Continuous and semi-continuous methods of semi-solid electrode and battery manufacturing
Embodiments described herein relate generally to systems and methods for continuously and/or semi-continuously manufacturing semi-solid electrodes and batteries incorporating semi-solid electrodes. In some embodiments, the process of manufacturing a semi-solid electrode includes continuously dispensing a semi-solid electrode slurry onto a current collector, separating the semi-solid electrode slurry into discrete portions, and cutting the current collector to form a finished electrode.
1. A method, comprising:
disposing a current collector material on a first plate and a second plate such that a first portion of the current collector material is on the first plate, and a second portion of the current collector material is on the second plate;
moving the first plate relative to the second plate such that a third portion of the current collector material is disposed between the first plate and the second plate;
dispensing a semi-solid electrode material onto the first portion of the current collector material and the second portion of the current collector material; and
moving the second plate relative to the first plate, such that the first portion of the current collector material moves relative to the second portion of the current collector material, and the third portion of the current collector material is removed from between the first plate and the second plate, the third portion of the current collector being uncoated.
2. The method of claim 1 , wherein the semi-solid electrode material is binderless.
3. The method of claim 1 , wherein the third portion of the current collector is disposed between, or removed from between the first plate and the second plate by pushing and/or pulling the third portion of the current collector material between the first portion of the current collector material and the second portion of the current collector material via a tucking device.
4. The method of claim 1 , wherein the first plate and the second plate are movable between a first configuration and a second configuration, an edge of the first plate abutting an edge of the second plate to frictionally engage the third portion of the current collector material in the first configuration, the edge of the first plate separated from the edge of the second plate in the second configuration so that the portion of the third current collector material can be removed from between the two plates.
5. The method of claim 1 , further comprising:
adjoining a portion of the semi-solid electrode material with a second electrode interposed by a separator to form a finished electrochemical cell.
6. The method of claim 1 , further comprising:
inspecting the semi-solid electrode material via a video camera and computer processor.
7. The method of claim 1 , wherein moving the second plate relative to the first plate is via rotating the first plate away from the second plate.
8. The method of claim 1 , further comprising:
conveying the first plate and the second plate via a conveyor.
9. The method of claim 8 , wherein the conveyor includes a vacuum pallet.
10. A method, comprising:
disposing a current collector material on a first pallet and a second pallet such that a first portion of the current collector material is on the first pallet, and a second portion of the current collector material is on the second pallet;
moving the first pallet relative to the second pallet such that a third portion of the current collector material is disposed between the first pallet and the second pallet;
dispensing a semi-solid electrode material onto the first portion of the current collector material and the second portion of the current collector material; and
moving the second pallet relative to the first pallet such that the first portion of the current collector material moves relative to the second portion of the current collector material, and the third portion of the current collector material is removed from between the first pallet and the second pallet, the third portion of the current collector being uncoated.
11. The method of claim 10 , wherein the semi-solid electrode slurry is binderless.
12. The method of claim 10 , wherein the third portion of the current collector is disposed between, or removed from between the first pallet and the second pallet by pushing and/or pulling the third portion of the current collector material between the first portion of the current collector material and the second portion of the current collector material via a tucking device.
13. The method of claim 10 , wherein the first pallet has a first securing edge and the second pallet has a second securing edge, the first securing edge abutting the second securing edge to frictionally engage the third portion of the current collector material.
14. The method of claim 10 , further comprising:
adjoining a portion of the semi-solid electrode material with a second electrode interposed by a separator to form a finished electrochemical cell.
15. The method of claim 10 , wherein moving the second pallet relative to the first pallet is via rotating the first pallet away from the second pallet.
16. The method of claim 10 , further comprising:
conveying the first pallet and the second pallet via a conveyor.
17. The method of claim 16 , wherein the conveyor includes a vacuum pallet.
18. A method, comprising:
placing a current collector material on a first plate and a second plate such that a first portion of the current collector material is on the first plate, and a second portion of the current collector material is on the second plate;
moving the first plate relative to the second plate such that a third portion of the current collector material is disposed between the first plate and the second plate;
dispensing a semi-solid electrode material onto the first portion of the current collector material and the second portion of the current collector material; and
rotating the second plate relative to the first plate, such that the first portion of the current collector material moves relative to the second portion of the current collector material, and the third portion of the current collector material is removed from between the first plate and the second plate, the third portion of the current collector being uncoated.
19. The method of claim 18 , wherein the semi-solid electrode slurry is binderless.
20. The method of claim 18 , wherein the third portion of the current collector is disposed between, or removed from between the first plate and the second plate by pushing and/or pulling the third portion of the current collector material between the first portion of the current collector material and the second portion of the current collector material via a tucking device.
21. The method of claim 18 , wherein the first plate has a first securing edge and the second plate has a second securing edge, the first securing edge abutting the second securing edge to frictionally engage the third portion of the current collector material.
22. The method of claim 18 , further comprising:
adjoining a portion of the semi-solid electrode material with a second electrode interposed by a separator to form a finished electrochemical cell.
23. The method of claim 18 , further comprising:
conveying the first plate and the second plate via a conveyor.
24. The method of claim 23 , wherein the conveyor includes a vacuum pallet.