Electrode assembly and secondary battery

Patent metadata

Field	Value
Publication number	US-12206106-B2
Application number	US-202217674133-A
Country	US
Kind code	B2
Filing date	Feb 17, 2022
Priority date	Nov 15, 2017
Publication date	Jan 21, 2025
Grant date	Jan 21, 2025

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 lithium 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 a ratio of the maximum length L EA and the maximum width W EA to the maximum height H EA is at least 2:1
(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 material 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 H E and W E is at least 5:1;
(ii) each member of the population of positive electrode active 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 H C and W C is at least 5:1
(iii) members of the negative electrode active material layer population comprise a particulate material having at least 60 wt % of negative electrode active material, less than 20 wt % conductive aid, and binder material, and where the negative electrode active material comprises a silicon-containing material,

(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 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 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) the electrode assembly comprises a population of unit cells, wherein each unit cell comprises a unit cell portion of a first member of the electrode current collector layer population, a member of the separator population that is ionically permeable to the carrier ions, a first member of the electrode active material layer population, a unit cell portion of first member of the counter-electrode current collector population and a first member of the counter-electrode active material layer population, wherein (aa) the first member of the electrode active material layer population is proximate a first side of the separator and the first member of the counter-electrode material layer population is proximate an opposing second side of the separator, (bb) the separator electrically isolates the first member of the electrode active material layer population from the first member of the counter-electrode active material layer population and carrier ions are primarily exchanged between the first member of the electrode active material layer population and the first member of the counter-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 electrode and the counter-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 electrode active material in the X-Z plane, along the length L E of the 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 counter-electrode active material layer in the X-Z plane, along the length L C of the counter-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 counter-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 electrode and counter-electrode active material layers, the first vertical end surface of the counter-electrode active material layer is inwardly disposed with respect to the first vertical end surface of the electrode active material layer,
b. the second vertical end surfaces of the electrode and counter-electrode active material layer are on the same side of the electrode assembly, and oppose the first vertical end surfaces of the electrode and counter-electrode active material layers, respectively, a 2D map of the median vertical 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

• H01M4/624

  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

• H01M50/103

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

• H01M50/46

  Separators, membranes or diaphragms characterised by their combination with electrodes · CPC title