Dimensional constraints for three-dimensional batteries

Patent metadata

Field	Value
Publication number	US-11444310-B2
Application number	US-202117335725-A
Country	US
Kind code	B2
Filing date	Jun 1, 2021
Priority date	May 13, 2016
Publication date	Sep 13, 2022
Grant date	Sep 13, 2022

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 method of manufacturing a structure comprising an electrode assembly, carrier ions, and a constraint system, the method comprising
forming the electrode assembly, the electrode assembly having 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 ratio of each of L EA and W EA to H EA being at least 2:1, respectively,
the electrode assembly comprising 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, with members of the electrode and counter-electrode structure populations being arranged in an alternating sequence in the longitudinal direction,

constraining the electrode assembly with the constraint system, the constraint system comprising first and second primary growth constraints separated from each other in the longitudinal direction, the first and second primary growth constraints being placed in tension with one another via connection through first and second primary connecting members, the first and second primary connecting members being separated from each other in the vertical direction, and
connecting one or more of (i) member(s) of the population of electrode structures, or (ii) member(s) of population of counter-electrode structures to the first and second primary connecting members.

2. The method according to claim 1 , comprising connecting both member(s) of the population of electrode structures and member(s) of population of counter-electrode structures to the first and second primary connecting members.

3. The method according to claim 1 , comprising connecting member(s) of the population of electrode structures to the first and second primary connecting members.

4. The method according to claim 1 , comprising forming an electrode assembly in which members of the population of electrode structures comprise an electrode current collector, and comprising connecting the first and second primary connecting members to the electrode current collectors of the members of the population of electrode structures.

5. The method according to claim 1 , comprising forming an electrode assembly in which members of the population of counter-electrode structures comprise a counter-electrode current collector, and comprising connecting the first and second primary connecting members to the counter-electrode current collectors of the members of the population of counter-electrode structures.

6. The method according to claim 1 , wherein the constraint system comprises first and second secondary growth constraints separated in a second direction and being placed in tension with one another via connection through first and second secondary connecting members.

7. The method according to claim 6 , wherein the first and second secondary growth constraints correspond to the first and second primary connecting members, and the first and second secondary connecting members correspond to any of (i) the first and second primary growth constraints, (ii) the member(s) of the population of electrode structures, or (ii) the member(s) of population of counter-electrode structures to the first and second primary connecting members.

8. The method according to claim 1 , wherein at least a portion of the constraint system comprises any of stainless steel, aluminum, titanium, beryllium copper, copper, nickel, alumina, zirconia, yttria-stabilized zirconia, Schott D263 tempered glass, polyetheretherketone (PEEK), PEEK with carbon, polyphenylene sulfide (PPS) with carbon, polyetheretherketone (PEEK) with 30% glass, polyimide, E Glass Std Fabric/Epoxy, 0 deg, E Glass UD/Epoxy, 0 deg, Kevlar Std Fabric/Epoxy, 0 deg, Kevlar UD/Epoxy, 0 deg, Carbon Std Fabric/Epoxy, 0 deg, Carbon UD/Epoxy, 0 deg, Toyobo Zylon® HM Fiber/Epoxy, Kevlar 49 Aramid Fiber, S Glass Fibers, Carbon Fibers, Vectran UM LCP Fibers, Dyneema, and Zylon, or combinations thereof.

9. The method of claim 1 , wherein the electrode assembly comprises at least 10 electrode structures and at least 10 counter-electrode structures.

10. The method of claim 1 , wherein the electrode assembly comprises at least 50 electrode structures and at least 50 counter-electrode structures.

11. The method of claim 1 , wherein at least a portion of the constraint system comprises a sheet of material having a thickness in the range of about 10 to about 100 micrometers.

12. The method of claim 1 , wherein at least a portion of the constraint system comprises a sheet of material having a thickness in the range of about 30 to about 75 micrometers.

13. The method of claim 1 , comprising constraining the electrode assembly such that 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 stacking direction.

14. The method of claim 1 , comprising constraining the electrode assembly such that 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 stacking direction by a factor of at least 2.

15. The method of claim 1 , comprising constraining the electrode assembly such that 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 stacking direction by a factor of at least 3.

16. The method of claim 1 , wherein the structure is a secondary battery further comprising a battery enclosure.

17. The method of claim 16 , comprising hermetically sealing the electrode assembly and constraint system within the battery enclosure.

18. The method of claim 16 , comprising filling the battery enclosure with non-aqueous liquid electrolyte.

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

20. The method of claim 19 , wherein the carrier ions comprise lithium ions.

21. The method of claim 1 , comprising forming an electrode assembly wherein 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, and wherein the electrode active material has the capacity to accept more than one mole of carrier ion per mole of electrode a

Assignees

• Enovix Corp
• Enovix Operations Inc

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