Continuous process for producing electrodes and alkali metal batteries having ultra-high energy densities

摘要

A process for producing an electrode for an alkali metal battery, comprising: (a) Continuously feeding an electrically conductive porous layer to an anode or cathode material impregnation zone, wherein the conductive porous layer has two opposed porous surfaces and contain interconnected conductive pathways and at least 70% by volume of pores; (b) Impregnating a wet anode or cathode active material mixture into the porous layer from at least one of the two porous surfaces to form an anode or cathode electrode, wherein the wet anode or cathode active material mixture contains an anode or cathode active material and an optional conductive additive mixed with a liquid electrolyte; and (c) Supplying at least a protective film to cover the at least one porous surface to form the electrode.

主权项

1. A process for producing an alkali metal battery wherein said alkali metal is selected from Li, Na, K, or a combination thereof; said process comprising:
(A) Continuously feeding an electrically conductive porous layer to a cathode material impregnation zone, wherein said conductive porous layer has two opposed porous surfaces and contains interconnected electron-conducting pathways; (B) Impregnating a wet cathode active material mixture into said electrically conductive porous layer from at least one of said two porous surfaces to form a cathode electrode, wherein said wet cathode active material mixture contains a cathode active material and an optional conductive additive mixed with a first liquid electrolyte; (C) Continuously feeding an electrically conductive porous layer to an anode material impregnation zone, wherein said conductive porous layer has two opposed porous surfaces and contains interconnected electron-conducting pathways; (D) Impregnating a wet anode active material mixture into said electrically conductive porous layer from at least one of said two porous surfaces to form an anode electrode, wherein said wet anode active material mixture contains an anode active material and an optional conductive additive mixed with a second liquid electrolyte; and (E) Stacking said anode electrode, a porous separator, and said cathode electrode to form said alkali metal battery, wherein said anode electrode and/or said cathode electrode has a thickness no less than 100 μm; said anode active material has a material mass loading no less than 20 mg/cm2 in said anode electrode; and/or said cathode active material has a material mass loading no less than 15 mg/cm2 for an organic or polymer material or no less than 30 mg/cm2 for an inorganic and non-polymer material in said cathode electrode.