PROCESS FOR LITHIUM LOADED ELECTRODE MANUFACTURING FOR LITHIUM-ION CAPACITORS

Abstract

The present invention is directed to a Process for Lithium Loaded Electrode Manufacturing for Lithium-Ion Capacitors, wherein there is provided a system of manufacture of electrodes using a lithium foil, and in particular, to the process of manufacturing lithium loaded negative electrodes for lithium-ion capacitors and the like using lithium foil, lithium strips and/or lithium films, employing a roll-to-roll manufacturing process wherein there is no drying time and no heat required to be applied to the laminator rolls, and wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, may include a top lithium strip and a bottom lithium strip on the negative electrode generated by the roll-to-roll process.

Claims

1. A system of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process.

2. The system of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 1, wherein the width range of said negative electrode is about 2 mm to about 300 mm.

3. The system of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 1, wherein the thickness range of said negative electrode before being loaded with lithium is about 20 μm to about 400 μm.

4. The system of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 1, wherein the said negative electrode material includes graphite, hard carbon, soft carbon and Li.sub.4T.sub.15O.sub.12.

5. The system of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 1, wherein the width range of said lithium foil strips are about 1 mm to about 100 mm.

6. The system of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 1, wherein the thickness range of said lithium films is about 5 μm to about 150 μm.

7. The system of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 1, wherein the number range of said lithium foil strips on one side of negative electrode is from 2 to about 10.

8. The system of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 7, wherein the gap distance between all lithium strips on one side of negative electrode is about 0.5 mm to about 50 mm.

9. The system of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 1, includes a top lithium strip and a bottom lithium strip.

10. The system of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 9, further includes a top lithium strip and a bottom lithium strip, wherein the gap distance between said top lithium strip and said bottom lithium strip is about 0 mm to about 50 mm.

11. A method for lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium negative electrode is manufactured using lithium foil strips in a roll-to-roll process, comprising the steps of: (a) the manufacturing process should be done in a temperature and humidity controlled clean and dry room; (b) providing the negative electrode sheet and the top Li foil strip and bottom Li foil strip; (c) feed insertion of the bottom Li film strip through tension controlled rolls and the lamination rolls; (d) feed roll and the insertion of the negative electrode sheet through the tension control rolls and into the lamination rolls; (e) feed roll insertion of the top Li film strip through the tension rolls and into the lamination rolls; and (f) exertion of pressure on the lamination rolls and the extension of the laminated Li loaded negative electrode sheet through the tension control rolls and on to the take up roll to be completed and ready for use in Li-ion capacitors; wherein there is no adhesive drying time and no heat required on the lamination rolls, the pressure may be adjusted to a pressure range of 40 to 400 kg/cm.sup.2 as required to press the top Li foil strip and bottom Li foil strip into the negative electrode sheet and the gap between the top Li foil strip, and bottom Li foil strip may be adjusted according to the to the laminated Li loaded negative electrode sheet requirements.

12. The method of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 11, wherein the width range of said negative electrode is about 2 mm to about 300 mm.

13. The method of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 11, wherein the thickness range of said negative electrode before being loaded with lithium is about 20 μm to about 400 μm.

14. The method of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 11, wherein the said negative electrode material includes graphite, hard carbon, soft carbon and Li.sub.4T.sub.15O.sub.12.

15. The method of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 11, wherein the width range of said lithium films is about 1 mm to about 100 mm.

16. The method of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 11, wherein the thickness range of said lithium films is about 5 μm to about 150 μm.

17. The method of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 11, wherein the number range of said lithium foil strips on one side of negative electrode is from 2 to about 10.

18. The method of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 17, wherein the gap distance between all lithium strips on one side of negative electrode is about 0.5 mm to about 50 mm.

19. The method of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 11, includes a top lithium film and a bottom lithium film.

20. The method of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to claim 19, further includes a top lithium film and a bottom lithium film, wherein the gap distance between said top lithium strip and said bottom lithium strip is about 0 mm to about 50 mm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the Process for Electrode Manufacturing and together with the description, serve to explain the principles of this application.

[0034] FIG. 1 is a block diagram of the steps for the Process of Electrode Manufacturing.

[0035] FIG. 2 is a diagram of the roll with the negative electrode sheet, the top and bottom rolls of the Li foil sheets, the tension rolls, the lamination rolls, the secondary tension rolls and the take up roll.

[0036] FIG. 3 is an illustration of the combination of rolls used in the manufacturing process of a laminated Li loaded negative electrode sheet with a single set of top and bottom Li foil strips used to determine the correct roll location and the proper gap between the top and bottom Li foil strips.

[0037] FIG. 4 is a side view of a section of the Li foil strips illustrating the thickness requirement.

[0038] FIG. 5 is a top plan view of a segment of the laminated product illustrating a top strip of Li foil above the negative electrode sheet with the bottom strip of Li foil below, indicating the gap tolerances between the foil segments.

[0039] FIG. 6 is a top plan view of the negative electrode sheet on its feed roll adjacent to the rollers of the op and bottom Li foil strips and back around between the lamination rollers and out the other side. For illustration purposes the tension rollers have been omitted and the segments have been broken to indicate that varying numbers of top and bottom Li foil strip combinations can be manufactured in this process.

[0040] FIG. 7 is an illustration of a combination of rolls used in the manufacturing process of a lithium loaded negative electrode sheet between seven sets of top and bottom Li foil strips in a mass production operation. The number of top and bottom Li foil strips and the width of the negative electrode sheet may vary depending upon the quantity required.

[0041] FIG. 8 is a cross section through segment of the negative electrode sheet between the top and bottom Li foil strips.

[0042] For a fuller understanding of the nature and advantages of the Process for Electrode Manufacturing, reference should be had to the following detailed description taken in conjunction with the accompanying drawings which are incorporated in and form a part of this specification, illustrate embodiments of the design and together with the description, serve to explain the principles of this application.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0043] Referring now to the drawings, wherein similar parts of the Process for Electrode Manufacturing 10 are identified by like reference numerals, there is seen in FIG. 1 a block diagram that describes the steps for the Process for Electrode Manufacturing 10 wherein said process includes, but is not limited to, the following seven steps:

[0044] Step one 14 describes that the manufacturing process should be done in a temperature and humidity controlled clean and dry room.

[0045] Step two 16 describes providing the negative electrode sheet 18 and the top Li foil strip 20 and bottom Li foil strip 22. The terms “lithium foil strips,” or “Li foil” and “lithium films” or “Li film” will be used interchangeably throughout this specification detailed description.

[0046] Step three 24 describes the feed roll 26 insertion of the bottom Li film strip 22 through tension control rolls 28, 30 and 32 and the lamination rolls 34 and 36.

[0047] Step four 38 describes the feed roll 40 and the insertion of the negative electrode sheet 18 through the tension control rolls 42 and 44 and into the lamination rolls 34 and 36.

[0048] Step five 46 describes the feed roll 48 and the insertion of the top Li film strip 20 through the tension rolls 50, 52 and 54 and into the lamination rolls 34 and 36.

[0049] Step six 56 explains the exertion of pressure on the lamination rolls 34 and 36 and the extension of the laminated Li loaded negative electrode sheet 58 through the tension control rolls 60 and 62 and on to the take up roll 64 to be ready for the use in the Li-ion capacitors.

[0050] Step seven 66 explains that there is no adhesive drying time and no heat required on the lamination rolls 34 and 36. The pressure may be adjusted as required to press the top Li foil strip 20 and bottom Li foil strip 22 into the negative electrode sheet 18 and the gap 68 between the top Li foil strip 20 and bottom Li foil strip 22 may be adjusted according to the to the laminated Li loaded negative electrode sheet 58 requirements.

[0051] FIG. 2 is a diagram of the Process for Electrode Manufacturing with the top Li foil strip 20 material feeding into the three tension rolls 50, 52 and 54 and into the lamination rolls 34 and 36.

[0052] The feed roll 40 with the negative electrode sheet 18 fed through the tension control rolls 42 and 44 and into the lamination rolls 34 and 36.

[0053] The feed roll 26 with the bottom Li film strip 22 fed through tension control rolls 28, 30 and 32 and the lamination rolls 34 and 36.

[0054] The pressure is applied with the lamination rolls 34 and 36 and the laminated Li loaded negative electrode sheet 58 passes through the tension control rolls 60 and 62 and on the take up roll 64 to complete the manufacture process and generate a lithium loaded negative electrode ready for use in Li-ion capacitors. There is no adhesive drying time and no heat required on the lamination rolls, the pressure may be adjusted to a pressure range of 40 to 400 kg/cm.sup.2 as required to press the top Li foil strip and bottom Li foil strip into the negative electrode sheet and the gap between the top Li foil strip, and bottom Li foil strip may be adjusted according to the laminated lithium loaded negative electrode sheet requirements. The resulting width range of the manufactured negative electrode is about 2 mm to about 300 mm. The thickness range of the negative electrode before being loaded with lithium is about 20 μm to about 400 μm. The negative electrode materials used in manufacturing include graphite, hard carbon, soft carbon and Li.sub.4Ti.sub.15O.sub.12. The width range of the lithium strips and lithium films is about 1 mm to about 100 mm. The thickness range of the lithium strips/films is about 5 μm to about 150 μm. The number range of the lithium foil strips on one side of negative electrode is from 2 to about 10. The gap distance between all lithium strips on one side of negative electrode is about 0.5 mm to about 50 mm. Furthermore, the present method of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, according to the instant invention, may include a top lithium fill and a bottom lithium film within the manufactured negative electrode. When both a top and bottom lithium strip or film is present, the gap distance between said top lithium strip and said bottom lithium strip is about 0 mm to about 50 mm.

[0055] FIG. 3 is an illustration of the combination of rolls used in the manufacturing process of a laminated Li loaded negative electrode sheet 58 with a single set of top and bottom Li foil strips 20 and 22 used to determine the correct roll location and the proper gap 68 (as shown in FIG. 5) between the top and bottom Li foil strips 20 and 22.

[0056] FIG. 4 is a side view of a section of the pure Li foil strips 20 and 22 illustrating the thickness requirements of about 5 μm to about 150 μm thick with a preferred thickness of about a range of 20 μm to 50 μm. The total thickness range of the negative electrode 18 before being loaded with lithium is about 20 μm to about 400 μm.

[0057] FIG. 5 is a top plan view of a segment of the laminated product illustrating a top strip of Li foil 20 above the negative electrode sheet 18 with the bottom strip of Li foil 22 below, indicating the proper gap 68 tolerances between the foil segments as a range of approximately 0 mm to 50 mm, and the width of the top and bottom Li foil strips 20 and 22 has a range of approximately 1 mm to 100 mm. The total width range of the negative electrode is about 2 mm to about 300 mm. The thickness range of said lithium films is about 5 μm to about 150 μm. The number range of said lithium foil strips on one side of negative electrode is from about 2 strips to about 10 strips. The gap distance between all lithium strips on one side of negative electrode is about 0.5 mm to about 50 mm. As shown, lithium strips may be placed on the top surface and the bottom surface of the negative electrode during manufacture, according to the present invention. Therefore, the present system of lithium loaded electrode manufacturing for lithium-ion capacitors wherein a lithium loaded negative electrode is manufactured using lithium foil strips in a roll-to-roll process, may include a top lithium strip and a bottom lithium strip, as required. When both top and bottom lithium strips are present, the gap distance between the top lithium strip and the bottom lithium strip is about 0 mm to about 50 mm.

[0058] FIG. 6 is a top plan view of the negative electrode sheet 18 on its feed roll adjacent to the rollers of the top and bottom Li foil strips 20 and 22 and back around between the lamination rollers 34 and 36 and out the other side. For illustration purposes the tension rollers have been omitted and the segments have been broken to indicate that varying numbers of top and bottom Li foil strip 20 and 22 combinations can be manufactured in this process. The total width range of the lithium foil strips are about 1 mm to about 100 mm.

[0059] FIG. 7 is an illustration of a combination of rolls used in the manufacturing process of a laminated Li loaded negative electrode sheet 58 between seven sets of top and bottom Li foils strips 20 and 22 in a mass production operation. The number of top and bottom Li foils strips 20 and 22 and the width of the negative electrode sheet 18 may vary depending upon the quantity required. The total width range of the negative electrode is about 2 mm to about 300 mm.

[0060] FIG. 8 is a cross section through segment of the negative electrode sheet 18 between the top and bottom Li foil strips 20 and 22. The negative electrode materials include graphite, hard carbon, soft carbon and Li.sub.4T.sub.15O.sub.12.

[0061] The Process for Lithium Loaded Electrode Manufacturing for Lithium-Ion Capacitors 10 shown in the drawings and described in detail herein disclose arrangements of elements of particular construction and configuration for illustrating preferred embodiments of structure and method of operation of the present application. It is to be understood, however, that elements of different construction and configuration and other arrangements thereof, other than those illustrated and described may be employed for providing a Process for Lithium Loaded Electrode Manufacturing for Lithium-Ion Capacitors 10 in accordance with the spirit of this disclosure, and such changes, alternations and modifications as would occur to those skilled in the art are considered to be within the scope of this design as broadly defined in the appended claims.

[0062] Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.