Three-dimensional batteries with compressible cathodes

Patent metadata

Field	Value
Publication number	US-11063299-B2
Application number	US-201716349785-A
Country	US
Kind code	B2
Filing date	Nov 16, 2017
Priority date	Nov 16, 2016
Publication date	Jul 13, 2021
Grant date	Jul 13, 2021

Abstract

A secondary battery for cycling between a charged and a discharged state is provided. The secondary battery has an electrode assembly having a population of anode structures, a population of cathode structures, and an electrically insulating microporous separator material. The electrode assembly also has a set of electrode constraints that at least partially restrains growth of the electrode assembly. Members of the anode structure population have a first cross-sectional area, A1 when the secondary battery is in the charged state and a second cross-sectional area, A2, when the secondary battery is in the discharged state, and members of the cathode structure population have a first cross-sectional area, C1 when the secondary battery is in the charged state and a second cross-sectional area, C2, when the secondary battery is in the discharged state, where A1 is greater than A2, and C1 is less than C2.

First claim

What is claimed is:

1. A secondary battery for cycling between a charged and a discharged state, the secondary battery comprising a battery enclosure, an electrode assembly, carrier ions, and a non-aqueous liquid electrolyte within the battery enclosure, wherein
the electrode assembly comprises a population of anode structures, a population of cathode structures, and an electrically insulating microporous separator material electrically separating members of the anode and cathode structure populations, wherein the anode and cathode structure populations are arranged in an alternating sequence in a longitudinal direction, each member of the anode structure population has a first cross-sectional area, A 1 when the secondary battery is in the charged state and a second cross-sectional area, A 2 , when the secondary battery is in the discharged state, each member of the cathode structure population has a first cross-sectional area, C 1 when the secondary battery is in the charged state and a second cross-sectional area, C 2 , when the secondary battery is in the discharged state, and the cross-sectional areas of the members of the anode and cathode structure populations are measured in a first longitudinal plane that is parallel to the longitudinal direction;
the electrode assembly further comprises a set of electrode constraints that at least partially restrains growth of the electrode assembly in the longitudinal direction upon cycling of the secondary battery between the charged and discharged states;
each member of the population of cathode structures comprises a layer of a cathode active material comprising filler particles that are compressible and elastic, and each member of the population of anode structures comprises a layer of an anode active material having a capacity to accept more than one mole of carrier ion per mole of anode active material when the secondary battery is charged from a discharged state to a charged state,
A 1 is greater than A 2 for each of the members of a subset of the anode structure population and C 1 is less than C 2 for each of the members of a subset of the cathode structure population, and wherein a difference C 2 −C 1 does not exceed a difference A 1 −A 2 during cycling of the secondary battery;
wherein a ratio of C 2 to C 1 for each of the members of the subset of the cathode structure population is at least 1.1:1; and
the charged state is at least 75% of the rated capacity of the secondary battery, and the discharged state is less than 25% of the rated capacity of the secondary battery.

2. The secondary battery of claim 1 , wherein the anode structure population subset has a first median cross-sectional area MA A1 when the secondary battery is in the charged state and a second median cross-sectional area MA A2 when the secondary battery is in the discharged state, and the cathode structure population subset has a first median cross-sectional area MA C1 when the secondary battery is in the charged state and a second median cross-sectional area MA C2 when the secondary battery is in the discharged state, wherein MA A1 is greater than MA A2 and MA C1 is less than MA C2 .

3. The secondary battery of claim 1 , wherein the anode structure population subset comprises at least 10% of the total population of anode structures, and the cathode structure population subset comprises at least 10% of the total population of cathode structures.

4. The secondary battery of claim 1 , wherein each member of the cathode population comprises orthogonal height H C , width W C , and length L C directions, and wherein a ratio of the length L C to each of the height H c and the width W C is at least 5:1.

5. The secondary battery of claim 1 , wherein at least one member of the anode structure population subset has a first median cross-sectional area, ML A1 when the secondary battery is in the charged state, and a second median cross-sectional area, ML A2 when the secondary battery is in the discharged state, and at least one member of the cathode structure population subset has a first median cross-sectional area, ML C1 when the secondary battery is in the charged state, and a second median cross-sectional area ML C2 when the secondary battery is in the discharged state, where the median cross-sectional areas ML A1 , ML A2 , ML C1 and ML C2 are measured in a plurality of longitudinal planes parallel to the longitudinal direction for each member, and wherein ML A1 is greater than ML A2 for each of the members of the subset of the anode structure population and ML C1 is less than ML C2 for each of the members of the subset of the cathode structure population.

6. The secondary battery of claim 1 , wherein C 1 is in the range of from 2×10 2 μm 2 to 3×10 7 μm 2 .

7. The secondary battery of claim 1 , wherein C 2 is in the range of from 1.0×10 3 μm 2 to 1.0×10 7 μm 2 .

8. The secondary battery of claim 1 , wherein A 1 is in the range of from 100 μm 2 to 1.5×10 7 μm 2 .

9. The secondary battery of claim 1 , wherein A 2 is in the range of from 500 μm 2 to 3×10 7 μm 2 .

10. The secondary battery of claim 1 , wherein the ratio of C 2 to C 1 is at least 3:1.

11. The secondary battery of claim 1 , wherein the ratio of the A 2 to A 1 is at least 1.01:1.

12. The secondary battery of claim 1 , wherein the ratio of the A 2 to A 1 is at least 3:1.

13. The secondary battery of claim 2 , wherein the first median cross-sectional area MA A1 of the subset of the population of anode structures is in the range of from 100 μm 2 to 1.5×10 7 μm 2 , and the second median cross sectional area MA A2 of the subset of the population of anode structures is in the range of from 500 μm 2 to 3×10 7 μm 2 .

14. The secondary battery of claim 2 , wherein the second median cross-sectional area MA C2 of the subset of the population of cathode structures is in the range of from 1.01×10 2 μm 2 to 1.5×10 10 μm 2 , and the first median cross-sectional MA C1 of the subset of the population of cathode structures is in the range of from 1×10 2 μm 2 to 3×10 7 μm 2 .

15. The secondary battery of claim 2 , wherein a ratio of the first median cross-sectional area MA A1 of the subset of the population of anode structures to the second median cross sectional area MA A2 of the subset of the population of anode structures is at least 1.01:1.

16. The secondary battery of claim 2 , wherein a ratio of the first median cross-sectional area MA A1 of the subset of the population of anode structures to the second median cross sectional area MA A2 of the subset of the population of anode structures is at least 3:1.

17. The secondary battery of claim 2 , wherein the ratio of the second median cross-sectional area MA C2 of the subset of the population of cathode structures to the first median cross-sectional MA C1 of the subset of the population of cathode structures is at least 3:1.

18. The secondary battery of claim 5 , wherein the first median cross-sectional area ML A1 of the subset of the population of anode structures is in the range of from 100 μm 2 to 1.5×10 7 μm 2 , and the second median cross sectional area ML A2 of the subset of the population of anode structures is in the range of from 500 μm 2 to 3×10 7 μm 2 .

19. The secondary battery of claim 5 , wherein the second median cross-sectional area ML C2 of the subset of the population of cathode structures is in the range of from 1.01×10 2 μm 2 to 1.5×10 10 μm 2 , and the first median cross-sectional ML C1 of the subset of the population of cathode structures is i

Assignees

• Enovix Corp

Inventors

• Busacca Robert S
• Ramasubramanian Murali
• Valdes Bruno A
• Wilcox James D
• Spindt Christopher J
• Ho Geoffrey Matthew
• Varni John F
• Lee Kim Han
• Contreras Richard J
• Schuerlein Thomas John
• Lahiri Ashok

Classifications

• H01M50/491

  Porosity · CPC title

• H01M50/489

  Separators, membranes, diaphragms or spacing elements inside the cells, characterised by their physical properties, e.g. swelling degree, hydrophilicity or shut down properties · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M10/054

  Accumulators with insertion or intercalation of metals other than lithium, e.g. with magnesium or aluminium · CPC title

• H01M2010/4292

  Aspects relating to capacity ratio of electrodes/electrolyte or anode/cathode · CPC title