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13 coatingtheanodesluryontooneorbothprimarysurfaces ofananodecurentcolector(e.g.Cufoil),dryingthecoated layerbyvaporizingthesolvent(e.g.NMP)toform adried anode electrodecoatedon Cu foil.Similarly,thecathode 14 4)CurentLi—SandNa—Sbateriesstilsuferfrom a relatively low gravimetric energy density and low volumetricenergydensity.Hence,neithertheLi-S norrom temperatureNa-Sbateryhasmadeitothe structure.(d)Therectangularorcylindricallaminatedstruc tureisthenencasedinanaluminum-plasticlaminatedenve lopeorstelcasing.(e)Aliquidelectrolyteistheninjected 15 intothelaminatedstructuretomakeasodium-ionorlithium baterycel. Thereareseveralseriousproblemsasociatedwiththe processandtheresultingsodium-ioncelsand lithium-ion baterycels(orLi-SandNa-Scels): be taken into account. The convention production procesresultsintheweightproportionoftheanode activematerial(e.g.carbonparticles)inasodium ionbaterybeingtypicalyfrom 15%to20%,and thatof the cathode activematerial (e.g.sodium transitionmetaloxide)from 20% to30%. US 9,905,856 B1 sluryiscoatedanddriedtoform adriedcathodeelectrode 5 coatedonAlfoil.Slurycoatingisnormalydoneina Inliterature,theenergydensitydatareportedbasedon rol-to-rolmannerinarealmanufacturingsituation;(c)The eithertheactivematerialweightaloneortheelec thirdstepincludeslaminatingananode/Cu foilshet,a trodeweightcannotdirectlytranslateintotheenergy porousseparatorlayer,andacathode/Alfoilshettogether densitiesofapracticalbaterycelordevice.The toform a3-layeror5-layerasembly,whichiscutandslit10 "overheadweight”orweightsofotherdevicecom intodesiredsizesandstackedtoform arectangularstructure ponents(binder,conductiveaditive,curentcollec (asanexampleofshape)orroledintoacylindricalcel tors,separator,electrolyte,andpackaging)mustalso Thepresentinventionprovidesaprocessforproducinga 20flexible,shape-conformable,andnon-flammable alkali 1)Itisverydificulttoproduceanelectrodelayer(anode metal-sulfurbaterycelhavingaropeshape,highactive layerorcathodelayer)thatisthickerthan10um,letalone materialmassloading,lowoverheadweightandvolume, 200um.Thereareseveralreasonswhythisisthecase.An highgravimetricenergydensity,andhighvolumetricenergy electrodeof10umthicknestypicalyrequiresaheating density.Inadition,themanufacturingcostsofthealkali zoneof30-100meterslonginaslurycoatingfacility,which 25metalbateriesproducedbythepresentlyinventedprocess istotimeconsuming,toenergyintensive,andnotcost- canbesignificantlylowerthanthosebyconventionalpro efective.Forsomeelectrodeactivematerials,suchasmetal cesessincenoexpensiveslurycoatingfacilitiesfeaturing oxideparticlesorsulfur,ithasnotbeenpossibletoproduce expensivecoatingheadsandlongdryingzonesareneeded. anelectrodeofgoodstructuralintegritythatisthickerthan Inoneembodimentofthepresentinvention,asilustrated 10um inarealmanufacturingenvironmentonacontinu-30inFIG.1(C),thepresentrope-shapedalkalimetalbatery ousbasis.Theresultingelectrodesareveryfragileand containsbraid-oryarn-shapeelectrodes.Thebatterycanbe britle.Thickerelectrodeshaveahightendencytodelami- madebyaprocesthatincludesafirststepofsuplyinga nateandcrack. firstelectrode1,which iscomposedofanelectricaly 2)Withaconventionalproces,asdepictedinFIG.1(A), conductiveporousrodhavingporesthatarepartialyorfuly the actualmass loadings of the electrodes and the 35 loadedwith amixtureofafirstelectrodeactivematerialand apparentdensitiesfortheactivematerialsaretolow afirstelectrolyte.Aconductiveaditiveoraresinbinder toachieveahighenergydensity.Inmostcases,the maybeoptionalyadedintothemixture,butthisisnot anodeactivematerialmassloadingoftheelectrodes requiredorevendesired.Thisfirstelectrode1canoption (arealdensity)issignificantlylowerthan15mg/cm2 alycontainanactivematerial-freandelectrolyte-freend andtheapparentvolumedensityortapdensityofthe 40 section13thatcanserveasaterminaltabforconnectingto activematerialistypicalylesthan1.2g/cmevenfor anexternalload.Thisfirstelectrodecanassumeacross relativelylargeparticlesofgraphite.Thecathodeactive sectionthatisofanyshape;e.g.circular,rectangular, materialmassloadingoftheelectrodes(arealdensity) eliptic,square,hexagonal,hollow,oriregularinshape. issignificantlylowerthan 10mg/cm2forthesulfur Alternatively,inthefirststep,thefirstelectrodecomprises cathode.Inaddition,therearesomanyothernon-active45 aconductiverod(notaporousfoam)andthefirstmixtureis materials(e.g.conductiveaditiveandresinbinder) coatedordepositedonthesurfaceofthisconductiverod. thatadaditionalweightsandvolumestotheelec- Thisrodcanbeassimpleasametalwire,conductive trodewithoutcontributingtothecelcapacity.These polymerfiberoryarn,carbonorgraphitefiberoryarn,or lowarealdensitiesandlowvolumedensitiesresultin multiplethinwires,fibers,oryarns.However,inthissitu a relatively low gravimetric energy density and low 50 ation, the second electrode must contain a porous foam volumetricenergydensity. structure. 3)Theconventionalprocessrequiresdispersingelectrode Thesecondstepinvolveswrappingaroundorencasing activematerials(anodeactivematerialandcathode thefirstelectrode1withathinlayerofporousseparator15 activematerial)inaliquidsolvent(e.g.NMP)tomake (e.g.porousplasticfilm,paper,fibermat,non-woven,glas asluryand,uponcoatingonacurrentcollectorsur-55 fibercloth,etc.)thatispermeabletoLi+,Na+,orK+ions. face,theliquidsolventhastoberemovedtodrythe Thisstepcanbeassimpleaswrappingthefirstelectrode electrodelayer.Oncetheanodeandcathodelayers, withathin,porousplastictapeinonefulcircleorslightly alongwithaseparatorlayer,arelaminatedtogetherand morethanonefulcircle,orinaspiralmanner.Themain packagedinahousingtomakeasupercapacitorcel, purposeistoelectronicalyseparatetheanodeandthe one then injects a liquid electrolyte (using a salt dis- 60 cathode to prevent internal shorting. The porous separator solvedinasolventdiferentthanNMP)intothecel.In layercanbesimplydepositedalaroundthefirstelectrode actuality,onemakesthetwoelectrodeswet,thenmakes byspraying,printing,coating,dipcasting,etc. theelectrodesdry,andfinalymakesthem wetagain. Thethirdstepinvolvespreparingasecondelectrode17 Suchawet-dry-wetprocesisnotagoodprocesatal. thatcomprisesamixtureofasecondactivematerialand Furthermore,themostcommonlyusedsolvent(NMP)65secondelectrolyteand,optionaly,aconductiveaditiveor isanotoriouslyundesirablesolvent(knowntocause resinbinder(althoughnotnecesaryandnotdesirable).This birthdefect,forinstance). secondelectrode17canoptionalycontainanactivemate marketplace.PDF Image | FLEXIBLE AND SHAPE-CONFORMAL ROPE-SHAPE ALKALI METAL-SULFUR BATTERIES
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