US 11,870,052 B2
Sprayed formation of batteries
Aaron M. Birt, Worcester, MA (US); Diran Apelian, West Boylston, MA (US); Joseph Heelan, Woodstock, CT (US); Ryan Mocadlo, Worcester, MA (US); and Ali Valamanesh, Worcester, MA (US)
Assigned to Worcester Polytechnic Institute, Worcester, MA (US)
Filed by Worcester Polytechnic Institute, Worcester, MA (US)
Filed on Feb. 6, 2020, as Appl. No. 16/783,657.
Application 16/783,657 is a continuation in part of application No. 15/814,781, filed on Nov. 16, 2017, abandoned.
Claims priority of provisional application 62/550,846, filed on Aug. 28, 2017.
Claims priority of provisional application 62/423,237, filed on Nov. 17, 2016.
Prior Publication US 2020/0176752 A1, Jun. 4, 2020
Int. Cl. H01M 10/04 (2006.01); H01M 10/0525 (2010.01); H01M 10/0562 (2010.01); H01M 4/04 (2006.01); H01M 4/1393 (2010.01); H01M 4/505 (2010.01); H01M 4/525 (2010.01); H01M 4/1395 (2010.01)
CPC H01M 4/0419 (2013.01) [H01M 4/1393 (2013.01); H01M 4/1395 (2013.01); H01M 4/505 (2013.01); H01M 4/525 (2013.01); H01M 10/0525 (2013.01); H01M 10/0562 (2013.01)] 21 Claims
OG exemplary drawing
 
1. A method of forming a solid-state battery, comprising:
cooling a granular form of a lithium-ion transport medium below a glass transition temperature T_g of a conductive polymer included in the lithium-ion transport medium for imparting a brittle granular texture to the cooled, granular form of the lithium-ion transport medium;
forming agglomerates including a conductive medium, the lithium-ion transport medium and an active charge material, the agglomerates including particles of evenly dispersed powders of the conductive medium and the active charge material bonded by the lithium-ion transport medium;
propelling the agglomerates at a predetermined temperature and a predetermined pressure to form sprayed agglomerates, the predetermined temperature based on the glass transition temperature of the conductive polymer included in the lithium-ion transport medium, and the predetermined pressure based on deformation of the sprayed agglomerates upon impact at the predetermined temperature; and
accumulating the sprayed agglomerates for deforming the sprayed agglomerates responsive to an impact against a collection surface and forming a layered structure for an active charge material layer of a battery based on multiple spraying iterations of the sprayed agglomerates for propelled deformation.