Method for automatic mass production of electrochemical cells

Abstract

Method for automatic mass production and packaging of electrochemical cells where a current collector web with attached masked terminals is rolled onto a spool, which spool is placed in a cathodic coating machine where the web is pulled through a dip tank for coating and then pulled vertically through a solidification tower, the terminals are unmasked, an insulating plastic net is provided in an electrolyte coating chamber where it is pulled through a dip tank filled with liquid polymer electrolyte, and is laid on top of the cathode web while still wet and tacky, and then travels through a solidification chamber after which an adhesive tape carrying leaf anodes is laid on top, pressed together to form cell assemblies which are cut between the anode leafs to prevent shorting and, to form individual cell assemblies, which are picked up, stacked into multiple packs, heat sealed in a plastic coated metal foil bag which is inserted into a hard casing. Similar but expanded apparatus and methods for mass production of bi-cells or bi-polar batteries are also described, where the anode carrying tape is omitted and additional layers are added to form bi-cells or bi-polar electrochemical devices. The configuration of the cell assemblies may be reversed with single cells having the anode with electrolyte layer on the bottom, and leafs of cathodes on top with adhesive tape retaining and protecting them, the reverse bi-cell assemblies have two anode layers with electrolyte layers on the bottom and top with leafs or cathode inserted therebetween. The operations may take place in an inert environment.