, gasket 444 may be composed of a deformable material, an elastomeric material, natural rubber, silicone rubber, neoprene rubber, neoprene sponge, cork, or any combination thereof. In some embodiments, gasket 444 may include a seal or sealing member. This may prevent electrolyte or semi-solid electrode material from leaking into sandwiched portions of the current collectors and / or film material during fabrication, while allowing for less than perfect metal-to-metal contact.

[0098] FIG. 13 illustrates a neighboring system 570 having a set of rotating drums 571 a, 571 b for assembling an electrochemical cell, according to one embodiment. FIG. 13 illustrates an anode rotating drum 571 a and a cathode rotating drum 571 b. As shown, the anode rotating drum 571 a includes a pallet 572 a, a cam lever 573 a, a plate cam 575 a, and a conveyor 578 a on which the anode A is disposed. As shown, the cathode rotating drum 571 b includes a pallet 572 b, a cam lever 573 b, a plate cam 575 b, and a conveyor 578 b on which the cathode C is disposed. Separator material SM is dispensed between the anode A and the cathode C. The separator material SM is smoothed via a separator roller. In some embodiments, the rotating drums 571a, 571c, pallets 572a, 572b, cam levers 573a, 573b, plate cams 575a, 575b, and conveyors 578a, 578b may be the same as or substantially similar to the rotating drum 441, pallet 442, cam lever 443, plate cam 445, and conveyor 448 described above with reference to Figures 12A-12C. Accordingly, certain aspects of the rotating drums 571a, 571c, pallets 572a, 572b, cam levers 573a, 573b, plate cams 575a, 575b, and conveyors 578a, 578b will not be described in further detail herein. In some embodiments, casting may be performed on the rotating drums 571a, 571b. In some embodiments, casting may be performed on one or more rotating drums different from the rotating drums 571a, 571b.

[0099] As shown, anode A and cathode C are aligned with a portion of separator material SM disposed therebetween. Cam levers 573a, 573b and plate cams 575a, 575b can induce movement of pallets 572a, 572b relative to the rest of rotating drums 571a, 571b so that anode A and cathode C can be properly aligned. This increases the margin of error in casting anode A onto pallet 572a and cathode C onto pallet 572c. In other words, if the current collector materials (not shown) on which anode A and cathode C are disposed are moving out of phase with each other, movement of pallets 572a, 572b can help correct this misalignment. More specifically, timing errors in dispensing anode A and cathode C can be compensated for by inducing movement of pallets 572a, 572b so that anode A and cathode C can be properly aligned when fabricating the electrochemical cell. In some embodiments, the anode rotating drum 571a and / or cathode rotating drum 571b can include a vacuum disposed therein. In some embodiments, the vacuum can help force the current collector material between the pallets 572a, 572b. In some embodiments, the vacuum can perpetuate the movement of the pallets 572a, 572b relative to the rest of the rotating drums 571a, 571b. In other words, an inward force exerted on the conveyor 578a and the current collector material disposed thereon can exert a force on the pallets 572a on the rotating drum 571a, pushing the pallets 572a away from each other. Similarly, an inward force exerted on conveyor 578b and the current collector material disposed thereon may exert a force on pallets 572b on rotating drum 571b, pushing pallets 572b away from each other.

[0100] In some embodiments, movement of pallets 572a, 572b can align anode A and cathode C in the formed electrochemical cell to within a range of error of less than about 1 mm. In other words, the centerline through anode A can be less than about 1 mm from the centerline through cathode C. In some embodiments, the range of error can be less than about 900 μm, less than about 800 μm, less than about 700 μm, less than about 600 μm, less than about 500 μm, less than about 400 μm, less than about 300 μm, less than about 200 μm, or less than about 100 μm (including all values ​​and ranges therebetween).

[0101] In some embodiments, fiducials or fiducial marks may be added to the anode A, cathode C, current collector material, and / or film. The use of fiducials may help facilitate the alignment process of the anode A and cathode C. For example, an imaging device (e.g., X-ray, CT machine, ultrasound) may detect the fiducials on the anode A and cathode C and communicate with plate cams 575a, 575b to adjust their alignment so that the anode A and cathode C are properly aligned when brought together to form the electrochemical cell. The fiducials may also enable one-sided inspection of a completed electrochemical cell or a completed electrode having multiple layers. For example, if the current collector of a completed electrochemical cell has a visible fiducial on the outside, inspection of the fiducial may be sufficient to confirm proper alignment of the electrodes and other components of the electrochemical cell because they will have been aligned earlier in the fabrication process.

[0102] 14A-14C illustrate a nozzle 636 and its various components, according to one embodiment. The nozzle 636 includes a nozzle opening 637, a side plate 654, and a clamp 655. In some embodiments, the nozzle opening 637 and side plate 654 can be the same as or substantially similar to the nozzle opening 237 and side plate 254 described above with reference to FIG. 5 . Accordingly, certain aspects of the nozzle opening 637 and side plate 654 will not be described in further detail herein. FIG. 14A illustrates a corner view of the nozzle 636 with the side plate 654 attached via the clamp 655. FIG. 14B illustrates an exploded view of the side plate 654 and clamp 655 removed from the nozzle 636. FIG. 14C illustrates a side view of the nozzle 636, showing the side plate 634 contacting and applying a force to the conveyor 648, thereby forming a seal that prevents the semi-solid electrode material from leaking out the sides of the nozzle 636.

[0103] As shown in FIG. 14C , the shroud 654 extends beyond the bottom edge of the nozzle 636 by a margin M. In some embodiments, the margin M can be at least about 0.5 mm, at least about 0.6 mm, at least about 0.7 mm, at least about 0.8 mm, or at least about 0.9 mm. In some embodiments, the margin M can be about 1 mm or less, about 0.9 mm or less, about 0.8 mm or less, about 0.7 mm or less, or about 0.6 mm or less. Combinations of the above ranges for the margin M (e.g., at least about 0.5 mm and about 1 mm or less, or at least about 0.6 mm and about 0.8 mm or less) are also possible, including all values ​​and ranges therebetween. In some embodiments, the margin M can be about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, or about 1 mm.

[0104] FIG. 15 is a diagram of a densification station 790, according to one embodiment. In some embodiments, the densification station 790 may use any of the electrode densification methods described in the '192 publication. As shown, the densification station 790 includes a conveyor 791 having a pallet 797, absorbent material 792, material spools 793a, 793b (collectively referred to as material spools 793), a contact spool 794, a contact spool press 795, and a tacking arm 796. In use, the electrode material EM is transported along the conveyor 791, while the absorbent material 792 is urged adjacent the conveyor 791 and into contact with the electrode material EM. As shown, the electrode material EM is disposed on a current collector material CCM. In some embodiments, the current collector material CCM is disposed on a film (not shown). Absorbent material 792 is supplied from material spool 793a and received by material spool 793b. The absorbent material 792 contacts contact spool 794 and tacking arm 796. Contact spool 794 is positioned above conveyor 791 to place absorbent material 792 in contact with electrode material EM. A portion of the liquid in the electrode material EM is transferred to the absorbent material 792. Contact spool press 795 may adjust the position of contact spool 794 relative to the conveyor. For example, if a greater amount of densification and / or liquid absorption is desired, contact spool press 795 may press down on contact spool 794 with increased force. In some embodiments, the horizontal distance between contact spool 794 and tacking arm 796 may be adjustable. The horizontal distance between contact spool 794 and tacking arm 796 may be adjusted based on the size of the contact area between absorbent material 792 and electrode material EM. As shown, a densification station 790 is included within the cathode casting station. In some embodiments, the anode casting station may include a densification station. In some embodiments, both the anode casting station and the cathode casting station may include a densification station.

[0105] As shown, the densification station 790 is mounted on a flat surface. In some embodiments, the densification station 790 may be mounted on a rotating drum (e.g., the rotating drum 441 described above with reference to FIGS. 12A-12E ). As described above, the rotating drum may be constructed to be wide and sturdy so that it can withstand the forces exerted from densification. In some embodiments, the film and / or current collector material CCM may be pressed between pallets 797 during densification. In some embodiments, densification may be performed on the same rotating drum as casting. That is, densification may be performed on the electrode material EM immediately after it is cast.

[0106] Various concepts may be embodied as one or more methods, at least one example of which has been provided. Actions performed as part of a method may be ordered in any suitable manner. Thus, while shown as sequential actions in an exemplary embodiment, embodiments may be constructed in which actions are performed in an order different from that depicted, which may include performing some actions simultaneously. In other words, it should be understood that such features are not necessarily limited to a particular order of execution, but rather to any number of threads, processes, services, servers, etc., that may execute sequentially, asynchronously, concurrently, in parallel, simultaneously, synchronously, etc., in a manner consistent with this disclosure. Thus, some of these features may be inconsistent with one another in that they cannot coexist in a single embodiment. Similarly, some features may be applicable to one aspect of the innovation and not to other aspects.

[0107] Additionally, the present disclosure may include other innovations not currently described. The applicants reserve all rights in such innovations, including the right to embody such innovations and to file additional applications, continuations, continuations-in-part, divisional applications, etc. Thereof. Accordingly, it should be understood that the advantages, embodiments, examples, functional, characteristic, logical, operational, organizational, structural, topological, and / or other aspects of the present disclosure should not be construed as limitations on the present disclosure as defined by the embodiments, or limitations on equivalents of the embodiments. Depending on the particular needs and / or characteristics of individual and / or business users, database organization and / or relational models, data types, data transmission and / or network frameworks, syntax structures, etc., various embodiments of the technology disclosed herein may be implemented in a manner that allows for great flexibility and customization, as described herein.

[0108] All definitions defined and used herein should be understood to supersede dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0109] As used herein, in certain embodiments, the terms "about" or "approximately," when preceding a numerical value, indicate a range of that value ±10%. When a range of values ​​is provided, it is understood that each intervening value between the upper and lower limits of that range, to one-tenth of the unit of the lower limit unless the context clearly dictates otherwise, and any other stated or intervening value within that stated range, is encompassed within the disclosure. The upper and lower limits of these smaller ranges, which may independently be included in the smaller ranges, are also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. When a stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included within the disclosure.

[0110] The phrase "and / or" as used in the specification and embodiments should be understood to mean "either or both" of the elements so conjoined, i.e., elements that are present conjunctively in some cases and disjunctively in other cases. Multiple elements listed with "and / or" should be construed in the same manner, i.e., "one or more" of the elements so conjoined. Other elements other than the elements specifically identified by the "and / or" clause may optionally be present, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to "A and / or B," when used in conjunction with open-ended language such as "comprising," can refer in one embodiment to A only (optionally including elements other than B), in another embodiment to B only (optionally including elements other than A), in yet another embodiment to both A and B (optionally including other elements), etc.

[0111] As used in the specification and embodiments, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" shall be interpreted as being inclusive, i.e., including at least one of several elements or a list of elements, but also including two or more, and optionally including additional unlisted items. Only terms clearly indicated to the contrary, such as "only one of" or "exactly one of," or, when used in embodiments, "consisting of," shall refer to the inclusion of exactly one element of several elements or a list of elements. Generally, as used herein, the term "or" shall be interpreted as indicating exclusive alternatives (i.e., "one or the other, but not both") only when preceded by terms of exclusivity, such as "either," "one of," "only one of," or "exactly one of." "Consisting essentially of," when used in embodiments, shall have its ordinary meaning as used in the field of patent law.

[0112] As used herein and in the embodiments, the phrase "at least one" in reference to a list of one or more elements should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed in the list of elements, and not excluding any combination of elements in the list of elements. This definition also allows for elements other than those specifically identified in the list of elements to which the phrase "at least one" refers, whether related or unrelated to those specifically identified elements, may optionally be present. Thus, as a non-limiting example, "at least one of A and B" (or equivalently, "at least one of A or B," or equivalently, "at least one of A and / or B") can refer in one embodiment to at least one, optionally including more than one, i.e., A without the presence of B (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, i.e., B without the presence of A (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, i.e., A, and at least one, optionally including more than one, i.e., B (optionally including other elements); etc.

[0113] In the embodiments, as well as in the above specification, all transitional phrases such as "comprise," "include," "carry," "have," "contain," "accompany," "hold," "consisting of," and the like, are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases "consisting of" and "consisting essentially of" shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.

[0114] While specific embodiments of the present disclosure have been outlined above, many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, the embodiments described herein are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the present disclosure. Where the methods and steps described above indicate that certain events occur in a particular order, those skilled in the art, having the benefit of this disclosure, will recognize that the order of certain steps may be changed, and that such changes are in accordance with variations of the present invention. In addition, some of the steps may be performed simultaneously, in a parallel process where possible, or sequentially, as described above. While embodiments have been specifically shown and described, it will be understood that various changes in form and detail may be made.

Claims

1. mixing an active material, a conductive material, and an electrolyte to form a semi-solid electrode material; a gap is present between a first member and a second member disposed along an outer edge of a rotating drum, and a current collector material is transported along a surface of the first member and a surface of the second member; disposing a portion of the current collector material in the gap between the first member and the second member; moving the first member relative to the second member to at least partially close the gap between the first member and the second member such that the current collector material frictionally engages a portion of the first member and a portion of the second member; Dispensing at least a portion of the semi-solid electrode material onto the first member and onto the second member; and moving the first member relative to the second member to reform the gap between the first member and the second member such that a first distinct portion of electrode material and a second distinct portion of electrode material are formed on the surface of the current collector material.

2. The method of claim 1 , wherein the disposing is via a vacuum within the rotating drum.

3. 3. The method of claim 1 or 2, further comprising laser cutting a portion of the current collector material between the first distinct portion of electrode material and the second distinct portion of electrode material to form a first electrode and a second electrode.

4. 4. The method of claim 1, wherein the first member includes a deformable material at an edge of the first member adjacent the second member to prevent lateral sliding of the second member relative to the first member.

5. A method according to any one of claims 1 to 4, wherein movement of the first member relative to the second member is controlled via a cam lever coupled to the first member.

6. The method according to any one of claims 1 to 5, wherein a cam lever rotates around a stationary anvil drum at the centre of the rotating drum.

7. The method of any one of claims 1 to 6, wherein the dispensing is substantially horizontal and tangential to the movement of the current collector material.

8. the rotating drum is a first rotating drum, and the method comprises: conveying the current collector material along a member of a second rotating drum; conveying a third separate portion of the electrode material along a third rotating drum member; 8. The method of any one of claims 1 to 7, further comprising abutting the first distinct portion of electrode material with a third distinct portion of electrode material with a separator material disposed therebetween.

9. 10. The method of claim 8, further comprising cutting the separator material and the current collector material to form an electrochemical cell.

10. 9. The method of claim 8, further comprising: during said abutting, moving said member of said second rotating drum to properly align said first separate portion of electrode material with said third separate portion of electrode material.

11. 10. The method of claim 8, further comprising applying a criterion to at least one of an outer surface of the first discrete portion of electrode material or the current collector material.

12. rotating the current collector material around a plurality of members disposed around an outer periphery of a rotating drum, the plurality of members including a first member and a second member; applying a vacuum to the current collector material from within the rotating drum to draw a portion of the current collector material into the gap between the first member and the second member; frictionally engaging the portion of the current collector between an edge of the first member and an edge of the second member; Dispensing a semi-solid electrode material onto the first member and onto the second member; and separating the edge of the first member from the edge of the second member to form two separate portions of electrode material.

13. The method of claim 12, wherein the current collector material contacts about 90 degrees to about 180 degrees of the rotating drum.

14. 14. The method of claim 12 or 13, wherein a film is disposed between the current collector material and the outer edge of the rotating drum.

15. 15. The method of any one of claims 12 to 14, wherein frictionally engaging the portion of the first current collector is via movement of a first cam lever coupled to the first member and a second cam lever coupled to the second member.

16. 16. The method of any one of claims 12 to 15, wherein the first member and / or the second member comprises a deformable member for increasing friction between the first member and the second member.

17. The method of claim 16 , wherein the deformable member comprises an O-ring.

18. The method of any one of claims 12 to 17, wherein the dispensing is substantially horizontal and tangential to the movement of the current collector material.

19. The method of any one of claims 12 to 18, wherein the dispensing is substantially vertical and tangential to the movement of the current collector material.

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