US 2019/0067732 Al  3  Feb.28,2019  SUMMARY OF THE INVENTION  [0029]  In any version of the invented process, the wet  cathode active material mixture and/or the wet anode active  material mixture may contain a polymer binder. The first  polymer gel electrolyte or the second polymer gel electrolyte  may contain a reactive monomer or oligomer that gets  polymerized or cured after the cathode electrode or the  anode electrode is formed.  [0028]  The cathode electrode thickness or the anode elec› trode thickness is preferably >250 µm, further preferably  >300 µm,  more preferably >400 µm;  further more preferably  >500 µm,  still more preferably >600  µm,  or even> 1,000 µm;  no theoretical limitation on the thickness of the presently  invented electrode.  [0024]  In certain embodiments, either the anode electrode  or the cathode electrode is made by using the presently  invented direct mixture deposition method. For instance, in  one embodiment, the cathode is produced by the instant  process but the anode can be produced by a different  [0023]  In certain embodiments, in the above process, step  (A) includes delivering, continuously or intermittently on  demand, the wet cathode active material mixture to the at  least a surface through spraying, printing, coating, casting,  conveyor film delivery, and/or roller surface delivery; and/or  wherein step (B) includes delivering, continuously or inter› mittently on demand, the wet anode active material mixture  to the at least a surface through spraying, printing, coating,  casting, conveyor film delivery, and/or roller surface deliv› ery.  [0027]  Alternatively, step (C) comprises cutting the anode  electrode into multiple anode layers and cutting the cathode  electrode into multiple cathode layers and assembling at  least an anode layer and at least a cathode layer to form an  electrochemical cell. Multiple cells can be made this way.  [0026]  In any of the above versions of the process, step (C)  may comprise continuously laminating the anode electrode,  a separator layer, and the cathode electrode into a multi-layer  laminated electrochemical cell having a length greater than  10 cm, preferably > 100 cm, and further preferably > 100  meters; there is no theoretical limitation on the length of the  laminated cell, which is limited by the length of the anode  current collector or the length of the cathode current col› lector.  [0025]  In another embodiment, the anode is produced by  the instant process but the cathode can be produced by a  different process. In this embodiment, the process com› prises: (A) continuously or non-continuously depositing a  wet anode active material mixture onto at least a surface of  an anode current collector to form an anode electrode,  wherein the wet anode active material mixture contains an  anode active material, an optional conductive additive, and  a first liquid or polymer gel electrolyte; wherein the anode  electrode has a thickness from 200 µm to 3,000 µm; (B)  introducing a cathode electrode having a cathode current  collector that has two opposed primary surfaces wherein at  least one of the two primary surfaces is deposited with a  layer of a cathode active material; and  (C) combining the  cathode electrode or a portion thereof and the wet anode  electrode or a portion thereof to form an electrochemical  cell.  [0022]  In some embodiments, the invention provides a  process for producing an electrochemical cell. The process  comprises: (A) continuously depositing a wet cathode active  material mixture onto at least a surface of a cathode current  collector to form a wet cathode electrode ( electrode remain› ing wet; the liquid solvent in the electrolyte not fully  removed), wherein the wet cathode active material mixture  preferably contains 30% to 85% by volume of a cathode  active material and 0% to 15% by volume of a conductive  additive dispersed in a first liquid or polymer gel electrolyte;  (B) continuously depositing a wet anode active material  mixture onto at least a surface of an anode current collector  to form a wet anode electrode, wherein the wet anode active  material mixture contains 30% to 85% by volume of an  anode active material and 0% to 15% by volume of a  conductive additive dispersed in a second liquid or polymer  gel electrolytes; and  (C) combining the wet cathode elec› trode or a portion thereof and the wet anode electrode or a  portion thereof to form an electrochemical cell or multiple  electrochemical cells; wherein the anode electrode and/or  the cathode electrode has a thickness from 200  µm  to 3,000  µm.  Each cathode electrode may be cut and slit into multiple  pieces of cathode layers and each anode electrode may be  cut and slit into multiple pieces of anode layers. A cathode  layer and an anode layer (along with a separator disposed  between the two layers) may be assembled into a battery  cell.  [0021]  The present invention provides a process for pro› ducing an electrochemical cell (e.g. a battery or lithium-ion  capacitor) having a high active material mass loading,  exceptionally low overhead weight and volume (relative to  the active material mass and volume), high volumetric  capacity, and unprecedentedly high volumetric energy den› sity and power density. This battery metal battery can be a  primary battery (non-rechargeable) or a secondary battery  (rechargeable), including a rechargeable alkali metal battery  (having a lithium, sodium, or potassium metal anode) and an  alkali metal-ion battery (e.g. having a first lithium or sodium  intercalation compound as an anode active material and a  second lithium or sodium intercalation or absorbing com› pound, having a much higher electrochemical potential than  the first one, as a cathode active material). The electrochemi› cal potential of the cathode active material in a battery of the  instant invention is higher than that of the anode active  material by at least 1.0 volt, preferably at least 1.5 volts,  further preferably at least 2.0 volts, more preferably at least  3.0 volts, even more preferably at least 3.5 volts, and most  preferably at least 4.0 volts.  process. In this embodiment, the process comprises: (A)  continuously or non-continuously depositing a wet cathode  active material mixture onto at least a surface of a cathode  current collector to form a wet cathode electrode, wherein  the wet cathode active material mixture contains a cathode  active material, an optional conductive additive, and a first  liquid or polymer gel electrolyte; wherein the cathode elec› trode has a thickness from 200 µm to 3,000 µm; (B)  introducing an anode electrode having an anode current  collector that has two opposed primary surfaces wherein at  least one of the two primary surfaces is deposited with a  layer of an anode active material; and (C) combining the wet  cathode electrode or a portion thereof and the anode elec› trode or a portion thereof to form an electrochemical cell. In  this process, step (A) preferably includes delivering the wet  cathode active material mixture, continuously or intermit› tently on demand, to the at least a surface through spraying,  printing, coating, casting, conveyor film delivery, and/or  roller surface delivery. 