Processes for the manufacture of conductive particle films for lithium ion batteries and lithium ion batteries
AssigneeDragonfly Energy Corp.
InventorsDenis Phares, Justin S. Ferranto
Life of this patent
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Abstract
The invention is directed to a process for forming a particle film on a substrate. Preferably, a series of corona guns, staggered to optimize film thickness uniformity, are oriented on both sides of a slowly translating grounded substrate (copper or aluminum for the anode or cathode, respectively). The substrate is preferably slightly heated to induce binder flow, and passed through a set of hot rollers that further induce melting and improve film uniformity. The sheeting is collected on a roll or can be combined in-situ and rolled into a single-cell battery. The invention is also directed to products formed by the processes of the invention and, in particular, batteries.
Claims16
A method for forming a conductive particle film comprising:
- spraying a mixture of conductive particles and a binder toward a substrate at a spray deposition site;
- passing a current through the substrate between a first electrode in electrical contact with the substrate and a second electrode in electrical contact with the substrate to generate heat in the substrate, wherein the first electrode is disposed upstream of the spray deposition site and the second electrode is disposed downstream of the spray deposition site;
- and
- applying the sprayed mixture to a first side and a second opposing side of the heated substrate at the spray deposition site to form the conductive particle film.
Dependencies are inferred from the claim text.