One variation of the method includes: receiving a section of a substrate tape including a substrate within a coating zone; dispensing a volume of separator material droplets onto the first substrate, each droplet in the volume of separator material droplets including a first solvent, a first polymer, and a second polymer; heating the substrate and the proportion of the separator material to a first temperature; dissolving the second polymer out of the volume of separator material droplets to render an open-celled network of pores by washing the volume of separator material droplets and the substrate with a second solvent; and irradiating the volume of separator material droplets to crosslink the first polymer and form a discrete separator layer with the open-celled network of pores sized to transport ions through the discrete separator layer.
A method includes, by a folding station: receiving an anode assembly including anode collectors connected by anode interconnects and coated with a separator; receiving a cathode assembly including cathode collectors connected by cathode interconnects; locating a first anode collector over a folding stage; locating a first cathode collector over the first anode collector to form a first battery cell between the first anode collector and the first cathode collector; folding a first anode interconnect to locate a second anode collector over the first cathode collector to form a second battery cell between the first cathode collector and the second anode collector; folding a first cathode interconnect to locate a second cathode collector over the second anode collector to form a third battery cell between the second anode collector and the second cathode collector; wetting the separator with solvated ions; and loading the anode and cathode assemblies into a battery housing.
H01M 10/0583 - Construction or manufacture of accumulators with folded construction elements except wound ones, i.e. folded positive or negative electrodes or separators, e.g. with ‘’Z’’-shaped electrodes or separators
H01M 50/109 - Primary casingsJackets or wrappings characterised by their shape or physical structure of button or coin shape
H01M 50/403 - Manufacturing processes of separators, membranes or diaphragms
One variation of the method includes: receiving a section of a substrate tape including a substrate within a coating zone; depositing a constellation of separator material droplets over the first substrate, each droplet in the constellation of separator material droplets including a first solvent, a first polymer, and a second polymer; heating the substrate and the proportion of the separator material to a first temperature; dissolving the second polymer out of the constellation of separator material droplets to render an open-celled network of pores by washing the constellation of separator material droplets and the substrate with a second solvent; and irradiating the constellation of separator material droplets to crosslink the first polymer and form a discrete separator layer with the open-celled network of pores sized to transport ions through the discrete separator layer.
One variation of the method includes: receiving a section of a substrate tape including a substrate within a coating zone; depositing a constellation of separator material droplets over the first substrate, each droplet in the constellation of separator material droplets including a first solvent, a first polymer, and a second polymer; heating the substrate and the proportion of the separator material to a first temperature; dissolving the second polymer out of the constellation of separator material droplets to render an open-celled network of pores by washing the constellation of separator material droplets and the substrate with a second solvent; and irradiating the constellation of separator material droplets to crosslink the first polymer and form a discrete separator layer with the open- celled network of pores sized to transport ions through the discrete separator layer.
H01M 10/0585 - Construction or manufacture of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
H01M 50/46 - Separators, membranes or diaphragms characterised by their combination with electrodes
H01M 10/0525 - Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodesLithium-ion batteries
H01M 50/449 - Separators, membranes or diaphragms characterised by the material having a layered structure
One variation of the method includes: receiving a section of a substrate tape including a substrate within a coating zone; depositing a constellation of separator material droplets over the first substrate, each droplet in the constellation of separator material droplets including a first solvent, a first polymer, and a second polymer; heating the substrate and the proportion of the separator material to a first temperature; dissolving the second polymer out of the constellation of separator material droplets to render an open-celled network of pores by washing the constellation of separator material droplets and the substrate with a second solvent; and irradiating the constellation of separator material droplets to crosslink the first polymer and form a discrete separator layer with the open-celled network of pores sized to transport ions through the discrete separator layer.
H01M 10/0585 - Construction or manufacture of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
6.
Three-dimensional folded battery unit and methods for manufacturing the same
One variation of a battery unit includes: a series of anode collectors; a set of anode electrodes including anode material arranged on both side of the anode collectors; a set of anode interconnects interposed between and electrically coupling adjacent anode collectors and folded to locate the anode collectors in a boustrophedonic anode stack; a series of cathode collectors; a set of cathode electrodes including cathode material arranged on both side of the cathode collectors; a set of cathode interconnects interposed between and electrically coupling adjacent cathode collectors and folded to locate the cathode collectors in a boustrophedonic cathode stack with cathode collectors interdigitated between anode collectors in the boustrophedonic anode stack; and a set of separators arranged between the anode and cathode electrodes and transporting solvated ions between the anode and cathode electrodes.
H01M 50/534 - Electrode connections inside a battery casing characterised by the material of the leads or tabs
H01M 4/587 - Carbonaceous material, e.g. graphite-intercalation compounds or CFx for inserting or intercalating light metals
H01M 10/0525 - Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodesLithium-ion batteries
H01M 50/403 - Manufacturing processes of separators, membranes or diaphragms
H01M 10/0583 - Construction or manufacture of accumulators with folded construction elements except wound ones, i.e. folded positive or negative electrodes or separators, e.g. with ‘’Z’’-shaped electrodes or separators
A method includes, by a folding station: receiving an anode assembly including anode collectors connected by anode interconnects and coated with a separator; receiving a cathode assembly including cathode collectors connected by cathode interconnects; locating a first anode collector over a folding stage; locating a first cathode collector over the first anode collector to form a first battery cell between the first anode collector and the first cathode collector; folding a first anode interconnect to locate a second anode collector over the first cathode collector to form a second battery cell between the first cathode collector and the second anode collector; folding a first cathode interconnect to locate a second cathode collector over the second anode collector to form a third battery cell between the second anode collector and the second cathode collector; wetting the separator with solvated ions; and loading the anode and cathode assemblies into a battery housing.
H01M 10/0583 - Construction or manufacture of accumulators with folded construction elements except wound ones, i.e. folded positive or negative electrodes or separators, e.g. with ‘’Z’’-shaped electrodes or separators
One variation of a battery unit includes: a series of anode collectors; a set of anode electrodes including anode material arranged on both side of the anode collectors; a set of anode interconnects interposed between and electrically coupling adjacent anode collectors and folded to locate the anode collectors in a boustrophedonic anode stack; a series of cathode collectors; a set of cathode electrodes including cathode material arranged on both side of the cathode collectors; a set of cathode interconnects interposed between and electrically coupling adjacent cathode collectors and folded to locate the cathode collectors in a boustrophedonic cathode stack with cathode collectors interdigitated between anode collectors in the boustrophedonic anode stack; and a set of separators arranged between the anode and cathode electrodes and transporting solvated ions between the anode and cathode electrodes.
H01M 10/0583 - Construction or manufacture of accumulators with folded construction elements except wound ones, i.e. folded positive or negative electrodes or separators, e.g. with ‘’Z’’-shaped electrodes or separators
One variation of a battery unit includes: a series of anode collectors; a set of anode electrodes including anode material arranged on both side of the anode collectors; a set of anode interconnects interposed between and electrically coupling adjacent anode collectors and folded to locate the anode collectors in a boustrophedonic anode stack; a series of cathode collectors; a set of cathode electrodes including cathode material arranged on both side of the cathode collectors; a set of cathode interconnects interposed between and electrically coupling adjacent cathode collectors and folded to locate the cathode collectors in a boustrophedonic cathode stack with cathode collectors interdigitated between anode collectors in the boustrophedonic anode stack; and a set of separators arranged between the anode and cathode electrodes and transporting solvated ions between the anode and cathode electrodes.
H01M 50/534 - Electrode connections inside a battery casing characterised by the material of the leads or tabs
H01M 4/587 - Carbonaceous material, e.g. graphite-intercalation compounds or CFx for inserting or intercalating light metals
H01M 10/0525 - Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodesLithium-ion batteries
H01M 50/403 - Manufacturing processes of separators, membranes or diaphragms
H01M 10/0583 - Construction or manufacture of accumulators with folded construction elements except wound ones, i.e. folded positive or negative electrodes or separators, e.g. with ‘’Z’’-shaped electrodes or separators
A method includes, by a folding station: receiving an anode assembly including anode collectors connected by anode interconnects and coated with a separator; receiving a cathode assembly including cathode collectors connected by cathode interconnects; locating a first anode collector over a folding stage; locating a first cathode collector over the first anode collector to form a first battery cell between the first anode collector and the first cathode collector; folding a first anode interconnect to locate a second anode collector over the first cathode collector to form a second battery cell between the first cathode collector and the second anode collector; folding a first cathode interconnect to locate a second cathode collector over the second anode collector to form a third battery cell between the second anode collector and the second cathode collector; wetting the separator with solvated ions; and loading the anode and cathode assemblies into a battery housing.
H01M 10/04 - Construction or manufacture in general
H01M 10/0583 - Construction or manufacture of accumulators with folded construction elements except wound ones, i.e. folded positive or negative electrodes or separators, e.g. with ‘’Z’’-shaped electrodes or separators
H01M 10/0525 - Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodesLithium-ion batteries
11.
Three-dimensional folded battery unit and methods for manufacturing the same
A method includes, by a folding station: receiving an anode assembly including anode collectors connected by anode interconnects and coated with a separator; receiving a cathode assembly including cathode collectors connected by cathode interconnects; locating a first anode collector over a folding stage; locating a first cathode collector over the first anode collector to form a first battery cell between the first anode collector and the first cathode collector; folding a first anode interconnect to locate a second anode collector over the first cathode collector to form a second battery cell between the first cathode collector and the second anode collector; folding a first cathode interconnect to locate a second cathode collector over the second anode collector to form a third battery cell between the second anode collector and the second cathode collector; wetting the separator with solvated ions; and loading the anode and cathode assemblies into a battery housing.
H01M 10/0583 - Construction or manufacture of accumulators with folded construction elements except wound ones, i.e. folded positive or negative electrodes or separators, e.g. with ‘’Z’’-shaped electrodes or separators
One variation of a battery unit includes: a substrate including silicon and defining a cell, wherein the cell includes a base encompassed by a continuous wall and a set of posts extending normal to the base; an electrolyte material coating vertical surfaces of each post, in the set of posts, and vertical surfaces of the continuous wall in the cell; a cathode material filling the cell over the electrolyte material, between posts in the set of posts, and between the set of posts and the continuous wall; a seal extending along a top of the continuous wall; and a cathode current collector bonded to the seal, electrically coupled to the cathode material, and cooperating with the substrate to enclose the cell to form a single-cell battery.
H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
H01M 10/04 - Construction or manufacture in general
H01M 10/0565 - Polymeric materials, e.g. gel-type or solid-type
H01M 4/13 - Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulatorsProcesses of manufacture thereof
H01M 10/0585 - Construction or manufacture of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
One variation of a battery unit includes: a substrate including silicon and defining a cell, wherein the cell includes a base encompassed by a continuous wall and a set of posts extending normal to the base; an electrolyte material coating vertical surfaces of each post, in the set of posts, and vertical surfaces of the continuous wall in the cell; a cathode material filling the cell over the electrolyte material, between posts in the set of posts, and between the set of posts and the continuous wall; a seal extending along a top of the continuous wall; and a cathode current collector bonded to the seal, electrically coupled to the cathode material, and cooperating with the substrate to enclose the cell to form a single-cell battery.
H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
H01M 2/36 - Arrangements for filling, topping-up or emptying cases with or of liquid, e.g. for filling with electrolytes, for washing-out
H01M 10/04 - Construction or manufacture in general
H01M 10/0565 - Polymeric materials, e.g. gel-type or solid-type
H01M 4/13 - Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulatorsProcesses of manufacture thereof
H01M 10/0585 - Construction or manufacture of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
H01M 4/02 - Electrodes composed of, or comprising, active material
14.
Electrolyte material, battery assembly, and production method
One variation of a method for fabricating an electrolyte includes: depositing an electrolyte material over a substrate, the electrolyte material including a monomer miscible in a first volume of solvent, a polymer semi-miscible in the monomer and miscible in the first volume of solvent, and a photoinitiator; exposing the electrolyte material to electromagnetic radiation to disassociate the photoinitiator into a reactive subspecie that crosslinks the monomer to form an electrolyte structure with the polymer phase-separated from the electrolyte structure; dissolving the polymer out of the electrolyte structure with a second volume of solvent to render a network of open-cell pores in the electrolyte structure; and exposing the electrolyte structure to a third volume of solvent and ions to fill the network of open-cell pores with solvated ions.
H01M 10/0585 - Construction or manufacture of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators
H01M 10/0525 - Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodesLithium-ion batteries
15.
ELECTROLYTE MATERIAL, BATTERY ASSEMBLY, AND PRODUCTION METHOD
One variation of a method for fabricating an electrolyte includes: depositing an electrolyte material over a substrate, the electrolyte material including a monomer miscible in a first volume of solvent, a polymer semi-miscible in the monomer and miscible in the first volume of solvent, and a photoinitiator; exposing the electrolyte material to electromagnetic radiation to disassociate the photoinitiator into a reactive subspecie that crosslinks the monomer to form an electrolyte structure with the polymer phase-separated from the electrolyte structure; dissolving the polymer out of the electrolyte structure with a second volume of solvent to render a network of open-cell pores in the electrolyte structure; and exposing the electrolyte structure to a third volume of solvent and ions to fill the network of open-cell pores with solvated ions.
One variation of a battery unit includes: a substrate including silicon and defining a cell, wherein the cell includes a base encompassed by a continuous wall and a set of posts extending normal to the base; an electrolyte material coating vertical surfaces of each post, in the set of posts, and vertical surfaces of the continuous wall in the cell; a cathode material filling the cell over the electrolyte material, between posts in the set of posts, and between the set of posts and the continuous wall; a seal extending along a top of the continuous wall; and a cathode current collector bonded to the seal, electrically coupled to the cathode material, and cooperating with the substrate to enclose the cell to form a single-cell battery.
One variation of a battery unit includes: a substrate including silicon and defining a cell, wherein the cell includes a base encompassed by a continuous wall and a set of posts extending normal to the base; an electrolyte material coating vertical surfaces of each post, in the set of posts, and vertical surfaces of the continuous wall in the cell; a cathode material filling the cell over the electrolyte material, between posts in the set of posts, and between the set of posts and the continuous wall; a seal extending along a top of the continuous wall; and a cathode current collector bonded to the seal, electrically coupled to the cathode material, and cooperating with the substrate to enclose the cell to form a single-cell battery.
H01M 10/48 - Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
H01M 2/36 - Arrangements for filling, topping-up or emptying cases with or of liquid, e.g. for filling with electrolytes, for washing-out
H01M 4/02 - Electrodes composed of, or comprising, active material
