I 1111111111111111 1111111111 11111 lllll 111111111111111 11111 lll111111111111111  USO 10026995B2  c12)  United States Patent  Zhamu et al.  (IO)  Patent No.:  US 10,026,995 B2  *Jul. 17, 2018  (45)  Date of Patent:  (54)  METHOD OF PRODUCING ALKALI METAL  OR ALKALI-ION BATTERIES HAVING HIGH  VOLUMETRIC AND GRAVIMETRIC  ENERGY DENSITIES  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.  (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)  (57)  ABSTRACT  2002/0195591 Al  2005/0238961 Al  2009/0155676 Al  2014/0234702 Al  12/2002 Ravet et al.  10/2005 Barker et al.  6/2009 Zhamu et al.  8/2014 Zhang et al.  H0lM 10100  H0lM 1010585  H0lM 101054  H0lM 1010525  H0lM 4180  (2006.01)  (2010.01)  (2010.01)  (2010.01)  (2006.01)  OTHER PUBLICATIONS  U.S. PATENT DOCUMENTS  38 Claims, 16 Drawing Sheets  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.  This patent is subject to a terminal dis› claimer.  (65)  Prior Publication Data  (22)  Filed:  Jan. 15, 2016  (21)  Appl. No.:  14/998,514  (51)  Int. Cl.  Primary Examiner  - Nicholas P D’  Aniello  US 2017/0207489 Al  Jul. 20, 2017  (56)  References Cited  See application file for complete search history.  280  ( *)  Notice:  Subject to any disclaimer, the term ofthis  patent is extended or adjusted under 35  U.S.C. 154(b) by 355 days.  (58)  Field of Classification Search  CPC ...... H0lM 4/5815; H0lM 4/625; H0lM 4/38;  H0lM 4/1397; H0lM 10/0585; H0lM  (52)  U.S. Cl.  CPC .......  H0lM 1010585  (2013.01);  H0lM 41808  (2013.01);  H0lM 101054  (2013.01);  H0lM  1010525  (2013.01)  4/587; H01M 4/5835; H01M 4/1393;  H0lM 4/133; H0lM 4/808; H0lM 4/663;  H01M 4/661; H0lM 10/054 