Systems and methods for infusion mixing a slurry based electrode
Embodiments described in this application relate generally to a system, an apparatus and/or methods for manufacturing electrodes by infusion electrolyte into compacted electrode materials. In some embodiments, a working electrode materials can be produced using an infusion mixing and manufacturing process. In some embodiments, a single-sided finished electrode can be produced directly from a dry powder mixture using an infusion mixing and manufacturing process. In some embodiments, a double-sided finished electrode can be produced directly from a dry powder mixture using an infusion mixing and manufacturing process. The electrodes produced by an infusion mixing and manufacturing process generally perform better than those produced by non-infusion processes.
1. A method of preparing a semi-solid electrode, the method comprising:
combining an active material with a conductive material to form a dry powder intermediate material;
compressing the dry powder intermediate material to form a compressed intermediate material;
infusing an electrolyte into the compressed intermediate material to form a semi-solid material; and
dispensing the semi-solid material onto a current collector to form the semi-solid electrode,
wherein the semi-solid electrode remains semi-solid after the dispensing.
2. The method of claim 1 , further comprising:
drawing a vacuum on the compressed intermediate material.
3. The method of claim 2 , wherein the vacuum is drawn prior to infusion of the electrolyte.
4. The method of claim 2 , wherein the vacuum is drawn during infusion of the electrolyte.
5. The method of claim 1 , wherein the electrolyte is infused via a plurality of inlet ports.
6. The method of claim 1 , further comprising:
drawing a vacuum on the compressed intermediate material via a plurality of outlet ports.
7. A method of preparing a semi-solid electrode, the method comprising:
combining an active material and a conductive material in a vessel of a mixer;
mixing the active material and the conductive material in the mixer to form a mixed dry powder;
after the mixing, compressing the mixed dry powder;
after the compressing, evacuating the vessel to reduce pressure in the vessel;
after the evacuating, transferring an electrolyte to the vessel to form a semi-solid working electrode material; and
dispensing the semi-solid working electrode material from the vessel and onto a current collector to form the semi-solid electrode,
wherein the semi-solid electrode remains semi-solid after the dispensing.
8. The method of claim 7 , further comprising:
evacuating the vessel to reduce pressure in the vessel to near vacuum.
9. The method of claim 8 , wherein evacuation of the vessel to reduce pressure in the vessel achieves an inner-vessel gauge pressure of less than or equal to −28 inches Hg.
10. The method of claim 8 , wherein the vacuum is drawn prior to infusion of the electrolyte.
11. The method of claim 8 , wherein the vacuum is drawn during infusion of the electrolyte.
12. The method of claim 7 , wherein the working electrode material is dispensed through a flow control mechanism.
13. A method of preparing a semi-solid electrode, the method comprising:
combining an active material with a conductive material to form a dry powder intermediate material;
compressing the dry powder intermediate material to form a compressed intermediate material;
transferring a wetting agent to the compressed intermediate material;
infusing an electrolyte into the compressed intermediate material to form a semi-solid material; and
dispensing the semi-solid material onto a current collector to form the semi-solid electrode,
wherein the semi-solid electrode remains semi-solid after the dispensing.
14. The method of claim 13 , further comprising:
drawing a vacuum on the compressed intermediate material prior to transferring the wetting agent to the intermediate material.
15. The method of claim 13 , further comprising:
drawing a vacuum on the compressed intermediate material prior to infusion of the electrolyte.
16. The method of claim 13 , further comprising:
drawing a vacuum on the compressed intermediate material during a first time period prior to transferring the wetting agent to the intermediate material; and
drawing a vacuum on the compressed intermediate material during a second time period prior to transferring the wetting agent to the intermediate material.
17. The method of claim 13 , further comprising:
drawing a vacuum on the compressed intermediate material to achieve an inner-chamber gauge pressure of less than or equal to −28 inches Hg to evacuate air from the compressed intermediate material prior to transfer of the wetting agent to the chamber.
18. The method of claim 13 , further comprising:
drawing a vacuum on the compressed intermediate material to achieve an inner-chamber gauge pressure of less than or equal to −28 inches Hg to evacuate wetting agent from the compressed intermediate material prior to the electrolyte infusion.
19. The method of claim 13 , wherein the active material and the conductive material are combined in a vessel of a mixer and mixed to form the dry powder intermediate material.