Electrode assembly and secondary battery

Patent metadata

Field	Value
Publication number	US-2025105283-A1
Application number	US-202418974556-A
Country	US
Kind code	A1
Filing date	Dec 9, 2024
Priority date	Nov 15, 2017
Publication date	Mar 27, 2025
Grant date	—

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 comprises a series of layers stacked in a stacking direction 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, and (b) 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 stacking 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 stacking direction,
(ii) the secondary constraint system comprises first and second secondary growth constraints separated in a second direction and connected by members of the 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 stacking 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 to the stacking direction.

2 . The secondary battery of claim 1 , wherein the population of negative electrode active material layers and/or the population of positive electrode active material layers comprises one or more materials selected from the group consisting of: graphite, tin, lead, magnesium, aluminum, boron, gallium, silicon, Si/C composites, Si/graphite blends, SiOx, porous Si, intermetallic Si alloys, indium, zirconium, germanium, bismuth, cadmium, antimony, silver, zinc, arsenic, hafnium, yttrium, lithium, sodium, graphite, carbon, lithium titanate, and palladium.

3 . The secondary battery of claim 1 , wherein the carrier ions pass through a solid electrolyte.

4 . The secondary battery according to claim 1 , wherein 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 a longitudinal direction, and a lateral surface surrounding an electrode assembly longitudinal axis AEA 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 WEA measured in the longitudinal direction, a maximum length LEA bounded by the lateral surface and measured in a transverse direction, and a maximum height HEA bounded by the lateral surface and measured in a vertical direction, wherein each of the maximum length LEA and maximum width WEA are greater than the maximum height HEA.

5 . The secondary battery according to claim 4 , wherein members of the population of negative electrode current collectors or members of the population of positive electrode current collectors comprise opposing end surfaces comprising surface regions that exhibit plastic deformation and fracturing oriented in the transverse direction, due to elongation and narrowing at the opposing end surfaces.

6 . The secondary battery according to claim 4 , wherein the first and second primary growth constraints overlay the first and second longitudinal end surfaces, respectively.

7 . The secondary battery according to claim 1 , wherein:
(i) each member of the population of negative electrode active material layers has a length LE that corresponds to a Feret diameter of the negative electrode active material layer as measured in a transverse direction between first and second opposing transverse end surfaces of the negative electrode active material layer, and a height HE that corresponds to the Feret diameter of the negative electrode active material layer as measured in a vertical direction between first and second opposing vertical end surfaces of the negative electrode active material layer, and a width WE that corresponds to the Feret diameter of the negative electrode active material layer as measured in a longitudinal direction between first and second opposing surfaces of the negative electrode active material layer, wherein a ratio of LE to each of HE and WE is at least 5:1; and (ii) each member of the population of positive electrode material layers has a length LC 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 HC 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 WC 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 LC to each of HC and WC is at least 5:1.

8 . The secondary battery according to claim 1 , wherein the first and second secondary growth constraints are connected to each other by members of the population of negative electrode current collector layers.

9 . The secondary battery according to claim 1 , wherein the first and second secondary growth constraints are connected to each other by members of the population of positive electrode current collector layers.

10 . 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, and (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 t

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