Electrode assembly manufacture and device

Patent metadata

Field	Value
Publication number	US-2025149642-A1
Application number	US-202418952252-A
Country	US
Kind code	A1
Filing date	Nov 19, 2024
Priority date	Aug 6, 2018
Publication date	May 8, 2025
Grant date	—

Abstract

Embodiments of a method for the preparation of an electrode assembly, include removing a population of negative electrode subunits from a negative electrode sheet, the negative electrode sheet comprising a negative electrode sheet edge margin and at least one negative electrode sheet weakened region that is internal to the negative electrode sheet edge margin, removing a population of separator layer subunits from a separator sheet, and removing a population of positive electrode subunits from a positive electrode sheet, the positive electrode sheet comprising a positive electrode edge margin and at least one positive electrode sheet weakened region that is internal to the positive electrode sheet edge margin, and stacking members of the negative electrode subunit population, the separator layer subunit population and the positive electrode subunit population in a stacking direction to form a stacked population of unit cells.

First claim

1 .- 152 . (canceled)

153 . A battery, the battery comprising:
an electrode assembly comprising (a) a population of electrode structures, (b) a population of electrode current collectors, (c) a population of counter-electrode structures, and (d) a population of counter-electrode current collectors, each member of the population of electrode structures and each members of the population of counter-electrode structures, being arranged in an alternating sequence along a longitudinal axis; and an electrode busbar comprising a first conductive segment configured to electrically connect with the population of electrode current collectors, the conductive segment being of the electrode busbar comprising a first plurality of apertures, members of the first plurality of apertures being spaced apart along the longitudinal axis.

154 . The battery of claim 153 , wherein the battery is a secondary battery configured for cycling between a charged and a discharged state.

155 . The battery of claim 153 , wherein the battery comprises a counter-electrode busbar comprising a second conductive segment configured to electrically connect with the population of counter-electrode current collectors, the second conductive segment being of the counter-electrode busbar comprising a second plurality of apertures, members of the second plurality of apertures being spaced apart along the longitudinal axis.

156 . The battery of claim 153 , wherein each member of the population of electrode structures comprises an electrode active material layer and each member of the population of counter-electrode structures comprises a counter-electrode active material layer; wherein the electrode active material layer and/or the counter-electrode active material layer, comprises magnesium, aluminum, silicon, zirconium, yttrium, lithium, titanium, lanthanoid, manganese, copper, steel, nickel, cobalt, ceramic, or an allotrope of elemental carbon; and optionally wherein the silicon comprises electronic grade silicon, Si/C composites, Si/graphite blends, SiOx, porous Si, or intermetallic Si alloy.

157 . The battery of claim 156 , wherein the electrode active material layer and/or the counter-electrode active material layer, comprises: silicon, or an allotrope of elemental carbon; and wherein the counter-electrode active material layer, comprises lithium.

158 . The battery of claim 156 , wherein the electrode active material layer and/or the counter-electrode active material layer, comprises silicon; and wherein the counter-electrode active material layer, comprises lithium.

159 . The battery of claim 156 , wherein the electrode active material layer and/or the counter-electrode active material layer, comprises an allotrope of elemental carbon; and wherein the counter-electrode active material layer, comprises lithium.

160 . The battery of claim 155 , wherein the electrode assembly has mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y and z axes, respectively, of a cartesian coordinate system; and wherein each electrode active material layer has a length L E that corresponds to a Feret diameter of the electrode active material layer as measured in a transverse direction between (i) a first transverse end surface of the electrode active material layer and (ii) a second transverse end surface of the electrode active material layer, and a height H E that corresponds to the Feret diameter of the electrode active material layer as measured in a vertical direction between (iii) a first vertical end surface of the electrode active material layer and (iv) a second vertical end surface of the electrode active material layer, and a width W E that corresponds to the Feret diameter of the electrode active material layer as measured in a longitudinal direction between (v) a first longitudinal end surface of the electrode active material layer and (vi) a second longitudinal end surface of the electrode active material layer, wherein the battery comprises a counter-electrode busbar comprising the second conductive segment configured to electrically connect with the population of counter-electrode current collectors, the second conductive segment being of the counter-electrode busbar comprising a second plurality of apertures, members of the second plurality of apertures being spaced apart along the longitudinal axis; wherein the second conductive segment comprises a first side having an interior surface facing second transverse end surfaces of each electrode active material layer, and an opposing second side having an exterior surface, the second transverse end surfaces comprising the second transverse end surface.

161 . The battery of claim 153 , wherein the electrode assembly further comprises a population of separators and a population of unit cells, wherein each unit cell of the population of unit cells comprises (a) a unit cell portion of an electrode current collector of the population of electrode current collectors, (b) a unit cell portion of an electrode of the population of electrode structures, (c) a unit cell portion of a separator of the population of separators, (d) a unit cell portion of a counter-electrode structure of the population of counter-electrode structures, and (e) a unit cell portion of a counter-electrode current collector of the population of counter-electrode current collectors.

162 . The battery of claim 161 , wherein the unit cell portion of the electrode current collector extends at least partially along a length of the unit cell portion of the electrode in a transverse direction.

163 . The battery of claim 162 , wherein (I) the unit cell portion of the electrode current collector comprises an electrode current collector end that extends past a transverse end surface of the unit cell portion of the counter-electrode structure in a transverse direction and/or (II) the unit cell portion of the counter-electrode current collector extends at least partially along a length of the unit cell portion of the counter-electrode structure in a subject direction comprising a first direction or a second direction, the first direction being the transverse direction, and the second direction opposes the transverse direction.

164 . The battery of claim 163 , wherein (I) the unit cell portion of the electrode current collector comprises an electrode current collector end that extends past the transverse end surface of the unit cell portion of the counter-electrode structure in the transverse direction and (II) the unit cell portion of the counter-electrode current collector extends at least partially along the length of the unit cell portion of the counter-electrode structure in the subject direction.

165 . The battery of claim 164 , wherein the subject direction is the transverse direction.

166 . The battery of claim 165 , wherein the subject direction opposes the transverse direction.

167 . The battery of claim 153 , further comprising a set of electrode constraints, wherein the set of electrode constraints comprises a primary constraint system comprising (a) a first primary growth constraint, (b) a second primary growth constraint, and (c) at least one primary connecting member, the first primary growth constraint and the second primary growth constraint being separated from each other along the longitudinal axis, and the at least one primary connecting member connecting the first primary growth constraint and the second primary growth constraint.

168 . The battery of claim 167 , wherein the set of electrode constraints further comprises a secondary constraint system comprising (a) a f

Assignees

• Enovix Corp

Inventors

• Busacca Robert S
• Lahiri Ashok
• Ramasubramanian Murali
• Valdes Bruno A
• Dales Gardner Cameron
• Rust Iii Harrold J
• Varni John F
• Lee Kim Han
• Shah Nirav S
• Contreras Richard J
• Dalton Jeremie J
• Doan Jonathan C
• Armstrong Michael J
• Calcaterra Anthony
• Cardozo Benjamin J
• Winans Joshua David
• Singh Neelam
• Buck Jeffrey Glenn
• Schuerlein Thomas John
• Fortunati Kim Lester
• Sarswat Neal

Classifications

• H01M10/0525

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

• Y02P70/50

  Manufacturing or production processes characterised by the final manufactured product · CPC title

• H01M10/0404

  Machines for assembling batteries · CPC title

• Y02E60/10

  Energy storage using batteries · 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