IP Library › Granted Patent US 12,456,780
Granted Patent B2
US 12,456,780 · App. 17/733,658 · Granted Oct 28, 2025

Electrochemical cells with multiple separators, and methods of producing the same

Inventors: Junzheng Chen (Concord, MA); Naoki Ota (Lexington, MA); Jeffry Disko (Lexington, MA); Anthony D'Angelo (Medford, MA)
Assignee: 24M Technologies, Inc.
H01M50/414H01M4/131H01M4/136H01M4/1391H01M4/1397H01M10/0562H01M50/403H01M50/46H01M50/491H01M2300/0051
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Quick Facts
Patent No.
US 12,456,780
App. No.
17/733,658
Filed
Apr 29, 2022
Granted
Oct 28, 2025
Kind
B2
Art Unit
1727
USPC
429/129
Abstract

Embodiments described herein relate to electrochemical cells with multiple separators, and methods of producing the same. A method of producing an electrochemical cell can include disposing an anode material onto an anode current collector, disposing a first separator on the anode material, disposing a cathode material onto a cathode current collector, disposing a second separator onto the cathode material, and disposing the first separator on the second separator to form the electrochemical cell. The anode material and/or the cathode material can be a semi-solid electrode material including an active material, a conductive material, and a volume of liquid electrolyte. In some embodiments, less than about 10% by volume of the liquid electrolyte evaporates during the forming of the electrochemical cell. In some embodiments, the method can further include wetting the first separator and/or the second separator with an electrolyte solution prior to coupling the first separator to the second separator.

Claims (35)

1 . A method of forming an electrochemical cell, the method comprising:

disposing an anode material onto an anode current collector;

disposing a first separator on the anode material;

disposing a cathode material onto a cathode current collector;

disposing a second separator onto the cathode material;

wetting at least one of the first separator or the second separator with an electrolyte solution; and

disposing the first separator on the second separator to form the electrochemical cell,

wherein at least one of the anode material or the cathode material is a semi-solid electrode material including an active material, a conductive material, and a volume of a liquid electrolyte;

and wherein less than about 10% by volume of the liquid electrolyte and less than about 10% by volume of the electrolyte solution evaporates during the forming of the electrochemical cell.

2 . The method of claim 1 , wherein wetting the at least one of the first separator and the second separator is via spraying.

3 . The method of claim 1 , wherein less than about 10% of a total volume of a combination of the electrolyte solution and the liquid electrolyte evaporates during the forming of the electrochemical cell.

4 . The method of claim 1 , wherein at least one of the first separator or the second separator is composed of a material with a porosity of less than about 1%.

5 . The method of claim 1 , wherein the cathode current collector, the cathode material, and the second separator collectively form a cathode, the method further comprising:

conveying the cathode along a conveyor.

6 . The method of claim 5 , wherein the anode current collector, the anode material, and the first separator collectively form an anode, and wherein the conveyor is a first conveyor, the method further comprising:

conveying the anode along a second conveyor.

7 . The method of claim 5 , wherein the anode current collector, the anode material, and the first separator collectively form an anode, the method further comprising:

conveying the anode along the conveyor.

8 . The method of claim 1 , wherein the semi-solid electrode material is a first semi-solid electrode material, the method further comprising:

disposing a second semi-solid electrode material between the first separator and the second separator.

9 . The method of claim 8 , further comprising:

measuring a voltage between the second semi-solid electrode material and at least one of the anode current collector or the cathode current collector.

10 . A method of forming an electrochemical cell, the method comprising:

disposing a semi-solid cathode material onto a cathode current collector, the semi-solid cathode material including an active material, a conductive material, and a volume of non-aqueous liquid electrolyte, disposing an anode material onto an anode current collector;

disposing a first separator on the semi-solid cathode;

disposing a second separator on the anode material;

dispensing an electrolyte solution on at least one of the first separator or the separator; and

disposing the first separator on the second separator to form an electrochemical cell, wherein less than about 10% by volume of the electrolyte solution evaporates during the forming of the electrochemical cell.

11 . The method of claim 10 , wherein less than about 10% by volume of the non-aqueous liquid electrolyte evaporates during the forming of the electrochemical cell.

12 . The method of claim 10 , wherein dispensing the electrolyte solution is via spraying.

13 . The method of claim 10 , wherein less than about 10% of a total volume of a combination of the electrolyte solution and the non-aqueous liquid electrolyte evaporates during the forming of the electrochemical cell.

14 . The method of claim 10 , wherein the electrolyte solution includes a solid-state electrolyte.

15 . The method of claim 10 , wherein at least one of the first separator or the second separator has a porosity of less than about 1%.

16 . The method of claim 10 , wherein the cathode current collector, the cathode material, and the second separator collectively form a cathode and the anode current collector, the anode material, and the first separator collectively form an anode, the method further comprising:

conveying at least one of the cathode or the anode along a conveyor.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 4, 2024
From: CHEN, JUNZHENG; OTA, NAOKI; DISKO, JEFFRY; D'ANGELO, ANTHONY
To: 24M TECHNOLOGIES, INC.
Reel/Frame 067005/0096 →
Continuity (2)
Provisional Application 63181721 · Apr 29, 2021
Related Publication 20220352597A1 · Nov 3, 2022
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