I 1111111111111111 1111111111 1111111111 111111111111111 IIIII IIIIII IIII IIII IIII  US010903527B2  (IO)  Patent No.:  US 10,903,527 B2  Jan.26,2021  (45)  Date of Patent:  c12)  United States Patent  Liu et al.  (54)  ROLLED 3D ALKALI METAL BATTERIES  AND PRODUCTION PROCESS  HOJM 4/364  (2013.01);  HOJM 4/483  (2013.01);  HOJM 4/485  (2013.01);  HOJM  4/525  (2013.01);  (Continued)  (58)  Field of Classification Search  None  See application file for complete search history.  H0lM 1010587  H0lM 101054  (2010.01)  (2010.01)  ••••  ••..  •  •••  ■  ••••  :  Roll width  II II II II II II II  -20  35 Claims, 13 Drawing Sheets  (57)  ABSTRACT  Related U.S. Application Data  (65)  Prior Publication Data  OTHER PUBLICATIONS  U.S. PATENT DOCUMENTS  (56)  References Cited  (Continued)  (Continued)  Primary Examiner  - Carmen V Lyles-Irving  PCT/US18/31363 International Search Report dated Jul. 31, 2018,  10 pages.  Provided is a rolled alkali metal battery wherein the alkali  metal is selected from Li, Na,  K, or a combination thereof;  the battery comprising an anode having an anode active  material, a cathode containing a cathode active material, and  a separator-electrolyte layer, comprising a first electrolyte  alone or a first electrolyte-porous separator assembly, in  ionic contact with the anode and the cathode, wherein the  cathode contains a wound cathode roll of at least a discrete  layer of the cathode active material and an optional binder,  at least a discrete layer of a conductive material, and at least  a layer of a second electrolyte, identical or different in  composition than the first electrolyte, wherein the wound  cathode roll has a cathode roll length, a cathode roll width,  and a cathode roll thickness and the cathode roll width is  substantially perpendicular to the separator-electrolyte layer.  US 2019/0027788 Al  Jan. 24, 2019  4,880,508 A  5,109,070 A  11/1989 Aldissi  4/ 1992 Epstein et al.  (63)  Continuation-in-part of application No. 15/589,629,  filed on May 8, 2017.  (51)  Int. Cl.  (52)  U.S. Cl.  CPC .......  H0lM 1010587  (2013.01);  H0lM 41366  (2013.01);  H0lM 41386  (2013.01);  H0lM  41502  (2013.01);  H0lM 41505  (2013.01);  H0lM  41587  (2013.01);  H0lM  41623  (2013.01);  H0lM 41625  (2013.01);  H0lM  101054  (2013.01);  H0lM 1010525  (2013.01);  (Continued)  (22)  Filed:  Nov. 20, 2017  (21)  Appl. No.:  15/817,942  ( *)  Notice:  Subject to any disclaimer, the term ofthis  patent is extended or adjusted under 35  U.S.C. 154(b) by 27 days.  (73)  Assignee:  Global Graphene Group, Inc.,  Dayton,  OH (US)  (72)  Inventors:  Chueh Liu,  Dayton, OH (US);  Aruna  Zhamu,  Springboro, OH (US);  Bor Z  Jang,  Centerville, OH (US)  (71)  Applicant:  Nanotek Instruments, Inc.,  Dayton,  OH (US) 