Innovative Battery Manufacturing and Unit Cost reduction

"A new, innovative battery manufacturing process and related battery structure enabling conformal designs with more than 30% increase in energy/power density and more than 50% unit cost reduction compared to the state of the art, with substantially improvedcycle life and safety is proposed. The manufacturing process affords continuous multi-cell lamination from just one anode, one cathode and two separator feed rolls to laminate any number of cell layers together. The process requires certain modificationsin the support materials like the separator and the current collector. The separator technology uses a phase-inversion membrane to bond the separator and the electrodes at room temperature and under light pressure. Room temperature lamination eliminatesheat transfer problems that prevents one of the problems with multi-cell lamination. A highly conductivity composite current collector (instead of aluminum and copper foils/grids) with innovative trimming techniques eliminate burrs and stringers, thatplague the battery manufacturing process and prevents multi-cell lamination, while reducing weight and decreasing cost and increasing process yield significantly. The technology uses state of the art active materials. The material selection affordsavailability. The increased cycle life and reduced unit cost makes the unit cycle cost very low (<1/4th) compared to the state of the art. This technology is applicable to other battery