Methods are disclosed for manufacturing an electrode for use in a device such as a secondary battery. Electrodes may include a first layer having first active particles adhered together by a binder, a second layer having second active particles adhered together by a binder, and an interphase layer interposed between the first and second layers. In some examples, the interphase layer may include an interpenetration of the first and second particles, such that substantially discrete fingers of the first layer interlock with substantially discrete fingers of the second layer.

The present invention pertains to an electrode-forming composition, to use of said electrode-forming composition in a process for the manufacture of an electrode, to said electrode and to an electrochemical device comprising said electrode.

A method of fabricating an ion battery for a smart wearable device is proposed. The method includes the steps of: (a) continuously press-printing each of a positive electrode ink composition and a negative electrode ink composition in a coagulation bath and drying the same to manufacture one or more electrode fibers; (b) twisting the electrode fibers to manufacture an electrode assembly; (c) coating the electrode assembly with a separator composition; and (d) placing one or more electrode assemblies in a heat shrinkable tube and introducing a gel electrolyte.

An embodiment coating system for a secondary battery includes a supply tank connected to a slot-die and configured to store a slurry, an in-line viscometer configured to measure viscosity and temperature of the slurry, a flow meter configured to measure a flow rate of the slurry, a flow rate adjustment valve configured to adjust the flow rate according to a feedback signal based on the measured flow rate, a coating bead sensor configured to detect in real time a slurry coating bead shape discharged from the slot-die to a base material, and a coating controller configured to detect a process condition change event by monitoring a slurry property and the slurry coating bead shape in real time and to control the flow rate of the flow rate adjustment valve based on reference data corresponding to a changed slurry property.

A method of fabricating an electrode is provided. The method includes adding one or more dry powders to an extruder barrel of an extruder at a first location, adding one or more solvents to the extruder barrel at a second location that is downstream of the first location to form a material mixture, applying a mixing force to the material mixture to form a paste, and extruding the paste as a continuous film onto one or more surfaces of a current collector to form the electrode. The one or more dry powders include an electroactive material. The paste is a homogeneous semi-solid having a solids content greater than or equal to about 60% to less than or equal to about 90%. The continuous film has a thickness greater than or equal to about 50 μm to less than or equal to about 500 μm.

A printable lithium composition is provided. The printable lithium composition includes lithium metal powder; a polymer binder, wherein the polymer binder is compatible with the lithium powder; and a rheology modifier, wherein the rheology modifier is compatible with the lithium powder and the polymer binder. The printable lithium composition may further include a solvent compatible with the lithium powder and with the polymer binder.

In a method for producing batteries in which a suspension with a variable product parameter is extruded in an extrusion process by means of an extruder as an electrode paste, a number of extrusion parameters of the extrusion process are determined, an extruder-specific stress model is calculated on the basis of the extrusion parameters, and the extrusion process is controlled in an open loop and/or regulated, i.e., controlled in a closed loop, on the basis of the stress model.

Alkali metal secondary batteries that include anodes constructed from alkali metal foil applied to only one side of a porous current collector metal foil. Openings in the porous current collectors permit alkali metal accessibility on both sides of the anode structure. Such anode constructions enable the utilization of lower-cost and more commonly available alkali metal foil thickness, while still achieving high cell cycle life at a significantly reduced cost. Aspects of the present disclosure also include batteries with porous current collectors having increased volumetric and gravimetric energy densities, and methods of manufacturing anodes with porous current collectors.

The invention relates to a method for producing an electrode for an accumulator, wherein an electrode compound is applied to a carrier, in particular a metal foil, by means of an extrusion process. In the extrusion process, the electrode compound is fed through an extrusion die by means of a feeding device. The electrode compound is prepared by mixing in a mixing device and passed on from the mixing device to the feeding device, fluctuations in the flow rate of electrode compound that is passed on from the mixing device to the feeding device being evened out.

A method for manufacturing zinc negative electrodes includes mixing a powder including zinc with polytetrafluoroethylene to form a homogenous blend, injecting a lubricant into the homogenous blend to form a dough, kneading the dough to form a fibrillated dough, and extruding the fibrillated dough through a die to form a ribbon. The method also includes calendering the ribbon to a target thickness to form a plaque, drying the plaque to form an active material sheet, laminating portions of the active material sheet to a current collector substrate to form an electrode blank, and sectioning the electrode blank into zinc negative electrodes.