System and method for fabricating an electrode with separator

Abstract

A system and method for providing a ceramic-based separator onto an electrode is disclosed. A separator is formed on the electrode via a dry, solvent-free application of a ceramic-based separator to the electrode. An electrode is provided to an application area via a feed mechanism and a separator layer is then applied to the electrode that is comprised of a binder including at least one of a thermoplastic material and a thermoset material and an electrically non-conductive separator material, with the separator layer being applied to the electrode via a dry dispersion application.

What is claimed is: 
     
         1 . A system for applying a dry, solvent-free ceramic-based separator to an electrode, the system comprising:
 a spray mechanism configured to apply, via a dry dispersion application, a separator layer comprising a binder and an electrically non-conductive separator material to an electrode by spraying the binder and the electrically non-conductive separator material onto the electrode at between 2 and 20 pound-force per square inch (psi); and   a first heater configured to heat the electrode and/or the separator layer to adhere the separator layer to the electrode, the first heater comprising a radiant heater.   
     
     
         2 . The system of  claim 1  further comprising a feed mechanism configured to provide the electrode to an application region. 
     
     
         3 . The system of  claim 1  wherein the binder comprises a thermoplastic material, a thermoset material, or a combination thereof. 
     
     
         4 . The system of  claim 3  wherein the binder further comprises a filler comprising polypropylene or polyethylene. 
     
     
         5 . The system of  claim 1  further comprising a second heater positioned to heat a first surface of the electrode opposite a second surface of the electrode facing the spray mechanism. 
     
     
         6 . The system of  claim 1  wherein the binder includes a polymer; and
 wherein the first heater is configured to heat the binder without causing the polymer to readily flow. 
 
     
     
         7 . The system of  claim 1  further comprising a set of rollers or mandrels configured to compress and calendar the separator layer to a desired uniform thickness, density, porosity, and tortuosity after the electrode has been heated by the first heater. 
     
     
         8 . The system of  claim 7  wherein after passing through the set of rollers, the separator layer has a uniform thickness of less than 25 μm. 
     
     
         9 . The system of  claim 1  wherein the spray mechanism is configured to apply the separator layer to a top surface of the electrode, a bottom surface of the electrode, or a combination thereof and to at least one edge of the electrode to make a border on the at least one edge of the electrode. 
     
     
         10 . The system of  claim 9  wherein a distance between the border on the at least one edge of the electrode and the top surface of the electrode is less than 3.2 mm. 
     
     
         11 . The system of  claim 9  wherein a distance between the border on the at least one edge of the electrode and the top surface of the electrode is less than 1 mm. 
     
     
         12 . A method of applying a dry, solvent-free ceramic-based separator to an electrode, the method comprising:
 applying, via a spray mechanism, a separator layer comprised of a binder and an electrically non-conductive separator material to an electrode via a dry dispersion application by spraying the binder and the electrically non-conductive separator material onto the electrode at between 2 and 20 pound-force per square inch (psi); and   heating, via a radiant heater, the electrode and/or the separator layer to adhere the separator layer to the electrode.   
     
     
         13 . The method of  claim 12  further comprising providing the electrode to an application area via a feed mechanism. 
     
     
         14 . The method of  claim 12  further comprising gapped calendaring the separator layer with a set of rollers or mandrels to form a separator layer having a desired uniform thickness, density, porosity, and tortuosity. 
     
     
         15 . The method of  claim 12  wherein applying, via the spray mechanism, the separator layer comprises powder coating the separator layer such that the separator layer is formed on the electrode as a distinct layer from the electrode. 
     
     
         16 . A non-transitory computer readable storage medium having stored thereon a computer program comprising instructions which when executed by a computer cause a processor to:
 cause a spray mechanism to apply, via a dry dispersion application, a separator layer comprising a binder and an electrically non-conductive separator material to an electrode by spraying the binder and the electrically non-conductive separator material onto the electrode at between 2 and 20 pound-force per square inch (psi); and   cause a radiant heater to heat the electrode and/or the separator layer to adhere the separator layer to the electrode.   
     
     
         17 . The computer readable storage medium of  claim 16  wherein the computer program comprising instructions further cause the processor to cause a feed mechanism to provide the electrode to an application region. 
     
     
         18 . The computer readable storage medium of  claim 16  wherein the computer program comprising instructions further cause the processor to cause a set of rollers or mandrels to compress and calendar the separator layer to a desired uniform thickness, density, porosity, and tortuosity after the electrode has been heated by the radiant heater. 
     
     
         19 . The computer readable storage medium of  claim 16  wherein the computer program comprising instructions further cause the processor to cause the spray mechanism to apply the separator layer to a top surface of the electrode, a bottom surface of the electrode, or a combination thereof and to at least one edge of the electrode to make a border on the at least one edge of the electrode. 
     
     
         20 . The computer readable storage medium of  claim 19  wherein the computer program comprising instructions further cause the processor to cause the spray mechanism to make the border on the at least one edge of the electrode at a distance of less than 3.2 mm from the top surface of the electrode.