Components for use in energy storage devices or energy conversion devices and methods for manufacturing the same

Abstract

A method of manufacturing a component for an energy storage or energy conversion device includes providing a sheet having a plurality of thickness-wise openings, forming a slurry including particles of a ceramic material, depositing the slurry on the sheet having the plurality of thickness-wise openings, and sintering the slurry at a sintering temperature greater than 300°C and less than or equal to 900°C.

Claims

1. A method for manufacturing electrodes for battery cells, The steps include providing an electronically conductive sheet having multiple openings in the thickness direction and containing a metal or metal alloy, The steps include forming a slurry containing particles of electrode active material, The steps include: depositing the slurry on the sheet having the plurality of openings in the thickness direction, so that the slurry penetrates into the sheet; A step of sintering the slurry at a sintering temperature higher than 300°C and lower than or equal to 900°C, wherein the sheet is partially or completely embedded within the electrode, Includes, Before the step of depositing the slurry onto the sheet, A step of providing a support surface and a mask, wherein the mask has at least one window, A step of positioning the sheet between the support surface and the mask such that the first surface of the sheet faces the mask, wherein the first portion of the sheet is shielded by the mask and the second portion of the sheet is exposed through the window of the mask, The steps include: reversibly fixing the mask to the support surface; It further includes, A method wherein the mask is reversibly fixed to the support surface using magnetic means.

2. The slurry further comprises an inorganic sintering aid, The inorganic sintering aid is 10 －１０ Scm －１ Provided by an ion-conducting material having a higher ionic conductivity and a melting point of 900°C or lower, The method according to claim 1.

3. The inorganic sintering aid contains lithium and boron as constituent elements. The method according to claim 2.

4. The inorganic sintering aid is Li ３ BO ３ and Li ３－ｘ B １－ｘ C ｘ O ３ A group consisting of is selected such that 0 < x < 1. The method according to claim 3.

5. Before the step of depositing the slurry onto the sheet, The further step includes fixing the sheet to the substrate. The method according to claim 1.

6. The sheet is fixed to the substrate by a polymer-based adhesive. The method according to claim 5.

7. One of the mask and the support surface is magnetized, and the other of the mask and the support surface contains a magnetic material. The method according to claim 1.

8. Between the step of depositing the slurry and the step of sintering the slurry, The steps include removing the mask from the support surface, The steps include: turning the sheet over so that the first surface of the sheet faces the support surface; The steps include: placing the mask on the sheet and reversibly fixing the mask to the support surface; The steps include: depositing an additional amount of slurry containing the electrode active material particles onto a portion of the second surface of the sheet, which is opposite to the first surface of the sheet; The method according to claim 1, further comprising:

9. The slurry is deposited to a first thickness, the additional amount of slurry is deposited to a second thickness, and the ratio of the first thickness to the second thickness is between 0.5 and 2. The method according to claim 8.

10. Between the step of depositing the slurry and the step of sintering the slurry, The steps include removing the mask from the support surface, The steps include bending the sheet so that a portion of the first part of the sheet overlaps the slurry on which it has accumulated, The steps include: reversibly fixing the mask to the support surface and exposing a portion of the first part of the sheet through the window of the mask; The steps include depositing a further amount of the slurry containing the electrode active material particles onto the exposed portion of the first part of the sheet, The method according to claim 1, further comprising:

11. The step of bending the sheet to reversibly fix the mask to the support surface, followed by the step of further shielding a portion of the first part of the sheet with the mask, Between the step of depositing the further amount of slurry and the step of sintering the slurry, The steps include removing the mask from the support surface, The step of bending the sheet such that the further portion of the first portion of the sheet at least partially overlaps the further amount of slurry, The steps include: reversibly fixing the mask to the support surface such that the further portion of the first portion of the sheet is at least partially exposed through the window of the mask; The steps include depositing a further amount of the slurry containing the electrode active material particles onto the exposed portion of the further portion of the first portion of the sheet, Further including, The method according to claim 10.

12. The slurry is deposited onto the sheet by a tape casting method or a screen printing method. The method according to claim 1.

13. The aforementioned sheet includes iron or steel. The method according to claim 1.

14. The amount of the solid electronically conductive component in the slurry is less than 10 vol% of the total volume of the particles of the electrode active material. The method according to claim 1.

15. The particles of the electrode active material have a D50 particle size in the range of 10 nm to 50 μm. The method according to claim 1.

16. The aforementioned sheet is provided by a woven mesh. The method according to claim 1.

17. The woven mesh has 5-500 strands per centimeter when measured in a direction perpendicular to the strands. The method according to claim 16.

18. The opening has a width in the range of 10-1000 μm. The method according to claim 1.

19. A method for manufacturing battery cells, A step of manufacturing a component according to the method of claim 1, wherein the component is an electrode and the electrode active material is an electrode active material, The steps include fixing the electrode to the substrate, The steps include depositing a further battery layer on the electrode, Methods that include...

20. The step of fixing the electrode to the substrate includes the step of spot welding the electrode to the substrate. The method according to claim 19.

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