Dimensional constraints for three-dimensional batteries

Patent metadata

Field	Value
Publication number	US-11961952-B2
Application number	US-202217903250-A
Country	US
Kind code	B2
Filing date	Sep 6, 2022
Priority date	May 13, 2016
Publication date	Apr 16, 2024
Grant date	Apr 16, 2024

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 structure for cycling between a charged and a discharged state in a secondary battery, the structure comprising an electrode assembly and a constraint, wherein
the electrode assembly comprises a population of electrode structures, a population of counter-electrode structures, an electrically insulating separator material between members of the electrode and counter-electrode populations, an electrode bus, and a counter-electrode bus,
the electrode assembly has a shape that corresponds to a rectangular prism having opposed first and second longitudinal end surfaces separated along a longitudinal axis, and a lateral surface surrounding the longitudinal axis and connecting the first and second longitudinal end surfaces, the surface area of the first and second longitudinal end surfaces being less than 25% of the combined surface area of the lateral surface and the first and second longitudinal end surfaces,
members of the electrode population and members of the counter-electrode population are arranged in an alternating sequence in a stacking direction that parallels the longitudinal axis within the electrode assembly, and wherein each member of the electrode population has a bottom, a top, a length L E , a width W E , a height H E , a perimeter P E , and a central longitudinal axis A E extending from the bottom to the top of each such member and in a transverse direction that is generally perpendicular to the stacking direction, the length L E of each member of the electrode population being measured in the transverse direction, the width W E of each member of the electrode population being measured in the stacking direction, the height H E of each member of the electrode population being measured in a vertical direction that is perpendicular to each of the transverse and stacking directions, the perimeter P E of each member of the electrode population being the sum of the length(s) of the side(s) of a projection of each such member in a plane that is normal to the longitudinal axis A E , the ratio of L E to P E of each member of the electrode population being at least 1.25:1,
a projection of the members of the electrode population and the counter-electrode population onto the first longitudinal end surface circumscribes a first projected area, and a projection of the members of the electrode population and the counter-electrode population onto the second longitudinal end surface circumscribes a second projected area,
the constraint comprises first and second primary compression members that overlie the first and second projected areas, respectively, the first and second primary compression members being connected by first and second primary connecting members that overlie the lateral surface of the electrode assembly and pull the first and second primary compression members toward each other,
the constraint is adapted to maintain a pressure on the electrode assembly in the stacking direction that exceeds the pressure maintained on the electrode assembly in each of the transverse and vertical directions during cycling of the electrode assembly between a charged and a discharged state, and
the electrode bus and the counter-electrode bus are separated from each other in the transverse direction, the electrode bus is electrically connected to and pools current from each member of the electrode population, the counter-electrode bus is electrically connected to and pools current from each member of the counter-electrode population, and the electrode and counter-electrode buses extend in the stacking direction substantially the entire length of the alternating sequence of electrodes and counter-electrodes.

2. The structure according to claim 1 , wherein the surface area of the first and second longitudinal end surfaces is less than 20% of the combined surface area of the lateral surface and the first and second longitudinal end surfaces.

3. The structure according to claim 1 , wherein the surface area of the first and second longitudinal end surfaces is less than 15% of the combined surface area of the lateral surface and the first and second longitudinal end surfaces.

4. The structure according to claim 1 , wherein the surface area of the first and second longitudinal end surfaces is less than 10% of the combined surface area of the lateral surface and the first and second longitudinal end surfaces.

5. The structure according to claim 1 , wherein the ratio of LE to PE of each member of the electrode population being at least 2.5:1.

6. The structure according to claim 1 , wherein the ratio of LE to PE of each member of the electrode population being at least 3.75:1.

7. The structure according to claim 1 , wherein the P E is within the range of about 0.025 mm to about 25 mm.

8. The structure according to claim 1 , wherein the P E is within the range of about 0.1 mm to about 15 mm.

9. The structure according to claim 1 , wherein the P E is within the range of about 0.5 mm to about 10 mm.

10. The structure according to claim 1 , wherein the electrode assembly comprises at least 10 electrode structures and at least 10 counter-electrode structures.

11. The structure according to claim 1 , wherein the electrode assembly comprises at least 50 electrode structures and at least 50 counter-electrode structures.

12. The structure according to claim 1 , wherein the first and second primary connecting members are affixed to (i) member(s) of the population of electrode structures, or (ii) member(s) of the population of counter-electrode structures.

13. The structure according to claim 12 , wherein the first and second primary connecting members are affixed to (i) member(s) of the population of electrode structures, or (ii) member(s) 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.

14. The structure according to claim 1 , wherein the first and second primary connecting members each comprise a thickness that is less than 20% of the electrode or counter-electrode height.

15. The structure according to claim 1 , wherein the constraint comprises a material having an ultimate tensile strength of at least 10,000 psi (>70 MPa).

16. The structure according to claim 1 , wherein at least a portion of the constraint 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.

17. The structure according to claim 1 , wherein the constraint maintains a pressure on the electrode assembly in the stacking direction that exceeds the pressure maintained on the electrode assembly in each of transverse and vertical directions during cycling of the electrode assembly between a charged and a discharged state by a factor of at least 2.

18. The structure according to cl

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

• 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

• H01M4/386

  Silicon or alloys based on silicon · CPC title

• H01M10/4235

  Safety or regulating additives or arrangements in electrodes, separators or electrolyte (H01M10/4242 takes precedence) · CPC title