Flexible packaging with embedded electrode and method of making

1. A method of making an embedded electrode, the method comprising:

providing a bed of polymer particles that extends from a first side to a second side;

depositing a mixture on the first side of the bed of polymer particles to form a self-standing electrode, wherein the mixture comprises:

(a) nanotubes and/or nanofibers, and

(b) an active electrode material, and

treating at least a portion of the polymer particles to form a flexible solid body, wherein a portion of the self-standing electrode is embedded in the flexible solid body to form an embedded electrode.

2. The method of claim 1 , wherein at least a portion of the self-standing electrode penetrates the first side of the bed of polymer particles.

3. The method of claim 1 , wherein the self-standing electrode includes a first side and a second side, wherein the second side of the self-standing electrode is embedded in the flexible solid body and the first side of the self-standing electrode extends outward from the flexible solid body.

4. The method of claim 3 , wherein the self-standing electrode comprises the active electrode material distributed throughout an interlinked nanotube network, and a portion of the interlinked nanotube network is embedded in the flexible solid body.

5. The method of claim 1 , further comprising:

fluidizing the mixture with a gas or gas mixture, wherein the gas flows through the bed of polymer particles when the mixture is deposited on the first side of the bed of polymer particles to form the self-standing electrode.

6. The method of claim 1 , wherein the mixture includes a carrier liquid, wherein the liquid flows through the bed of polymer particles when the mixture is deposited on the first side of the bed of polymer particles to form the self-standing electrode.

7. The method of claim 1 , further comprising:

providing a porous substrate, wherein the second side of the bed of polymer particles is positioned on the porous substrate.

8. The method of claim 7 , further comprising:

fluidizing the mixture with a gas or gas mixture, wherein the gas flows through the bed of polymer particles and the porous substrate when the mixture is deposited on the first side of the bed of polymer particles to form the self-standing electrode.

9. The method of claim 7 , wherein the mixture includes a carrier liquid, wherein the liquid flows through the bed of polymer particles and the porous substrate when the mixture is deposited on the first side of the bed of polymer particles to form the self-standing electrode.

10. The method of claim 1 , further comprising:

densifying the self-standing electrode after forming the flexible solid body.

11. The method of claim 1 , wherein the nanotubes are carbon nanotubes and further comprising providing the nanotubes from a carbon nanotube synthesis reactor.

12. The method of claim 11 , wherein the carbon nanotubes are single-walled, multi-walled, or combinations thereof.

13. The method of claim 1 , wherein the active electrode material is selected from graphite, hard carbon, lithium metal oxides, and lithium iron phosphate.

14. The method of claim 13 , wherein the active electrode material comprises graphite.

15. The method of claim 13 , wherein the active electrode material comprises a lithium metal oxide.

16. The method of claim 15 , wherein the active electrode material comprises LiNiMnCoO 2 .

17. The method of claim 1 , wherein the treating comprises heating.

18. The method of claim 17 , wherein the heating forms a flexible solid body from the polymer particles.

19. The method of claim 18 , wherein the polymer particles are at least partially melted by the heating.

20. The method of claim 1 , wherein the embedded electrode is free of binder or metal-based current collector.

21. The method of claim 1 , wherein the depositing the mixture does not significantly degrade aspect ratio of the nanotubes or nanofibers.

22. A continuous method of making an embedded electrode, the method comprising:

continuously providing a bed of polymer particles that extends from a first side to a second side;

continuously depositing a mixture on the first side of the bed of polymer particles to form a self-standing electrode, wherein the mixture comprises:

(a) nanotubes and/or nanofibers, and

(b) an active electrode material, and

continuously treating at least a portion of the polymer particles to form a flexible solid body, wherein a portion of the self-standing electrode is embedded in the flexible solid body to continuously form an embedded electrode.

23. The method of claim 22 , wherein at least a portion of the self-standing electrode penetrates the first side of the bed of polymer particles.

24. The method of claim 22 , wherein the second side of the bed of polymer particles is in contact with a conveyor belt or a roll-to-roll system.

25. The method of claim 22 , further comprising continuously providing the nanotubes from a carbon nanotube synthesis reactor.

26. The method of claim 22 , wherein the active electrode material is selected from graphite, hard carbon, lithium metal oxides, and lithium iron phosphate.

27. The method of claim 26 , wherein the active electrode material comprises graphite.

28. The method of claim 26 , wherein the active electrode material comprises a lithium metal oxide.

29. The method of claim 28 , wherein the active electrode material comprises LiNiMnCoO 2 .

30. The method of claim 25 , wherein the nanotubes are single-walled or multi-walled.

31. The method of claim 22 , wherein the embedded electrode is free of binder or metal-based current collector.

32. The method of claim 22 , wherein the continuously depositing the mixture comprises distributing an aerosolizing gas through a bed of the active electrode material, in an aerosolizing reactor, to produce an aerosolized active electrode material.