Stack for an energy storage device

Patent metadata

Field	Value
Publication number	US-11990587-B2
Application number	US-201917261514-A
Country	US
Kind code	B2
Filing date	Jul 19, 2019
Priority date	Jul 20, 2018
Publication date	May 21, 2024
Grant date	May 21, 2024

Abstract

A method comprises obtaining a stack for an energy storage device, the stack comprising a substrate, a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer. The method comprises laser ablating the stack to form a plurality of first grooves in the stack, each of the plurality of first grooves being through the first electrode layer and the electrolyte layer. The method comprises forming, in or on the stack, at least one registration feature, different from each of the plurality of first grooves. An apparatus and a stack for an energy storage device is also disclosed.

First claim

The invention claimed is:

1. A method comprising:
obtaining a stack for an energy storage device, the stack comprising a substrate, a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer;
laser ablating the stack to form a plurality of first grooves in the stack, each of the plurality of first grooves being through the first electrode layer and the electrolyte layer; and
forming, in or on the stack, at least one registration feature, different from each of the plurality of first grooves,
wherein, for at least one of the plurality of first grooves, laser ablating to form the groove exposes a surface of at least the first electrode layer; and wherein the method further comprises:
providing a monomer suspended in an inert gas in the region of the groove during the laser ablating thereof such that the monomer is polymerised onto the exposed surface of the first electrode layer.

2. The method of claim 1 , wherein forming the at least one registration feature comprises laser ablating the stack to form the at least one registration feature.

3. The method of claim 2 , wherein laser ablating to form the plurality of first grooves and laser ablating to form the at least one registration feature use laser light from a common laser source.

4. The method of claim 2 , wherein the method comprises modifying a property of the laser ablating to form the plurality of first grooves, to provide the laser ablating to form the at least one registration feature.

5. The method of claim 4 , wherein modifying the property of the laser ablating comprises modifying a property of first laser light, used for the laser ablating to form the plurality of first grooves, to provide second laser light used for the laser ablating to form the at least one registration feature.

6. The method of claim 1 , wherein the method comprises moving, concurrently with or intermittently of the laser ablating to form the plurality of first grooves or the at least one registration feature, the stack in a first direction, and wherein each of the plurality of first grooves formed in the stack is elongate in a direction parallel to the first direction.

7. The method of claim 1 , wherein the at least one registration feature is formed per a given number of adjacent ones of the plurality of first grooves.

8. The method of claim 1 , wherein the plurality of first grooves are formed sequentially, and wherein the at least one registration feature is formed after a given number of sequential ones of the plurality of first grooves are formed.

9. The method of claim 1 , wherein the at least one registration feature comprises a mark on a surface of the stack, a groove into the stack that is at least wider, deeper, or has a different shape than each of the plurality of first grooves, or a perforation in the stack.

10. The method of claim 1 , wherein the method further comprises:
identifying the registration feature; and
folding the stack at or towards the identified registration feature.

11. Apparatus for processing a stack for an energy storage device, the stack comprising a substrate, a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer, the apparatus comprising:
a laser system arranged to, in use:
laser ablate the stack to form a plurality of first grooves in the stack, each of the plurality of first grooves being through the first electrode layer and the electrolyte layer; and

wherein the apparatus is arranged to:
form, in or on the stack, at least one registration feature, different from each of the plurality of first grooves; and
fold the stack at or towards the registration feature.

12. A stack for an energy storage device, the stack comprising a substrate, a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer; the stack defining a plurality of first grooves, each first groove being through the first electrode layer and the electrolyte layer; the stack further comprising at least one registration feature, different to each of the plurality of first grooves,
wherein the at least one registration feature is a mark on a surface of the stack or a groove that does not penetrate more than one layer of the stack.

13. The stack of claim 12 , wherein each of the plurality of first grooves has an electrically insulating material deposited therein.

14. A method comprising:
folding a stack for an energy storage device, at or towards a registration feature,
wherein the stack comprises a substrate, a first electrode layer, a second electrode layer, and an electrolyte layer between the first electrode layer and the second electrode layer; the stack defining a plurality of first grooves, each first groove being through the first electrode layer and the electrolyte layer; the stack further comprising the registration feature, different to each of the plurality of first grooves.

15. The method of claim 14 , wherein the method further comprises:
laser ablating to form the plurality of first grooves; and
laser ablating to form the at least one registration feature,
wherein each laser ablating step uses laser light from a common laser source.

16. The method of claim 14 , wherein the method further comprises:
laser ablating to form the plurality of first grooves; and
laser ablating to form the at least one registration feature,
wherein at least one property of the laser ablating is different between laser ablating to form the plurality of first grooves and laser ablating to form the at least one registration feature.

17. The method of claim 14 , wherein the method further comprises
moving, concurrently with or intermittently of laser ablating to form the plurality of first grooves or the at least one registration feature, the stack in a first direction, and wherein each of the plurality of first grooves formed in the stack is elongate in a direction parallel to the first direction.

18. The method of claim 14 , wherein at least one of the registration feature is formed per a given number of adjacent ones of the plurality of first grooves.

19. The method of claim 14 , wherein the plurality of first grooves are formed sequentially, and wherein the at least one registration feature is formed after a given number of sequential ones of the plurality of first grooves are formed.

20. The method of claim 14 , wherein the at least one registration feature comprises a mark on a surface of the stack, a groove into the stack that is at least wider, deeper, or has a different shape than each of the plurality of first grooves, or a perforation in the stack.

Assignees

• Dyson Technology Ltd

Inventors

• Rendall Michael Edward

Classifications

• H01M10/0585 Primary

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

• H01M10/045 Primary

  Cells or batteries with folded plate-like electrodes · CPC title

• H01M10/0525

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• H01M10/0583 Primary

  of accumulators with folded construction elements except wound ones, i.e. folded positive or negative electrodes or separators, e.g. with "Z"-shaped electrodes or separators · CPC title

• H01M2010/0495

  Nanobatteries · CPC title