Electrochemical cells and methods for making same
OwnerMarc Jaker, Kim Jakerinventors
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Abstract
The present disclosure is directed to electrochemical cells having injection molded or 3D printed components, such as cathodes, anodes, and/or electrolytes, and methods for making such electrochemical cells. The cathodes, anodes, and/or electrolytes can be formed from a binder resin and various conductive and active materials, mixtures of which are injected into a mold under heat and pressure to form the components of the electrochemical cells. The cathode can include conductive metallic powder, flakes, ribbons, fibers, wires, and/or nanotubes. Further, electrochemical arrays can be formed from multiple electrochemical cells having injection molded or 3D printed components.
Claims12
A method of forming an electrochemical cell comprising:
- injecting, via injection molding, a cathode mixture of a binder resin, a cathode conductive material, and a cathode active material into a cathode cavity of a mold at a first temperature between 150° C. and 350° C. and between 3.5×107 Pa and 1.6×108 Pa to form a first cathode, wherein the cathode conductive material comprises one of a wire, a fiber, and a ribbon having a length of between about 250 micron and about 4000 micron and a second dimension of between about 25 micron and about 5000 micron, wherein the cathode conductive material has at least one of a curved, bent, spiral, and non-straight configuration, and wherein the cathode conductive material comprises between 50% by volume and 70% by volume of the cathode mixture;
- injecting, via injection molding, a cathode current collector mixture of the binder resin and a first conductive material into a cathode current collector cavity within the first cathode under heat and pressure to form a cathode current collector and a cathode bus;
- injecting, via injection molding, an anode mixture of the binder resin and an anode conductive material into an anode cavity of the mold at a second temperature greater than the first temperature and between 150° C. and 350° C. and between 3.5×107 Pa and 1.6×108 Pa to form a first anode, wherein the anode conductive material comprises between 75% by volume and 85% by volume of the anode mixture;
- injecting, via injection molding, an anode current collector mixture of the binder resin and a second conductive material into an anode current collector cavity within the first anode under heat and pressure to form an anode current collector and an anode bus;
- injecting, via injection molding, an electrolyte mixture of the binder resin and an electrolytic material between the first anode and the first cathode under heat and pressure to form a first electrolyte;
- and
- forming a case surrounding at least a portion of the first cathode, the first anode, and the first electrolyte.
Dependencies are inferred from the claim text.