Electrochemical slurry compositions and methods for preparing the same

Abstract

Embodiments described herein generally relate to semi-solid suspensions, and more particularly to systems and methods for preparing semi-solid suspensions for use as electrodes in electrochemical devices such as, for example batteries. In some embodiments, a method for preparing a semi-solid electrode includes combining a quantity of an active material with a quantity of an electrolyte to form an intermediate material. The intermediate material is then combined with a conductive additive to form an electrode material. The electrode material is mixed to form a suspension having a mixing index of at least about 0.80 and is then formed into a semi-solid electrode.

1 .- 49 . (canceled) 
     
     
         50 . A method comprising:
 mixing an active material with an electrolyte and a conductive additive to form a semi-solid electrode material;   controlling evaporation of the electrolyte from the semi-solid electrode material during mixing;   forming the semi-solid electrode material into a first electrode;   forming a second electrode; and   combining the first electrode and the second electrode to form an electrochemical cell.   
     
     
         51 . The method of  claim 50 , wherein the semi-solid electrode material is a suspension of the active material and the conductive additive in the electrolyte. 
     
     
         52 . The method of  claim 50 , further comprising:
 mixing the semi-solid electrode material until the semi-solid electrode material has a mixing index of at least about 0.80.   
     
     
         53 . The method of  claim 50 , further comprising:
 mixing the semi-solid electrode material until the semi-solid electrode material has an electronic conductivity of at least about 10 −6  S/cm.   
     
     
         54 . The method of  claim 50 , further comprising:
 mixing the semi-solid electrode material until the semi-solid electrode material has an apparent viscosity of less than about 100,000 Pa-s at an apparent shear rate of 1,000 s −1 .   
     
     
         55 . The method of  claim 50 , wherein the active material is about 20% to about 75% by volume of the semi-solid electrode material. 
     
     
         56 . The method of  claim 50 , wherein the electrolyte is about 25% to about 70% by volume of the semi-solid electrode material. 
     
     
         57 . The method of  claim 50 , wherein the conductive material is about 0.5% to about 25% by volume of the semi-solid electrode material. 
     
     
         58 . A method comprising:
 mixing an active material and an electrolyte with a conductive additive in a mixer to form a semi-solid electrode material having a mixing index of at least about 0.80; and   controlling evaporation of the electrolyte material during mixing.   
     
     
         59 . The method of  claim 58 , wherein the active material is about 20% to about 75% by volume of the semi-solid electrode material, the conductive additive is about 0.5% to about 25% by volume of the semi-solid electrode material, and the electrolyte is about 25% to about 70% by volume of the semi-solid electrode material. 
     
     
         60 . The method of  claim 58 , wherein the mixer is a high shear mixer. 
     
     
         61 . The method of  claim 58 , wherein the mixer is a planetary mixer. 
     
     
         62 . The method of  claim 58 , wherein the mixer is a centrifugal planetary mixer. 
     
     
         63 . A method comprising:
 mixing an active material and an electrolyte with a conductive additive in a vessel of a mixer to form a semi-solid electrode material; and   forming the semi-solid electrode material into an electrode,   wherein the mixer is configured to impart a specific mixing energy to the semi-solid electrode material so as to control evaporation of the electrolyte.   
     
     
         64 . The method of  claim 63 , wherein the vessel of the mixer is cooled to a temperature of lower than 10 degrees Celsius during mixing. 
     
     
         65 . The method of  claim 63 , wherein the mixer is a high shear mixer. 
     
     
         66 . The method of  claim 63 , wherein the mixer is a planetary mixer. 
     
     
         67 . The method of  claim 63 , wherein the mixer is a centrifugal planetary mixer. 
     
     
         68 . The method of  claim 63 , wherein the mixer is a sigma mixer. 
     
     
         69 . The method of  claim 63 , wherein the mixer is a CAM mixer. 
     
     
         70 . The method of  claim 63 , wherein the mixer is a roller mixer.