Electrode assembly and secondary battery

Patent metadata

Field	Value
Publication number	US-11264680-B2
Application number	US-201816763110-A
Country	US
Kind code	B2
Filing date	Nov 15, 2018
Priority date	Nov 15, 2017
Publication date	Mar 1, 2022
Grant date	Mar 1, 2022

Abstract

Embodiments of secondary batteries having electrode assemblies are provided. A secondary battery can comprise an electrode assembly having a stacked series of layers, the stacked series of layers having an offset between electrode and counter-electrode layers in a unit cell member of the stacked series. A set of constraints can be provided with a primary constraint system with first and second primary growth constraints separated from each other in a longitudinal direction, and connected by at least one primary connecting member, and a secondary constraint system comprises first and second secondary growth constraints separated in a second direction and connected by members of the stacked series of layers. The primary constraint system may at least partially restrain growth of the electrode assembly in the longitudinal direction, and the secondary constraint system may at least partially restrain growth in the second direction that is orthogonal to the longitudinal direction.

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, and carrier ions within the battery enclosure, and a set of electrode constraints, wherein
(a) the electrode assembly has mutually perpendicular transverse, longitudinal and vertical axes corresponding to the x, y and z axes, respectively, of an imaginary three-dimensional cartesian coordinate system, 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, wherein each of the maximum length L EA and maximum width W EA are greater than the maximum height H EA ,
(b) the electrode assembly comprises a series of layers stacked in a stacking direction that parallels the longitudinal axis within the electrode assembly wherein the stacked series of layers comprises a population of negative electrode active material layers, a population of negative electrode current collector layers, a population of separator material layers, a population of positive electrode active material layers, and a population of positive electrode current collector layers, wherein
(i) each member of the population of negative electrode active material layers has a length L E that corresponds to the Feret diameter of the negative electrode active material layer as measured in the transverse direction between first and second opposing transverse end surfaces of the negative electrode active material layer, and a height H E that corresponds to the Feret diameter of the negative electrode active material layer as measured in the vertical direction between first and second opposing vertical end surfaces of the negative electrode active material layer, and a width W E that corresponds to the Feret diameter of the negative electrode active material layer as measured in the longitudinal direction between first and second opposing surfaces of the negative electrode active material layer, wherein a ratio of L E to each of H E and W E is at least 5:1;
(ii) each member of the population of positive electrode material layers has a length L C that corresponds to the Feret diameter of the positive electrode active material layer as measured in the transverse direction between first and second opposing transverse end surfaces of the positive electrode active material layer, and a height H C that corresponds to the Feret diameter of the positive electrode active material layer as measured in the vertical direction between first and second opposing vertical end surfaces of the positive electrode active material layer, and a width W C that corresponds to the Feret diameter of the positive electrode active material layer as measured in the longitudinal direction between first and second opposing surfaces of the positive electrode active material layer, wherein a ratio of L C to each of H C and W C is at least 5:1,

(c) the set of electrode constraints comprises a primary constraint system and a secondary constraint system wherein,
(i) the primary constraint system comprises first and second growth constraints, and at least one primary connecting member, the first and second primary growth constraints separated from each other in the longitudinal direction and overlying the first and second longitudinal end surfaces, respectively, and the at least one primary connecting member connecting the first and second primary growth constraints to at least partially restrain growth of the electrode assembly in the longitudinal direction, and
(ii) the secondary constraint system comprises first and second secondary growth constraints separated in a second direction and connected by members of the stacked series of layers, the stacked series of layers comprising members of the population of negative electrode current collector layers or members of the population of positive electrode current collector layers, wherein the secondary constraint system at least partially restrains growth of the electrode assembly in the second direction upon cycling of the secondary battery, the second direction being orthogonal to the longitudinal direction, and,
(iii) the primary constraint system maintains a pressure on the electrode assembly in the stacking direction that exceeds the pressure maintained on the electrode assembly in each of two directions that are mutually perpendicular and perpendicular to the stacking direction, and

(d) a plurality of the negative electrode or positive electrode current collector layers comprise opposing end surfaces of the layers comprising surface regions that exhibit plastic deformation and fracturing oriented in the transverse direction, due to elongation and narrowing of the layers at the opposing end surfaces.

2. The secondary battery according to claim 1 , wherein the electrode assembly comprises a population of unit cells, wherein each unit cell comprises a unit cell portion of a first member of the negative electrode current collector layer population, a member of the separator population that is ionically permeable to the carrier ions, a first member of the negative electrode active material layer population, a unit cell portion of first member of the positive electrode current collector layer population and a first member of the positive electrode active material layer population, wherein (aa) the first member of the negative electrode active material layer population is proximate a first side of the separator and the first member of the positive electrode active material layer population is proximate an opposing second side of the separator, (bb) the separator electrically isolates the first member of the negative electrode active material layer population from the first member of the positive electrode active material layer population and carrier ions are primarily exchanged between the first member of the negative electrode active material layer population and the first member of the positive electrode active material layer population via the separator of each such unit cell during cycling of the battery between the charged and discharged state, and (cc) within each unit cell,
a. the first vertical end surfaces of the negative electrode and the positive electrode active material layers are on the same side of the electrode assembly, a 2D map of the median vertical position of the first opposing vertical end surface of the negative electrode active material in the X-Z plane, along the length L E of the negative electrode active material layer, traces a first vertical end surface plot, E VP1 , a 2D map of the median vertical position of the first opposing vertical end surface of the positive electrode active material layer in the X-Z plane, along the length L C of the positive electrode active material layer, traces a first vertical end surface plot, CE VP1 , wherein for at least 60% of the length L c of the first positive electrode active material layer (i) the absolute value of a separation distance, S Z1 , between the plots E VP1 and CE VP1 measured in the vertical direction is 1000 μm≥|S Z1 |≥5 μm, and (ii) as between the first vertical end surfaces of the negative electrode and positive electrode active material layers, the first vertical end surface of the positi

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
• Matsubayashi Ken S
• Dalton Jeremie J
• Howard Jason Newton
• Rosen Robert Keith
• Doan Jonathan C
• Armstrong Michael J
• Calcaterra Anthony
• Cardozo Benjamin L
• Winans Joshua David
• Singh Neelam
• Buck Jeffrey Glenn
• Schuerlein Thomas John
• Fortunati Kim Lester
• Sarswat Neal

Classifications

• H01M4/525 Primary

  of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy · CPC title

• H01M50/54 Primary

  Connection of several leads or tabs of plate-like electrode stacks, e.g. electrode pole straps or bridges · CPC title

• H01M4/624

  Electric conductive fillers · CPC title

• H01M10/0472

  Vertically superposed cells with vertically disposed plates · CPC title

• H01M10/0585 Primary

  of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators · CPC title