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# c12) United States Patent Zhamu et al. 

# (54) METHOD OF PRODUCING ALKALI METAL OR ALKALI-ION BATTERIES HAVING HIGH VOLUMETRIC AND GRAVIMETRIC ENERGY DENSITIES 

(71) Applicant: Nanotek Instruments, Inc., Dayton, OH (US) 

(72) Inventors: Aruna Zhamu, Springboro, OH (US); Bor Z. Jang, Centerville, OH (US) 

(73) Assignee: Nanotek Instruments, Inc., Dayton, OH (US) 

( *) Notice: Subject to any disclaimer, the term ofthis patent is extended or adjusted under 35 U.S.C. 154(b) by 355 days. 

(21) Appl. No.: 14/998,514 

(22) Filed: Jan. 15, 2016 

## (65) Prior Publication Data 

US 2017/0207489 Al Jul. 20, 2017 

(51) Int. Cl. 

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(52) U.S. Cl. CPC ....... H0lM 1010585 (2013.01); H0lM 41808 (2013.01); H0lM 101054 (2013.01); H0lM 1010525 (2013.01) 

(58) Field of Classification Search CPC ...... H0lM 4/5815; H0lM 4/625; H0lM 4/38; H0lM 4/1397; H0lM 10/0585; H0lM 

This patent is subject to a terminal dis› claimer. 

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# (IO) Patent No.: US 10,026,995 B2 

# *Jul. 17, 2018 (45) Date of Patent: 

## (56) References Cited 

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Chen, Z. et al. "Three-dimensional flexible and conductive inter› connected graphene networks grown by chemical vapor deposi› tion," Nat. Mater. 10, 424-428 (2011). PCT/US17/12850 International Search Report and Written Opinion dated May 16, 2017, 10 pages. 

Primary Examiner - Nicholas P D’ Aniello 

## (57) ABSTRACT 

A process for producing an alkali metal battery, comprising: (a) preparing multiple conductive porous layers (having at least 80% by volume of pores), multiple wet anode layers of an anode active material mixed with a liquid electrolyte, and multiple wet cathode layers of a cathode active material mixed with a liquid electrolyte; (b) stacking and consolidat› ing a desired number of the porous layers and a desired number of wet anode layers to form an anode electrode; ( c) placing a porous separator layer in contact with the anode electrode; ( d) preparing a cathode electrode in a similar manner than anode; and ( e) assembling all the components in a housing to produce the battery; wherein the anode active material has a material mass loading no less than 20 mg/cm 2 in the anode and/or the cathode active material has a material mass loading no less than 30 mg/cm 2 in the cathode elec› trode. 

See application file for complete search history. 

USO 10026995B2 

4/587; H01M 4/5835; H01M 4/1393; 

H0lM 4/133; H0lM 4/808; H0lM 4/663; 

## U.S. PATENT DOCUMENTS 

## OTHER PUBLICATIONS 

## 38 Claims, 16 Drawing Sheets 

H01M 4/661; H0lM 10/054 

