Systems and methods for applying a chemical solution to an electrode

Abstract

Systems and methods including manufacturing a battery cell including first applying a pre-saturation solution to an electrode and second assembling the electrode and a separator into a package to form a battery cell, wherein the pre-saturation solution is applied only to a specified area of the electrode. Other embodiments are disclosed herein.

Description

Attorney Docket No.: 86965.00216TITLE: SYSTEMS AND METHODS FOR APPLYING A CHEMICALSOLUTION TO AN ELECTRODEINVENTORS: Franky Sabelli, Sepehr Khazraei, Jack Bekou, Daniel Le, GuidoBenvenutoCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to, and the benefit of, U.S. Provisional Application Number 63 / 734,602, filed December 16, 2024, which is herein incorporated by this reference in its entirety.BACKGROUND

[0002] Current battery' manufacturing systems and methods require a battery cell to be assembled and then filled with electrolyte solution to enable the flow of energy between electrodes. This filling requires lengthy wetting times to allow the electrolyte to saturate the electrode. Electrolyte filling also requires the battery cells to be filled and sealed under a vacuum. Currently, the wetting time may be as long as 24 hours. During this time the battery cells must be stored but cannot be used. Certain battery cell form factors, such as prismatic cells and cylindrical cells, may need to be degassed after cell formation has occurred. Additional battery cell form factors, such as bipolar cells, may not be suitable for electrolyte filling. Therefore, there is a need for a system and method to reduce the wetting time and to reduce problems related to degassing and electrolyte filling.

[0003] Current battery cells experience an irreversible loss of lithium during their initial charge cycle. To counteract this, electrodes may be prelithiated prior to assembling the battery cells. Prelithiation of an electrode may be performed by electrochemical methods, physical vapor deposition, chemical dipping, or by adding a lithium powder during electrode formation. Much of the lithium is lost during these electrode prelithiation techniques. Additionally, the techniques present significant safety issues for operators. Therefore, there is a need for a system and method to prelithiate electrodes in a safe and non-wasteful manner.SUMMARY

[0004] Various embodiments include a method of manufacturing a battery' cell. The method may include first applying a pre-saturation solution to an electrode, wherein the pre-Attorney Docket No.: 86965.00216 saturation solution is not applied to an edge of the electrode. The method may include second assembling the electrode and a separator into a package to form a battery cell.

[0005] Various embodiments include a method of manufacturing a battery cell. The method may include jetting a pre-s aturati on solution onto an electrode and sealing the electrode into the battery cell.

[0006] Various embodiments can include an article of manufacture. The article of manufacture may be a battery cell. The battery cell may include an electrolyte saturated electrode, wherein an edge of the electrolyte saturated electrode is not saturated with electrolyte. The battery cell may include a housing without a fill port, wherein the electrolyte saturated electrode is internal to the housing.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] To facilitate further description of the embodiments, the following drawings are provided in which:

[0008] FIG. 1A illustrates a battery cell, in accordance with various example embodiments.

[0009] FIG. IB illustrates a top view of an electrode, in accordance with various example embodiments.

[0010] FIG. 1C illustrates a cross section of an electrode, in accordance with various example embodiments.

[0011] FIG. 2 illustrates an electrode, in accordance with various example embodiments.

[0012] FIG. 3 illustrates a precision dispensing system, in accordance with various example embodiments.

[0013] FIGs. 4A-4B illustrate another precision dispensing system, in accordance with various example embodiments.

[0014] FIG. 5 illustrates yet another precision dispensing system, in accordance with various example embodiments.

[0015] FIG. 6 illustrates another precision dispensing system, in accordance with various example embodiments.Attorney Docket No.: 86965.00216

[0016] FIG. 7 illustrates a pouch cell formation process, in accordance with various example embodiments.

[0017] FIG. 8 illustrates a prismatic and / or cylindrical cell formation process, in accordance with various example embodiments.

[0018] FIG. 9 illustrates a bipolar cell formation process, in accordance with various example embodiments.

[0019] FIG. 10 illustrates a cross section view of a battery cell, in accordance with various example embodiments.

[0020] FIGs. 11A-11B illustrate a cross section view of a bipolar battery cell, in accordance with various example embodiments.

[0021] FIG. 12 illustrates a pre-s aturati on system integrated into an existing manufacturing process, in accordance with various example embodiments.DETAILED DESCRIPTION

[0022] The following description is of various example embodiments only, and is not intended to limit the scope, applicability or configuration of the present disclosure in any way. Rather, the following description is intended to provide a convenient illustration for implementing various embodiments including the best mode. As will become apparent, various changes may be made in the function and arrangement of the elements described in these embodiments without departing from the scope of the appended claims.

[0023] Disclosed herein are systems, methods, and devices for pre-s aturati on of a battery electrode. Aspects and / or embodiments are directed to an electrode that is pre-saturated with solution before being manufactured into a battery cell. The electrode can be saturated with a number of solutions and can be saturated by a variety of techniques. Moreover, other portions of a battery cell can be pre-saturated. Stated differently, the disclosure is not limited to saturating an electrode with an electrolyte solution.

[0024] Systems, apparatus, and methods of the present disclosure can be used for a great variety of applications, such as applications in which it is desirable to precisely saturate a substrate or portion of a substrate with a solution. Examples of such applications can be pouch cell manufacturing, prismatic cell manufacturing, cylindrical cell manufacturing, and bipolar cell manufacturing.Attorney Docket No.: 86965.00216

[0025] For the sake of brevity, conventional techniques for battery cell manufacturing and / or the like may not be described in detail herein. Furthermore, the connecting lines shown in various figures contained herein are intended to represent example functional relationships and / or physical couplings between various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system for pre-saturating battery elements and / or related methods.

[0026] According to various embodiments and with reference to FIG. 1A-C, components of a battery cell 100, particularly an electrode 110 and / or separator 120, may be pre-saturated with a solution prior to cell assembly. In this manner, the solution is applied to the electrode 110 and / or separator 120 before the electrode 110 and / or separator 120 are inserted into the cell housing 130 (i.e., a pouch for pouch cells or a can for cylindrical cells). When referenced herein as a solution, it is contemplated that the solution may be an electrolyte solution, a prelithiation solution, or any other suitable or desirable solution for pre-saturating a battery cell component prior to cell assembly. When referenced herein as an electrode, it is contemplated that the electrode may include a cathode 1080 (FIG. 10) or an anode 1090 (FIG. 10).

[0027] According to various embodiments, the electrode 110 may include a current collector 140. Current collector 140 may be made out of one or more metals, for example, aluminum, copper, nickel, and other suitable conductive materials. In various embodiments, current collector 140 may be made out of more than one conductive material. For example, current collector 140 may be made up of an aluminum plate coupled to a copper plate.

[0028] According to various embodiments, pre-saturating the electrode 110 and / or separator 120 with an electrolyte solution may reduce or completely eliminate the wetting time. In accordance with various example embodiments, the electrolyte solution may include ethylene carbonate (EC), ethyl methyl carbonate (EMC), diethyl carbonate (DEC), dimethyl carbonate (DMC) and / or any suitable electrolyte solvent. In an example embodiment, presaturation with the electrolyte solution may eliminate the need to fdl the battery cell with electrolyte after manufacturing. Therefore, pre-saturation enables cell form factors which present difficulty in filling with electrolyte solution, such as bipolar cells (FIG. 11), to be manufactured much more efficiently and easily. Further, a precision dispensing system 300 (FIG. 3) may deposit exactly the quantity of electrolyte solution required for an electrode 110 and / or separator 120, thereby reducing waste. Accordingly, pre-saturating the electrode 110Attorney Docket No.: 86965.00216 and / or separator 120 with an electrolyte solution prior to cell assembly presents many advantages.

[0029] In various embodiments, it may be desirable to prevent the electrolyte solution from evaporating prior to further processing. In such cases, the electrode may proceed to further processing steps immediately after pre-saturation with an electrolyte solution, thus reducing the opportunity for the evaporation to occur.

[0030] According to various embodiments, pre-saturating the electrode 110 with a prelithiation solution may counteract the loss of lithium that a batten' cell experiences during a first charge cycle. In an example embodiment, a prelithiation solution may comprise tetrahydrofuran (THF), linear ethers, and / or cyclic polyether solvents. Battery cells with electrodes that are not prelithiated may exhibit a first cycle columbic efficiency of about 80- 90%. Battery cells with prelithiated electrodes may exhibit a first cycle columbic efficiency of about 97 to 100%. In an example embodiment, the method of prelithiation of the electrode 110 is configured to generate greater battery efficiency.

[0031] With reference now to FIG. 3, and in accordance with various embodiments, to reduce waste and safety hazards associated with prelithiation of electrode 110, a precision dispensing system 300 may be used. In an example embodiment, the precision dispensing system 300 may be configured to eliminate the need for operators to handle or interact with large quantities of lithium. Further, the precision dispensing system 300 may be configured to deposit exactly the quantity of prelithiation solution required for an electrode 110, thereby reducing waste. In various embodiments, it may be desirable for the lithium carrying solvent of the prelithiation solution to evaporate prior to further processing of the electrode. In such cases, an optional dry ing step may be added.

[0032] According to various embodiments and with reference to FIG. 3, the precision dispensing system 300 may be configured to deposit an electrolyte solution onto an electrode 110. According to various embodiments, the precision dispensing system 300 may be used to deposit a prelithiation solution onto an electrode 1 10. According to various embodiments, a precision dispensing system 300 may be used to deposit both an electrolyte solution and a prelithiation solution onto an electrode 110. Multiple precision dispensing systems 300 may be used to deposit multiple different solutions. In an example embodiment, a first precision dispensing system 300 may be used to deposit a prelithiation solution on an electrode 1 10, and a second precision dispensing system 300 may be used to deposit an electrolyte solution on theAttorney Docket No.: 86965.00216 electrode 110. Deposition of a prelithiation solution may occur prior to deposition of an electrolyte solution. Deposition of a pre-saturation solution may create a coating 150 on the electrode 110.

[0033] According to various embodiments, the precision dispensing system 300 may be used to deposit an adhesive onto an electrode 110. In accordance with various example embodiments, the adhesive may be a polyurethane based adhesive, a silicone based adhesive, or any other suitable adhesive for sealing a battery cell.

[0034] With reference to FIG. 2, the precision dispensing system 300 (FIG. 3) is configured to deposit the pre-saturation solution 210 (e.g., an electrolyte solution and / or a prelithiation solution) only onto an interior portion of a face of the electrode 110. In this manner, the precision dispensing system 300 (FIG. 3) is configured to keep one or more edges of the electrode 110 clean and free of solution. The precision dispensing system 300 (FIG. 3) may deposit a pre-saturation solution 210 only on a specified area of an electrode 110. Put another way. the precision dispensing system may not apply a pre-saturation solution 210 to all of an electrode 110. According to various embodiments, it may be preferable to maintain clean and dry edges of the electrode 110 to promote effective sealing of the battery cell. Methods such as dipping or submerging the electrode 110 in a solution do not maintain a clean and dry edge of the electrode, making sealing of the battery cell problematic. Such methods may require additional steps of cleaning and / or drying one or more edges of electrode, adding inefficiency, additional manufacturing time, and additional labor into the battery cell manufacturing process. In an example embodiment, the precision dispensing system 300 (FIG. 3) is configured to eliminate the need for submerging and / or dipping the electrode 110 into a solution.

[0035] Unlike methods including dipping or submerging the electrode in a solution, the precision dispensing system 300 (FIG. 3) may deposit the exact amount of a solution required by the electrode 110. In accordance with another example embodiment, the precision dispensing system 300 (FIG. 3) may be configured to vary the amount of solution deposited on an electrode 110. In an example embodiment, the system may be configured to monitor the amount of solution applied, during the application of the solution, and to determine if sufficient solution has been applied or if more still needs to be applied. The system may further be configured to provide feedback, based on such measurement to control the further deposit of the solution. This is in contrast to the dipping or submerging systems that just apply all the solution possible inevitably over applying solution.Attorney Docket No.: 86965.00216

[0036] Furthermore, in an example embodiment, the precision dispensing system 300 (FIG. 3) is configured to greatly reduce contamination risks and material waste associated with pre-saturation of an electrode 110 with a solution as compared to dipping or submerging the electrode 110 in the solution.

[0037] The precision dispensing system may be configured to apply adhesive 212 in targeted locations on the electrode. With reference to FIG. 2, the precision dispensing system 300 (FIG. 3) may deposit the adhesive 212 only onto an exterior portion of a face of the electrode 110. In this manner, the adhesive 212 is contained to an edge of the electrode 110 to promote effective sealing of the battery cell without compromising efficiency or power density. Deposition of the adhesive 212 may be particularly useful in bipolar cell construction, as each electrode may be sealed to create stacked independent cells for combination into the bipolar cell. Adhesive 212 may additionally be deposited on the outer electrodes of a traditional battery cell. The outer electrodes may then be sealed together, by the adhesive 212, to create an effective pouch cell in combination with the inner electrodes. In this manner, the face of the outer electrodes may be the positive and negative terminals of the battery. In an example embodiment, the precision dispensing system 300 (FIG. 3) may enable precise deposition of a solution in both location for deposition and amount of material to be deposited, may eliminate the dipping process thereby reducing waste, and may ensure the edges of electrode 110 are kept clean and dry.

[0038] According to various embodiments and with further reference to FIG. 3, the precision dispensing system 300 may be any suitable precision dispensing device. For example, the precision dispensing system 300 may be a jetting device 310. The jetting device 310 may be ajet printer. A jetting device 310 may be spaced such that anozzle 320 of the jetting device 310 is spaced apart from electrode 110. For example, the jetting device 310 may be spaced such that the nozzle 320 is about 0.5 millimeters to about 100 millimeters above the electrode 110. In various embodiments, the nozzle 320 may be about 3 millimeters to about 10 millimeters above the electrode 110. In various embodiments, the nozzle may be any suitable distance above the electrode 110. In this manner, the nozzle 320 of the jetting device 310 does not come into physical contact with the electrode 110. Such an arrangement reduces the likelihood of causing damage to electrode 110. The nozzle 320 may be fluidly coupled to a storage of electrolyte solution. The nozzle 320 may be fluidly connected to a storage of prelithiation solution. The nozzle 320 may be fluidly connected to a storage of adhesive. The nozzle 320 may be fluidly connected to two or more storages of various solutions, for exampleAttorney Docket No.: 86965.00216 a storage of electrolyte solution, a storage of prelithiation solution, and a storage of adhesive solution. Although illustrated and described as being included on ajetting device, any suitable precision dispensing device may include a nozzle, such as nozzle 320. The storage of a solution may monitor the amount of fluid remaining in the storage to determine the quantity of solution that has been deposited on an electrode 110. In this manner, the storage of a solution may assist the precision dispensing system 300 in the deposition of a precise quantity of solution. The jetting device 310 may deposit, through the nozzle 320, a solution onto the electrode 110, thereby creating coating 150. The jetting device may deposit an adhesive on electrode 110. The jetting device may deposit the adhesive on an edge of electrode 110.

[0039] An electrolyte solution and / or a prelithiation solution may be deposited at a high kinetic energy. The high kinetic energy7deposition is configured to cause the solution to have greater penetration into the porosity of the electrode 110, enhancing and accelerating wettability. In an example embodiment, a loading (mg / cm2) of an electrolyte solution and / or a prelithiation solution may be about 2 milligrams per square centimeter to about 30 milligrams per square centimeter of electrode 110. In various embodiments, the loading may be about 3 milligrams per square centimeter to about 25 milligrams per square centimeter. In various embodiments, the loading may be any suitable loading for deposition of a solution on an electrode 1 10. In an example embodiment, the dispensing system is configured to eliminate the need to compress the electrode and / or separator after dipping and / or submerging in order to enhance wettability. The flow rate of the solution relative to the distance between the nozzle 320 and electrode 110 may be such that it minimizes any splashing of the solution into a clean edge of electrode 110 while promoting effective penetration of the porosity of electrode 110.

[0040] According to various embodiments and with reference to FIGS. 4A-B, the precision dispensing system 300 (FIG. 3) may be a pad printing apparatus 400. A pre-saturation solution bath 420 may be provided proximal to an electrode manufacturing line. The presaturation solution may be an electrolyte solution. The pre-saturation solution may be a prelithiation solution. A cliche of a pad printer may extend into the pre-saturation solution bath 420 and may retract from the pre-saturation solution bath 420, thereby coating the cliche in pre-saturation solution. The pad printer may then extend the cliche onto the electrode 110, thereby depositing the pre-saturation solution onto the electrode 110 and creating coating 150. The pad printer may deposit the pre-saturation solution on only an interior portion, not an edge, of the electrode 110. The pad printer may deposit the pre-saturation solution only in a specified area on electrode 110. In various embodiments, it may be desirable to repeat the pad printingAttorney Docket No.: 86965.00216 cycle one or more times. In this manner, additional pre-saturation solution may be deposited onto the electrode 110. The pad printing cycle may be repeated with multiple pre-saturation solutions, for example a prelithiation solution and then an electrolyte solution. The force of the cliche contacting the electrode 110 may accelerate and enhance wettability of the electrode 110. The pad printer may deposit an adhesive on electrode 110. The pad printer may deposit the adhesive on an edge of electrode 110.

[0041] According to various embodiments and with reference to FIG. 5, the precision dispensing system 300 (FIG. 3) may be a sprayer 500. The sprayer 500 may spray presaturation solution onto the electrode 110. The pre-saturation solution may be an electrolyte solution. The pre-saturation solution may be a prelithiation solution. The sprayer may spray both a prelithiation solution and then an electrolyte solution onto the electrode 110. The sprayer may create a coating 150 by spraying a pre-saturation solution. The sprayer may be used in combination with a paint mask. The paint mask may be placed around an edge of the electrode 110, such that the pre-saturation solution is prevented from contacting an edge of the electrode 110. In this manner, the edge of electrode 110 is kept clean and dry despite the spraying of presaturation solution. The sprayer may deposit an adhesive on electrode 110. The sprayer may deposit the adhesive on an edge of electrode 110.

[0042] According to various embodiments, the precision dispensing system 300 (FIG. 3) may be a 3D printer. The 3D printer may print a pre-saturation solution onto the electrode 110. The 3D printer may act similarly to or in the same manner as any of the precision dispensing systems and / or devices described above.

[0043] According to various embodiments and with reference to FIG. 6, any of the above discussed precision dispensing systems 300 may be used to apply a pre-saturation solution to a separator 120 that has been stacked on top of electrode 110. By stacking the separator 120 and the electrode 110 prior to application of a solution, the production line may be further simplified, and equipment requirements may be reduced. Furthermore, it was found that wettability of the electrode 110 is significantly enhanced in such an arrangement. In various embodiments, the separator 120 may be made out of a various polymers, such as polyethylene, polypropylene, and / or polyolefins, ceramics, fibrous materials, or any other suitable material for preventing contact between electrodes. A single layer separator may be made out of polyethylene and / or polypropylene. A multi-layer separator may be a tri-layer separator, with outer layers of polypropylene and an inner layer of polyethylene. Both a single layer separator and a multi-layer separator may also include a ceramic coating. In an exampleAttorney Docket No.: 86965.00216 embodiment the ceramic coating may be made out of alumina or silica, or any other suitable material.

[0044] Methods such as dipping and / or submerging an electrode in pre-saturation solution may lead to increased drippage as side and lower faces of the electrode and / or separator are coated in pre-saturation solution, which is then lost to gravity. Drippage of presaturation solution may constitute waste of solution that is unable to be recovered or reused. To prevent drippage, dipping and / or submerging methods use retention layers applied to the electrode to retain electrolyte solution. Retention layers, such as a polyvinylidene fluoride (PVDF) layer, may reduce the power density and performance of the resulting batten7cell. According to various embodiments, any of the foregoing precision dispensing systems and methods may be performed with the upper face of electrode 110 and / or separator 120 receiving the pre-saturation solution. The electrode 110 and / or separator 120 may then remain in a substantially upright orientation during further processing, thereby retaining the pre-saturation solution on the electrode 110 and / or separator 120. Further processing, such as stacking and sealing, may occur immediately after pre-saturation to further reduce drippage of pre-saturation solution from the electrode 110 and / or separator 120. In this manner, the retention layer may be eliminated, thereby increasing the effective power density and performance of the resulting battery cell. Stated another way, in an example embodiment, a cell formed according to the pre-saturation techniques described herein may have no retention layer. By non-limiting example, the temperature of the manufacturing environment may be altered to various effect. For example, the temperature of the manufacturing environment may be cooled to from about 0 degrees Celsius to about -40 degrees Celsius to further reduce drippage by increasing the viscosity of the pre-saturation solution and / or to reduce evaporation of a solution. In another example, the temperature of the manufacturing environment could be heated to increase wettability of the electrode and to reduce viscosity of the pre-saturation solution thereby enhancing deposition.

[0045] According to various embodiments and with reference to FIGs. 1 and 7-9. prior to deposition of the pre-saturation solution, the electrode 110 may be manufactured. Manufacturing of the electrode 110 may include mixing, cutting, and calendaring of the electrode 110 material. The electrode 110 may then undergo punching and / or slitting. The electrode 110 may be dried, after deposition of the pre-saturation solution, an electrode 110 and / or separator 120 may proceed to be stacked in layers with additional electrodes 110 and / or separators 120 to create a stack. Optionally, the electrode 110 and / or separator 120 may beAttorney Docket No.: 86965.00216 pressed after pre-saturation to enhance and accelerate wettability of the electrode 110. The exertion of pressure onto the electrode 110 may serve to force the pre-saturation solution deeper into the pores of the electrode 110. The stack may then be inserted into a package, such as the cell housing 130. The cell housing 130 may be a pouch, a can, a packaging, or any other suitable material for housing a number of electrodes 110 and / or separators 120 to form a battery' cell. The housing may then be sealed. While battery cell housings generally require fill ports to enable the battery cell to be filled with an electrolyte solution, the cell housing 130 does not require a fill port due to the electrode 110 undergoing pre-saturation. Thus, in an example embodiment, the battery' cell housing does not comprise a fill port. Moreover, in an example embodiment, the battery cell housing may comprise a vent port without comprising a fill port.Example Embodiments

[0046] According to one example embodiment and with reference to FIG. 7, a pouch cell may be manufactured according to the above listed sy stems and methods. A pouch cell may be manufactured according to method 700. An electrode may be manufactured (step 710), processed (step 720), and dried (step 730). The electrode may then be pre-saturated with an electrolyte solution and / or prelithiated with a prelithiation solution (step 740). An edge of the electrode may be kept clean and dry during pre-saturation. The electrode may then proceed to Z-fold stacking (step 750), arranging layers of electrodes in parallel. The tabs of the pouch cell may then be welded (step 760). The Z-folded stack may then be inserted into a pouch (step 770), and the pouch may' be sealed (step 780). Optionally, cell fill and wetting may occur (step 785). This cell wetting is an optional step, because in various example embodiments, no additional cell wetting is needed at this stage of the process. However, in other example embodiments, additional cell wetting may be performed, but for a shorter time frame than in methods that do not involve pre-saturation. For example, the additional cell wetting time may be reduced. The cell may then be formed (step 790).

[0047] According to one example embodiment and with reference to FIG. 8, a prismatic cell or a cylindrical cell may be manufactured according to the above listed systems and methods. A prismatic cell or a cylindrical cell may be manufactured according to method 800. An electrode may be manufactured (step 810), processed (step 820), and dried (step 830). The electrode may be pre-saturated (step 840) with an electrolyte solution. The electrode may be pre-saturated (step 840) with a prelithiation solution. The electrode may be pre-saturated (step 840) with an electrolyte solution and a prelithiation solution. An edge of the electrode may be kept clean and dry during pre-saturation. The electrode may then proceed to winding of theAttorney Docket No.: 86965.00216 jelly rolls (step 850). In various embodiments and with reference to FIG. 12, the precision dispensing system can be incorporated into the winding machine. For example, a pre-saturation solution may be deposited on an electrode, such as a cathode, provided by a cathode roll 1210. An anode may be provided by anode roll 1220. A separator may be provided by separator roll 1230. The winding machine may be configured to wind the cathode roll 1210, anode roll 1220, and separator roll 1230 such that the separator is disposed between the cathode and the anode. In such cases, a jetting device and / or a sprayer may be desirable for use as the precision dispensing system. As can be seen from this example embodiment, it is possible to pre-saturate the electrode with a solution while the electrode is moving throughout the manufacturing process (i.e., the electrode does not need to be stopped on the manufacturing line for presaturation). The speed and efficiency of the manufacturing process may therefore be increased, while the electrode handling steps may be reduced. The wound jelly rolls may then undergo welding operations (step 860). The welded jelly rolls may then be inserted into the casing or can, and the casing or can may be welded shut (step 870). Optionally, cell fill and wetting may occur (step 880). The cell may then be formed (step 890).

[0048] According to one example embodiment and with reference to FIG. 9, a bipolar cell may be manufactured according to the above listed systems and methods. A bipolar cell may be manufactured according to method 900. An electrode may be manufactured (step 910), processed (step 920), and dried (step 930). A separator may be stacked on top of the electrode (step 940). The separator, and the electrode, may then be pre-saturated with an electrolyte solution and / or prelithiated with a prelithiation solution (step 950). An edge of the electrode may be kept clean and dry during pre-saturation. The electrode and separator may then undergo stacking and sealing to create a stack (step 960). In various embodiments and with reference to FIG. 10, a cell may include a cathode 1080, an anode 1090 and a separator 120. The cell may further comprise a current collector 140. In the example illustrated in FIG. 10, the current collectors may be connected on their ends to other current collectors. As shown in FIG. 10. a current collector 140 may be in contact with two similar electrodes (i.e., two cathodes 1080 or two anodes 1090), for example in contact with a first electrode on a first face and in contact with a second electrode on a second face of the current collector opposite the first face. In this manner, layers of the cell may be arranged in parallel. Any of the electrodes and / or separators illustrated with respect to FIG. 10 may be treated with a pre-saturation solution as described herein.Attorney Docket No.: 86965.00216

[0049] In various embodiments, and with reference to FIGS 11 A-B, a bipolar cell may include a seal 1150. The seal 1150 may be configured to seal a cathode 1080 and / or an anode 1090 within cell packaging. The stack may then be inserted into the bipolar cell packaging (step 970). The cell may then be formed (step 980). Pre-saturation of the electrode may present several distinct advantages with respect to bipolar cells. For example: bipolar cells are very difficult if not impossible to fill with electrolyte after the stack has been sealed; pre-saturation with an electrolyte solution eliminates the need to fill the cell with electrolyte after sealing; pre-saturation greatly accelerates the wetting time for an electrode; the precision dispensing system ensures that the edge of the electrode are kept clean for sealing; and / or the deposition of the precise amount of required electrolyte solution eliminates cross-layer contamination of electrolyte. Because bipolar cells are arranged in series, cross-layer contamination can lead to shorting of the battery. As shown in FIGS. 11 A-B, a current collector 140 may be in contact with two different electrodes (i.e., a cathode 1080 and an anode 1090), for example in contact with a first electrode on a first face and in contact with a second electrode on a second face of the current collector 140 opposite the first face. In this manner, layers of the cell may be arranged in series. Any of the electrodes and / or separators illustrated with respect to FIGS. 1 1 A-B may be treated with a pre-saturation solution as described herein.

[0050] For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of some features and techniques may be omitted to avoid unnecessarily obscuring the present disclosure. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present disclosure. The same reference numerals in different figures denote the same elements.

[0051] The terms “first,” “second,” “third,” “fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms “include,” and “have,” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, device, or apparatus that comprises a list of elements is not necessarily limitedAttorney Docket No.: 86965.00216 to those elements, but may include other elements not expressly listed or inherent to such process, method, system, article, device, or apparatus.

[0052] The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,” “under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments of the apparatus, methods, and / or articles of manufacture described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

[0053] The terms “couple,” “coupled,” “couples,” “coupling,” and the like should be broadly understood and refer to connecting two or more elements mechanically and / or otherwise. Two or more electrical elements may be electrically coupled together, but not be mechanically or otherwise coupled together. Coupling may be for any length of time, e.g., permanent or semi-permanent or only for an instant. “Electrical coupling” and the like should be broadly understood and include electrical coupling of all types. The absence of the word “removably,” “removable,” and the like near the word “coupled,” and the like does not mean that the coupling, etc. in question is or is not removable.

[0054] As defined herein, two or more elements are “integral” if they are comprised of the same piece of material. As defined herein, two or more elements are “non-integral” if each is comprised of a different piece of material.

[0055] As defined herein, “approximately” can, in some embodiments, mean within plus or minus ten percent of the stated value. In other embodiments, “approximately” can mean within plus or minus five percent of the stated value. In further embodiments, “approximately” can mean within plus or minus three percent of the stated value. In yet other embodiments, “approximately” can mean within plus or minus one percent of the stated value.

[0056] Although systems and methods for pre-saturation of a battery electrode have been described with reference to specific embodiments, it will be understood by those skilled in the art that various changes may be made without departing from the spirit or scope of the disclosure. Accordingly, the disclosure of embodiments is intended to be illustrative of the scope of the disclosure and is not intended to be limiting. It is intended that the scope of the disclosure shall be limited only to the extent required by the appended claims. For example, to one of ordinary’ skill in the art, it will be readily apparent that any element of FIGs. 1-13 mayAttorney Docket No.: 86965.00216 be modified, and that the foregoing discussion of certain of these embodiments does not necessarily represent a complete description of all possible embodiments. For example, one or more of the procedures, processes, or activities of FIG. 3 may include different procedures, processes, and / or activities and be performed by many different modules, in many different orders.

[0057] All elements claimed in any particular claim are essential to the embodiment claimed in that particular claim. Consequently, replacement of one or more claimed elements constitutes reconstruction and not repair. Additionally, benefits, other advantages, and solutions to problems have been described with regard to specific embodiments. The benefits, advantages, solutions to problems, and any element or elements that may cause any benefit, advantage, or solution to occur or become more pronounced, however, are not to be construed as critical, required, or essential features or elements of any or all of the claims, unless such benefits, advantages, solutions, or elements are stated in such claim.

[0058] Moreover, embodiments and limitations disclosed herein are not dedicated to the public under the doctrine of dedication if the embodiments and / or limitations: (1) are not expressly claimed in the claims; and (2) are or are potentially equivalents of express elements and / or limitations in the claims under the doctrine of equivalents.

Claims

Attorney Docket No.: 86965.00216CLAIMSWhat is claimed is:

1. A method of manufacturing a batten' cell, comprising: first, applying a pre-saturation solution to an electrode, wherein the pre-saturation solution is not applied to an edge of the electrode; and second, assembling the electrode and a separator into a package to form the batten cell.

2. The method of claim 1 , further comprising applying an adhesive to the edge of the electrode by a precision dispensing system, wherein the applying the adhesive is prior to the assembling.

3. The method of claim 1, wherein the applying the pre-saturation solution is by a dispensing device.

4. The method of claim 3, further comprising stacking the electrode and the separator.

5. The method of claim 4, wherein the stacking is prior to the applying the pre-saturation solution.

6. The method of claim 3, wherein the pre-saturation solution is an electrolyte solution.

7. The method of claim 3, wherein the pre-saturation solution is a prelithiation solution.

8. The method of claim 3, wherein the pre-saturation solution is a prelithiation solution, and further comprising applying a second pre-saturation solution, wherein the second presaturation solution is an electrolyte solution.

9. The method of claim 1, wherein the applying the pre-saturation solution is by a pad printer.

10. The method of claim 3, wherein the dispensing device comprises ajetting device.

11. The method of claim 3, wherein the dispensing device comprises a 3D printer.Attorney Docket No.: 86965.0021612. A method of manufacturing a batten- cell, comprising: jetting a pre-saturation solution onto an electrode; and sealing the electrode into the battery- cell.

13. The method of claim 12, wherein the pre-saturation solution is an electrolyte solution.

14. The method of claim 12, wherein the pre-saturation solution is a prelithiation solution.

15. The method of claim 12, wherein the pre-saturation solution is a prelithiation solution, and further comprising applying a second pre-saturation solution, wherein the second presaturation solution is an electrolyte solution.

16. The method of claim 12, further comprising stacking a separator onto the electrode.

17. The method of claim 12, further comprising jetting an adhesive onto an edge of the electrode.

18. A battery cell, comprising: an electrolyte saturated electrode, wherein an edge of the electrolyte saturated electrode is not saturated with electrolyte; and a housing without a fill port, wherein the electrolyte saturated electrode is internal to the housing.

19. The battery cell of claim 18, wherein the battery cell does not have a retention layer.

20. The battery cell of claim 19, wherein the electrolyte saturated electrode is prelithiated.

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