Apparatus and method for forming a multilayer extrusion comprising component layers of an electrochemical cell

A co-extrusion die configured to produce a multilayer extrusion comprising layers of an electrochemical cell, the die comprising:

• a plurality of inlet ports configured to receive a plurality of pressurized fluids comprising at least a polymeric ink, a first microporous layer ink, a second microporous layer ink, a plurality of graded first electrode inks having different electrode material loading, and a plurality of graded second electrode inks having different electrode material loading, the plurality of inlet ports comprising a first inlet port oriented along a longitudinal axis of the die;
• a plurality of channels comprising a first channel orientated along the longitudinal axis of the die and a plurality of additional channels each oriented at an oblique angle or a right angle to the longitudinal axis of the die, the first channel fluidically coupled to the first inlet port, the plurality of additional channels arranged in a staggered arrangement along the longitudinal axis of the die, a first set of the additional channels arranged on a first side of the first channel and a second set of the additional channels arranged on a second side of the first channel opposing the first side, and each of the plurality of additional channels comprising an outlet to the first channel;
• the plurality of channels configured to separately transport and shape the plurality of fluids from the plurality of inlet ports to a merge section situated at the outlets of the plurality of channels, such that the plurality of fluids flow intact and in contact together in the merge section in a serialized manner and in accordance with the staggered arrangement to form the multilayer extrusion comprising, in order, a first microporous layer, a plurality of graded first electrode layers, a polymeric membrane layer, a plurality of graded second electrode layers, and a second microporous layer;
• an outlet port fluidically coupled to the merge section, the outlet port configured to output the multilayer extrusion onto a substrate, the multilayer extrusion comprising an inner layer, an outer layer, and one or more middle layers disposed between the inner and outer layers;
• and
• the die fluidically coupled to a plurality of pumps each separately coupled to a respective one of the plurality of inlet ports for pressurizing a respective one of the plurality of pressurized fluids, the plurality of pumps configured to adjust a pressure of the plurality of pressurized fluids, and a viscosity of the plurality of fluids is adjusted such that the one or more middle layers are reduced in thickness relative to the outer layer which is increased in thickness.