Methods and apparatuses for energy storage device electrode fabrication
An apparatus for forming an electrode film mixture can have a first source including a polymer dispersion comprising a liquid and a polymer, a second source including a second component of the electrode film mixture, and a fluidized bed coating apparatus including a first inlet configured to receive from the first source the dispersion, and a second inlet configured to receive from the second source the second component.
1. A method for preparing an energy storage device electrode film mixture, comprising:
providing a polymer dispersion to a chamber through a first inlet from a first source, the polymer dispersion comprising a liquid and a polymer, wherein the polymer is a first component of an energy storage device electrode film mixture;
providing a second component of the energy storage device electrode film mixture to the chamber through a second inlet from a second source;
vaporizing the liquid of the polymer dispersion within the chamber to form a dried polymer; and
forming a fluidized bed of the dried polymer and the second component of the electrode film mixture within the chamber to form an electrode film mixture.
2. The method of claim 1 , wherein providing the polymer dispersion comprises providing a dispersion comprising water and polytetrafluoroethylene.
3. The method of claim 1 , wherein providing the second component comprises providing dry particles.
4. The method of claim 1 , wherein providing the second component comprises providing an active electrode component of the electrode film mixture.
5. The method of claim 1 , wherein providing the second component comprises providing a carbon.
6. The method of claim 5 , wherein providing the carbon comprises providing graphite.
7. The method of claim 1 , wherein providing the second component comprises providing a lithium metal oxide.
8. The method of claim 1 , wherein vaporizing the liquid portion of the dispersion comprises passing the dispersion through a spray nozzle into the chamber.
9. The method of claim 1 , further comprising coating the second component with the dried polymer within the chamber.
10. The method of claim 1 , wherein providing the second component is performed prior to providing the polymer dispersion.
11. The method of claim 1 , wherein forming the electrode film mixture does not comprise applying high-shear forces to the dried polymer and the second component within the chamber.
12. The method of claim 1 , wherein forming the fluidized bed comprises introducing a continuous volume of gas into the chamber.
13. The method of claim 12 , further comprising heating the gas prior to introducing the gas into the chamber.
14. The method of claim 1 , further comprising providing a third component of the electrode film mixture to the chamber, the third component selected from the group consisting of an additional binder, an additional active material, a conductive material, and combinations thereof.
15. The method of claim 14 , wherein providing the third component comprises providing the third component to the dried polymer and the second component subsequent to forming the fluidized bed.
16. The method of claim 14 , wherein providing the third component comprises providing the third component to the dried polymer and the second component prior to forming the fluidized bed.
17. A method of forming an electrode film, comprising:
forming an energy storage device electrode film mixture using the method of claim 1 ; and
calendering the electrode film mixture to form an electrode film.
18. The method of claim 17 , wherein calendering the electrode film mixture comprises fibrillizing the polymer.
19. The method of claim 17 , wherein the electrode film is a free-standing film.
20. A method of forming an electrode, comprising:
forming the electrode film using the method of claim 17 ; and
disposing the electrode film over a current collector.