Electrode structures for three-dimensional batteries

Patent metadata

Field	Value
Publication number	US-10749207-B2
Application number	US-201816048620-A
Country	US
Kind code	B2
Filing date	Jul 30, 2018
Priority date	Aug 16, 2012
Publication date	Aug 18, 2020
Grant date	Aug 18, 2020

Abstract

An electrode structure for use in an energy storage device comprising a population of electrodes, a population of counter-electrodes and a microporous separator separating members of the electrode population from members of the counter-electrode population. Each member of the electrode population comprises an electrode active material layer and an electrode current conductor layer, and each member of the electrode population has a bottom, a top, a length L E , a width W E and a height H E , wherein the ratio of L E to each of W E and H E is at least 5:1, the ratio of H E to W E is between 0.4:1 and 1000:1, and the electrode current collector layer of each member of the electrode population has a length L C that is measured in the same direction as and is at least 50% of length L E .

First claim

What is claimed is:

1. An electrode structure comprising a population of electrodes, a population of counter-electrodes and a microporous separator separating members of the electrode population from members of the counter-electrode population, the populations of electrodes and counter-electrodes being arranged in an alternating sequence in which members of the electrode population are separated from each other by members of the counter-electrode population with the alternating sequence proceeding in a first direction, each member of the electrode population comprising an electrode active material layer and an electrode current collector layer, each member of the electrode population having a bottom, a top, a length L E , a width W E and a height H E , the length L E being measured from the bottom to the top of each such electrode, the width W E and the height H E being measured in directions that are perpendicular to each other and to the direction of measurement of the length L E , wherein
the length L E is measured in a direction that is orthogonal to the first direction, and the length L E is at least 10 mm,
the width W E is measured in a direction parallel to the first direction, and the width W E is in a range of from 0.01 mm to 5 mm,
the electrode current collector layer of each member of the electrode population is an internal layer comprising the electrode active material layer on lateral surfaces thereof, and
an electrode tab is electrically connected to an electrode tab extension that receives current from a plurality of members of the electrode population at a first side of the electrode structure, and a counter-electrode tab is electrically connected to a counter-electrode tab extension that receives current from a plurality of members of the counter-electrode population at a second side of the electrode structure opposing the first side.

2. The electrode structure of claim 1 wherein the electrode population has N members, the counter-electrode population has N+1 members, and N is at least 5.

3. The electrode structure of claim 1 wherein the electrode structure further comprises an electrode substrate and the bottom of each member of the population of electrodes is directly attached to the electrode substrate.

4. The electrode structure of claim 1 wherein the ratio of L E to each of W E and H E is at least 5:1, respectively, and the ratio of H E to W E is between 0.4:1 and 1000:1, respectively.

5. The electrode structure of claim 1 wherein H E has a value in the range of about 0.01 mm and 5 mm.

6. The electrode structure of claim 1 wherein the ratio of L E to each of W E and H E for each member of the electrode population is at least 10:1, respectively.

7. The electrode structure of claim 1 wherein the electrode current collector layer of each member of the electrode population has a length L E-C that is measured in the same direction as and is at least 50% of length L E .

8. The electrode structure of claim 1 wherein each member of the counter-electrode population comprises a counter-electrode active material layer and a counter-electrode current collector layer, each member of the counter-electrode population having a bottom, a top, a length L CE , a width W CE and a height H CE the length L CE being measured from the bottom to the top of each such counter-electrode, the width W CE and the height H CE being measured in directions that are perpendicular to each other and to the direction of measurement of the length L CE , the ratio of L CE to each of W CE and H CE being at least 5:1, respectively, the ratio of H CE to W CE being between 0.4:1 and 1000:1, respectively, the counter-electrode current collector layer of each member of the counter-electrode population having a length L CE-C that is measured in the same direction as and is at least 50% of length L CE .

9. The electrode structure of claim 1 wherein the electrode current collector layer and the electrode active material layer have an electrical conductance and the ratio of the electrical conductance of the electrode current collector layer to the electrical conductance of the electrode active material layer is at least 100:1, respectively, for each member of the population of electrodes.

10. The electrode structure of claim 1 wherein the population of electrodes is a population of negative electrodes, the population of counter-electrodes is a population of positive electrodes, the electrode active material layer is a negative electrode active material layer and the electrode current collector layer is a negative electrode current collector layer wherein the negative electrode active material layer comprises carbon, aluminum, tin, silicon or an alloy thereof.

11. The electrode structure of claim 10 wherein the negative electrode active material layer comprises nanowires of silicon or an alloy thereof, or porous silicon or an alloy thereof.

12. The electrode structure of claim 1 wherein the population of electrodes is a population of negative electrodes, the population of counter-electrodes is a population of positive electrodes, each member of the population of negative electrodes comprises a negative electrode active material layer and a negative electrode current collector layer, each member of the population of negative electrodes has a bottom, a top, a length L NE , a width W NE and a height H NE , the length L NE being measured from the bottom to the top of each such negative electrode, the width W NE and the height H NE being measured in directions that are perpendicular to each other and to the direction of measurement of the length L NE , the ratio of L NE to each of W NE and H NE being at least 5 : 1 , respectively, the ratio of H NE to W NE being between 0.4:1 and 1000:1, the negative electrode current collector layer of each member of the population having a length L NC that is measured in the same direction as and is at least 50% of L NE .

13. The electrode structure of claim 1 wherein the population of electrodes is a population of positive electrodes, the population of counter-electrodes is a population of negative electrodes,
(i) each member of the population of positive electrodes comprises a positive electrode active material layer and a positive electrode current collector layer, each member of the population of positive electrodes has a bottom, a top, a length L PE , a width W PE and a height H PE , the length L PE being measured from the bottom to the top of each such positive electrode, the width W PE and the height H PE being measured in directions that are perpendicular to each other and to the direction of measurement of the length L PE , the ratio of L PE to each of W PE and H PE being at least 5:1, respectively, the ratio of H PE to W PE being between 0.4:1 and 1000:1, respectively, the positive electrode current collector layer of each member of the positive population having a length L PC that is measured in the same direction as and is at least 50% of L PE , and
(ii) each member of the population of negative electrodes comprises a negative electrode active material layer and a negative electrode current collector layer, each member of the population of negative electrodes has a bottom, a top, a length L NE , a width W NE and a height H NE , the length L NE being measured from the bottom to the top of each such negative electrode, the width W NE and the height H NE being measured in directions that are perpendicular to each other and to the direction of measurement of the length L NE , the ratio of L NE to each of W NE and H NE being at least 5:1, respectively, the ratio of H NE to W NE being between 0 .

Assignees

• Enovix Corp

Inventors

• Rust Iii Harrold J
• Lahiri Ashok
• Ramasubramanian Murali
• Spotnitz Robert M
• Cole Robert A
• Koblmiller Gunther
• Shah Nirav S
• Brusca Brian E
• Castledine Christopher G
• Lauchlan Laurie J
• Wilcox James D

Classifications

• H01M10/052

  Li-accumulators · CPC title

• H01M4/134

  Electrodes based on metals, Si or alloys · CPC title

• H01M4/133 Primary

  Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx · CPC title

• H01M4/13 Primary

  Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title