Dimensional constraints for three-dimensional batteries

Patent metadata

Field	Value
Publication number	US-11081718-B2
Application number	US-201916241159-A
Country	US
Kind code	B2
Filing date	Jan 7, 2019
Priority date	May 13, 2016
Publication date	Aug 3, 2021
Grant date	Aug 3, 2021

Abstract

A secondary battery is provided for cycling between a charged and a discharged state, the secondary battery including a battery enclosure, an electrode assembly, carrier ions, a non-aqueous liquid electrolyte within the battery enclosure, and a set of electrode constraints. The set of electrode constraints includes a primary constraint system having first and second primary growth constraints and at least one primary connecting member, the first and second primary growth constraints separated from each other in the longitudinal direction, wherein the primary constraint array restrains growth of the electrode assembly in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction over 20 consecutive cycles of the secondary battery is less than 20%. The set of electrode constraints further includes a secondary constraint system having first and second secondary growth constraints connected by at least one secondary connecting member, wherein the secondary constraint system at least partially restrains growth of the electrode assembly in a second direction upon cycling of the secondary battery.

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, a non-aqueous liquid electrolyte within the battery enclosure, and a set of electrode constraints, wherein
the electrode assembly has mutually perpendicular longitudinal, transverse, and vertical axes, a first longitudinal end surface and a second longitudinal end surface separated from each other in the longitudinal direction, and a lateral surface surrounding an electrode assembly longitudinal axis A EA and connecting the first and second longitudinal end surfaces, the lateral surface having opposing first and second regions on opposite sides of the longitudinal axis and separated in a first direction that is orthogonal to the longitudinal axis, the electrode assembly having a maximum width W EA measured in the longitudinal direction, a maximum length L EA bounded by the lateral surface and measured in the transverse direction, and a maximum height H EA bounded by the lateral surface and measured in the vertical direction,
the electrode assembly further comprises a population of electrode structures, a population of counter-electrode structures, and an electrically insulating separator material electrically separating members of the electrode and counter-electrode populations, members of the electrode and counter-electrode structure populations being arranged in an alternating sequence in the longitudinal direction,
each member of the population of electrode structures comprises an electrode current collector, and each member of the population of counter-electrode structures comprises a counter-electrode current collector,
each member of the population of electrode structures comprises a layer of an electrode active material and each member of the population of counter-electrode structures comprises a layer of a counter-electrode active material,
the set of electrode constraints comprises a primary constraint system comprising first and second primary growth constraints and first and second primary connecting members, wherein the first and second primary growth constraints are separated from each other in the longitudinal direction, the first and second primary connecting members are under tension and connect the first and second primary growth constraints, and the primary constraint system restrains growth of the electrode assembly in the longitudinal direction
the first and second primary connecting members are affixed to (i) the electrode current collectors of the population of electrode structures, and/or (ii) the counter-electrode current collectors of the population of counter-electrode structures.

2. The secondary battery of claim 1 , wherein the electrode active material comprises silicon.

3. The secondary battery of claim 1 , wherein the electrode active material comprises graphite.

4. The secondary battery of claim 1 , wherein a surface area of a projection of the electrode assembly in a plane orthogonal to the longitudinal direction, is smaller than the surface areas of projections of the electrode assembly onto other orthogonal planes.

5. The secondary battery of claim 1 , wherein at least one of the first and second primary growth constraints is interior to longitudinal first and second ends of the electrode assembly along the longitudinal axis.

6. The secondary battery of claim 1 , wherein the electrically insulating separator material comprises a microporous separator material comprising a particulate material and a binder, has a void fraction of at least 20 vol. %, and is permeated by the non-aqueous liquid electrolyte.

7. The secondary battery of claim 1 , wherein the carrier ions are selected from the group consisting of lithium, potassium, sodium, calcium, and magnesium.

8. The secondary battery of claim 1 , wherein the non-aqueous liquid electrolyte comprises a lithium salt dissolved in an organic solvent.

9. The secondary battery of claim 1 , wherein the first and second primary connecting members are affixed to (i) the electrode current collectors of the population of electrode structures, and/or (ii) the counter-electrode current collectors of the population of counter-electrode structures, by any one or more of adhering, gluing, welding, bonding, soldering, sintering, press contacting, brazing, thermal spraying joining, clamping, wire bonding, ribbon bonding, ultrasonic bonding, ultrasonic welding, resistance welding, laser beam welding, electron beam welding, induction welding, cold welding, plasma spraying, flame spraying, and arc spraying.

10. The secondary battery of claim 9 , wherein the first and second primary connecting members are adhered to (i) the electrode current collectors of the population of electrode structures, and/or (ii) the counter-electrode current collectors of the population of counter-electrode structures.

11. The secondary battery of claim 1 , wherein the electrode current collectors and/or counter-electrode current collectors are under tension.

12. The secondary battery of claim 11 , wherein the first and second primary growth constraints exert a pressure on the first and second longitudinal end surfaces that exceeds the pressure maintained on the electrode assembly in each of two directions that are mutually perpendicular and perpendicular to the longitudinal direction by factor of at least 2.

13. The secondary battery of claim 11 , wherein the first and second primary growth constraints exert a pressure on the first and second longitudinal end surfaces that exceeds the pressure maintained on the electrode assembly in each of two directions that are mutually perpendicular and perpendicular to the longitudinal direction by factor of at least 3.

14. The secondary battery of claim 1 , wherein the first and second primary connecting members comprise first and second sheets of material separated in the vertical direction, and
wherein the first and second sheets are each affixed at bonded regions thereof to (i) the electrode current collectors of the population of electrode structures, and/or (ii) the counter-electrode current collectors of the population of counter-electrode structures.

15. The secondary battery of claim 1 , wherein the first and second primary connecting members comprise strips of bonded regions that are affixed to (i) the electrode current collectors of the population of electrode structures, and/or (ii) the counter-electrode current collectors of the population of counter-electrode structures.

16. The secondary battery of claim 1 , wherein the first and second primary connecting members restrain growth of the electrode assembly in the second direction such that any increase in the Feret diameter of the electrode assembly in the second direction over 20 consecutive cycles upon repeated cycling of the secondary battery is less than 20%.

17. The secondary battery of claim 1 wherein members of the population of counter-electrode structures comprise a top adjacent to the first primary connecting member, a bottom adjacent to the second primary connecting member, a vertical axis A CES parallel to and in the vertical direction extending from the top to the bottom, a lateral electrode surface surrounding the vertical axis A CES and connecting the top and the bottom, the lateral electrode surface having opposing first and second regions on opposite sides of the vertical axis and separated in a first direction that is orthogonal to the vertical axis, a length L CES , a width W CES , and a height H CES , the length L CES being bounded by the

Assignees

• Enovix Corp

Inventors

• Busacca Robert S
• Lahiri Ashok
• Ramasubramanian Murali
• Valdes Bruno A
• Dales Gardner Cameron
• Spindt Christopher J
• Ho Geoffrey Matthew
• Rust Iii Harrold J
• Wilcox James D
• Varni John F
• Lee Kim Han
• Shah Nirav S
• Contreras Richard J
• Van Erden Lynn
• Dioumaev Vladimir

Classifications

• Y02P70/50

  Manufacturing or production processes characterised by the final manufactured product · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title

• H01M50/176

  for prismatic or rectangular cells (H01M50/181 takes precedence) · CPC title

• H01M50/103

  prismatic or rectangular (H01M50/109, H01M50/11 take precedence) · CPC title

• H01M4/587

  for inserting or intercalating light metals · CPC title