Hybrid electrochemical cell and a method of producing thereof

A method of manufacturing an electrochemical cell, the method comprising:

• forming a hybrid cathode of the electrochemical cell by:
• coating a first side of a cathode current collector with a first composite active layer to form an energy side of the hybrid cathode, wherein the first composite active layer is prepared by:
• mixing a cathode electroactive material in a range of 75 to 96% by mass, a first conductive additive in a range of 5 to 20% by mass, and a first non-aqueous binder in a range of 5 to 20% by mass in a vacuum mixer for a predefined time duration of 6 to 12 hours, at a predefined temperature of 25 degree Celsius to obtain a first cathode slurry having a predefined viscosity ranging from 2000 mPa·s to 8000 mPa·s;
• and
• depositing the first cathode slurry on the first side of the cathode current collector uniformly in a controlled environment to form the first composite active layer;
• coating a second side of the cathode current collector with a hybrid active layer of form a power side of the hybrid cathode, wherein the hybrid active layer is prepared by:
• mixing the cathode electroactive material in a range of 60 to 95% by mass, a cathode capacitive material in a range of 5 to 20% by mass, a second conductive additive in a range of 5 to 20% and a second non-aqueous binder solution in a range of 5 to 30% by mass in a vacuum mixer for a predefined time duration of 6 to 12 hours, at a predefined temperature of 25 degree Celsius to obtain a second cathode slurry of predefined viscosity ranging from 2000 mPa·s to 8000 mPa·s;
• and
• depositing the second cathode slurry on the second side of the cathode current collector uniformly in a controlled environment to form the hybrid active layer;
• and
• drying the hybrid cathode under vacuum at a temperature of 110 to 130 degree Celsius;
• forming an anode of the electrochemical cell by:
• coating a first side of an anode current collector with a second composite active layer to form an energy side of the anode, wherein the second composite active layer is prepared by:
• mixing graphite in a range of 70 to 95% by mass, a third conductive additive in a range of 5 to 20% by mass, a third binder in a range of 5 to 20% by mass, in a vacuum mixer for a predefined time duration of 6 to 12 hours, at a predefined temperature of 25 to 35 degree Celsius to obtain a first anode slurry having a predefined viscosity ranging from 2000 mPa·s to 8000 mPa·s;
• and
• depositing the first anode slurry on the first side of the anode current collector uniformly in a controlled environment to form the second composite active layer;
• coating a second side of the anode current collector with a third composite active layer to form a power side of the anode, wherein the third composite active layer is prepared by:
• mixing silicon in a range of 5 to 20% by mass, graphite in a range of 80-95% by mass, a fourth conductive additive in a range of 2.5 to 15% by mass, a fourth binder in a range of 2.5 to 15% by mass and a solvent in a range of 2 to 8%, in a vacuum mixer for a predefined time duration of 6 to 12 hours, in a controlled environment of temperature 25 to 35 degree Celsius to obtain a second anode slurry of predefined viscosity ranging from 2000 mPa·s to 8000 mPa·s;
• and
• depositing the second anode slurry on the second side of the anode current collector uniformly in a controlled environment to form the third composite active layer;
• and
• drying the anode under vacuum at a temperature of 110 to 130 degree Celsius,
• wherein the drying of the hybrid cathode and the anode is performed prior to stacking the hybrid cathode and the anode along with a porous separator and an electrolyte solution within the electrochemical cell, wherein the porous separator is arranged between the cathode and the anode, wherein the porous separator is adjacent to the hybrid active layer and the third composite active layer,
• wherein a ratio of thickness of the cathode to thickness of the anode is 6:5, wherein a ratio of thickness of the first side of the cathode to thickness of the second side of the cathode is 6:5 and wherein a ratio of thickness of the first side of the anode to thickness of the second side of the anode is 6:5, and wherein a ratio of amount of electroactive material within the cathode to amount of electroactive material within the anode is 1:1.15,
• wherein each of the third conductive additive and the fourth conductive additive comprises one or more of conductive carbon, super P, blended carbon, graphene, carbon fibers, carbon nanotubes, carbon nanofibers, porous carbon, ketjen black, carbon mixture,
• wherein the third binder comprises one or more of a non-aqueous polyvinylidene fluoride binder solution, acrylonitrile-based binders, polyethylene oxide, and 5130 solvate, and wherein the one or more binders are dissolved in a n-methyl-2-pyrrolidone solvent at a concentration of 45 to 55% by weight to create a uniform binder solution,
• wherein the fourth binder comprises an aqueous binder selected from carboxymethyl cellulose, styrene-butadiene rubber, and polyacrylic acid,
• wherein the solvent is deionized water.