Method of automated hybrid lithium-ion cells production and method of the cell assembly and construction
First Claim
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1. A manufacturing method of lithium-ion based single cell electrochemical device comprising the steps of:
- providing a first porous electrode structure having an active material with a carbon and a polymeric binder coated on both sides of a porous metal current collector;
providing a second porous electrode structure having an active material with a carbon and a polymeric binder coated on both sides of a porous metal current collector;
providing a soaked microporous polymeric separator by an aprotic liquid;
bonding said separator between said first electrode structure and said second electrode structure by said binders of said electrodes;
and drying out said aprotic liquid.
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Abstract
The present invention pertains to hybrid lithium-ion based electrochemical devices having a thin microporous polymeric separator bonded to their porous electrodes without special treatment of the separator and without additional adhesive layers. Structures of superior high energy density and power density are disclosed herein, as well as the methods of their assembly and automated production.
21 Citations
18 Claims
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1. A manufacturing method of lithium-ion based single cell electrochemical device comprising the steps of:
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providing a first porous electrode structure having an active material with a carbon and a polymeric binder coated on both sides of a porous metal current collector;
providing a second porous electrode structure having an active material with a carbon and a polymeric binder coated on both sides of a porous metal current collector;
providing a soaked microporous polymeric separator by an aprotic liquid;
bonding said separator between said first electrode structure and said second electrode structure by said binders of said electrodes;
and drying out said aprotic liquid. - View Dependent Claims (7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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2. A manufacturing method of lithium-ion based bi-cell electrochemical device comprising the steps of:
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providing a first porous electrode structure having an active material with carbon and a polymeric binder coated on both sides of a porous metal current collector;
providing a second porous electrode structure having an active material with a carbon and a polymeric binder coated on both sides of a porous metal current collector;
providing a third porous electrode structure having an active material with a carbon and a polymeric binder coated on both sides of a porous metal current collector;
providing a first soaked microporous polymeric separator by an aprotic liquid;
providing a second soaked microporous polymeric separator by an aprotic liquid;
bonding said first separator between said first electrode structure and said second electrode structure, and said second separator between said second electrode structure and said third electrode structure by said binders of said electrodes;
and drying out said aprotic liquid.
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3. A manufacturing method of lithium-ion based bi-cell electrochemical device comprising the step of:
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providing a first porous electrode structure having an active material with a carbon and a polymeric binder coated on both sides of a porous metal current collector;
providing a second porous electrode structure having an active material with carbon and a polymeric binder coated on both sides of a solid metal foil current collector;
providing a third porous electrode structure having an active material with a carbon and a polymeric binder coated on both sides of a porous metal current collector;
providing a first soaked microporous polymeric separator by an aprotic liquid;
providing a second soaked microporous polymeric separator by an aprotic liquid;
bonding said first separator between said first electrode structure and said second electrode structure, and said second separator between said second electrode structure and said third electrode structure by said binders of said electrodes;
and drying out said aprotic liquid.
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4. A structure of lithium-ion based electrochemical device comprising at least two porous electrodes having an active material with a carbon and a polymeric binder coated on both sides of porous metal current collectors of said electrodes;
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at least one microporous polymeric separator bonded between said electrodes by said binders of said electrodes.
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5. A manufacturing method of automated production of a plurality of lithium-ion based single cell electrochemical devices which comprises:
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providing a first porous electrode length having an active material with a carbon and a polymeric binder coated on a porous metal current collector with spaced terminal tabs thereon;
providing a second porous electrode length having an active material with a carbon and a polymeric binder, coated on a porous metal current collector with spaced terminal tabs thereon;
providing first microporous polymeric separator length;
soaking said separator length in an aprotic liquid;
cutting said first electrode and said second electrode lengths into leafs with said terminal tabs thereon;
assembling said first electrode leafs and said second electrode leafs onto said separator length in spaced and synchronized and overlying relation;
bonding together by heat and pressure said first electrode leafs, said separator length and said second electrode leafs into a layered assembly in overlying relation, with said first separator length between said first electrode leafs and said second electrode leafs, wherein said first separator length, said first electrode leafs and said second electrode leafs are assembled in synchronized relation to form single cells layered assembly length;
winding said layered assembly length onto a spool;
or cutting said assembly length between said leafs to form individual single cells; and
drying out said aprotic liquid, stacking, electrically connecting, activating and packaging said cells. - View Dependent Claims (6)
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Specification