Electrochemical cells having semi-solid electrodes and methods of manufacturing the same
Embodiments described herein relate generally to electrochemical cells having semi-solid electrodes that are coated on only one side of a current collector. In some embodiments, an electrochemical cell includes a semi-solid positive electrode coated on only one side of a positive current collector and a semi-solid negative electrode coated on only one side of a negative current collector. A separator is disposed between the semi-solid positive electrode and the semi-solid negative electrode. At least one of the semi-solid positive electrode and the semi-solid negative electrode can have a thickness of at least about 250 μm.
1. A method of manufacturing an electrochemical cell stack, the method comprising:
coating a first semi-solid cathode onto a first surface of a first positive current collector, the first positive current collector having a second surface, the second surface being uncoated;
coating a second semi-solid cathode onto a first surface of a second positive current collector, the second positive current collector having a second surface, the second surface being uncoated;
coupling the second surface of the first positive current collector to the second surface of the second positive current collector.
2. The method of claim 1 , further comprising:
coating a first semi-solid anode onto a first surface of a first negative current collector, the first negative current collector having a second surface, the second surface being uncoated.
3. The method of claim 2 , further comprising:
disposing a first separator between the first semi-solid cathode and the first semi-solid anode.
4. The method of claim 3 , further comprising:
coating a second semi-solid anode onto a first surface of a second negative current collector, the second negative current collector having a second surface, the second surface being uncoated.
5. The method of claim 4 , further comprising:
disposing a second separator between the second semi-solid cathode and the second semi-solid anode.
6. The method of claim 5 , further comprising:
coating a third semi-solid anode onto a first surface of a third negative current collector, the third negative current collector having a second surface, the second surface being uncoated; and
coupling the second surface of the third negative current collector to the second surface of the first negative current collector.
7. The method of claim 6 , further comprising:
coating a third semi-solid cathode onto a first surface of a third positive current collector, the third positive current collector having a second surface, the second surface being uncoated.
8. The method of claim 7 , further comprising:
disposing a third separator between the third semi-solid cathode and the third semi-solid anode.
9. The method of claim 1 , wherein coating the semi-solid cathode onto the first surface of the first positive current collector and/or the first surface of the second positive current collector includes at least one of casting, drop coating, pressing, and roll-pressing.
10. The method of claim 1 , wherein coating the semi-solid cathode onto the first surface of the first positive current collector and/or the first surface of the second positive current collector further comprises:
disposing a frame on the first surface of the first positive current collector, the frame defining an opening;
disposing a semi-solid cathode material into the opening of the frame; and
removing excess semi-solid cathode material from the opening.
11. The method of claim 10 , wherein the frame has a thickness and the thickness of the frame determines the thickness of the semi-solid cathode material.
12. The method of claim 2 , further comprising:
analyzing the first semi-solid cathode, the second semi-solid cathode, and/or the first semi-solid anode with a non-contact instrument.
13. The method of claim 12 , wherein the non-contact instrument is an optical instrument.
14. The method of claim 12 , wherein the non-contact instrument is used to analyze at least one of a surface morphology and thickness uniformity.
15. A method of manufacturing an electrochemical cell stack, the method comprising:
coating a first semi-solid anode onto a first surface of a first negative current collector, the first negative current collector having a second surface, the second surface being uncoated;
coating a second semi-solid anode onto a first surface of a second negative current collector, the second negative current collector having a second surface, the second surface being uncoated;
coupling the second surface of the first negative current collector to the second surface of the first negative current collector.
16. The method of claim 15 , further comprising:
coating a first semi-solid cathode onto a first surface of a first positive current collector, the first positive current collector having a second surface, the second surface being uncoated.
17. The method of claim 16 , further comprising:
disposing a first separator between the first semi-solid cathode and the first semi-solid anode.
18. The method of claim 17 , further comprising:
coating a second semi-solid cathode onto a first surface of a second positive current collector, the second positive current collector having a second surface, the second surface being uncoated.
19. The method of claim 18 , further comprising:
disposing a second separator between the second semi-solid cathode and the second semi-solid anode.
20. The method of claim 19 , further comprising:
coating a third semi-solid cathode onto a first surface of a third positive current collector, the third positive current collector having a second surface, the second surface being uncoated; and
coupling the second surface of the third positive current collector to the second surface of the first positive current collector.
21. The method of claim 20 , further comprising:
coating a third semi-solid anode onto a first surface of a third negative current collector, the third negative current collector having a second surface, the second surface being uncoated.
22. The method of claim 21 , further comprising:
disposing a third separator between the third semi-solid cathode and the third semi-solid anode.
23. The method of claim 15 , wherein coating the semi-solid anode onto the first surface of the first negative current collector and/or the first surface of the second negative current collector includes at least one of casting, drop coating, pressing, and roll-pressing.
24. The method of claim 15 , wherein coating the semi-solid anode onto the first surface of the first negative current collector and/or the first surface of the second negative current collector further comprises:
disposing a frame on the first surface of the first negative current collector and/or the first surface of the second negative current collector, the frame defining an opening;
disposing a semi-solid anode material into the opening of the frame; and
removing excess semi-solid anode material from the opening.
25. The method of claim 24 , wherein the frame has a thickness and the thickness of the frame determines the thickness of the semi-solid anode material.
26. The method of claim 16 , further comprising:
analyzing the first semi-solid anode, the second semi-solid anode, and/or the first semi-solid cathode with a non-contact instrument.
27. The method of claim 26 , wherein the non-contact instrument is an optical instrument.
28. The method of claim 26 , wherein the non-contact instrument is used to analyze at least one of a surface morphology and thickness uniformity.