Energy storage cell

Abstract

A system for incorporating one or more individual energy cells is provided. The individual energy cells include a top surface having a central terminal and an outer terminal. The top surface may include a pressure dissipation element configured to dissipate pressure in a direction opposite the bottom surface. The first terminal and the second terminal may be substantially planar electrical contacts.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 366,454, filed on June 15, 2022, the disclosure of which is hereby incorporated by reference in its entirety for all purposes.

[0002] The present disclosure generally relates to energy storage devices, and more particularly to improved energy storage device housings.

Background Art

[0003] Generally speaking, some devices or components can be at least partially powered by a power source or an energy storage device. In the context of a vehicle, an electric vehicle can be powered, in whole or in part, by a power source. An example of a power source for an electric vehicle can be a "battery" which can represent individual battery cells or modules and / or a plurality of cells utilized in a pack. In some approaches, a cluster of cells can be considered an individual module, and a cluster of modules can be considered a pack. The power source for an electric vehicle can be installed and maintained in a pack configuration. Similar approaches / terminology can be applied to grid storage applications for collecting, storing, and distributing energy.

[0004] Electric vehicles typically require power on the order of thousands of times greater than that of typical consumer products (e.g., mobile devices). To meet these power requirements, the energy storage packs (e.g., battery packs) of electric vehicles typically include a highly dense configuration of individual cells that are individually arranged or configured into multiple modules. The composition and performance of the energy storage pack depend on the characteristics of the individual cells, the total number of individual cells incorporated into the energy storage pack, and the configuration / orientation of the cells and auxiliary components into the modules or energy storage pack. The energy storage pack can represent one of the most expensive and large-scale assemblies in the context of most electric vehicle transportation and grid storage applications.

[0005] Due to the large amount of electrical power stored in the energy storage device, the energy storage device can have the ability to cause damage to the surroundings (e.g., vehicle components and other energy storage devices) and / or harm to individuals if the cells are defective or damaged. Thus, the safety features of the energy storage device can help reduce the damage and harm that may be caused by such cells. SUMMARY OF THE INVENTION MEANS FOR SOLVING THE PROBLEM

[0006] For purposes of summarizing the advantages achieved over the present invention and the prior art, certain objects and advantages of the present invention are described herein. Not all such objects or advantages may be achieved in any particular embodiment of the present invention. Thus, for example, those skilled in the art will recognize that the present invention may be embodied or implemented without necessarily achieving one advantage or group of advantages as taught herein, without necessarily achieving other objects or advantages as may be taught or suggested herein.

[0007] In one aspect, an energy cell is disclosed. The energy cell has a circular top surface having a central terminal, an outer terminal, and a terminal insulator gasket, the circular top surface including a pressure dissipation element, the central terminal and the outer terminal being configured as electrical contacts, the central terminal being surrounded by the outer terminal, the pressure dissipation element surrounding the central terminal and the outer terminal, the central terminal and the outer terminal being separated by the terminal insulator gasket, the terminal insulator gasket being an electrical insulator, the pressure dissipation element being configured to be at least partially removed in response to a dissipation force in a direction opposite to the bottom surface, a circular top surface, a side surface mechanically connected to the top surface, and a circular bottom surface mechanically connected to the side surface having an annular interface, the annular interface being configured to form a base for the cell, and an energy storage material within the top surface, the side surface, and the bottom surface.

[0008] In some embodiments, the top surface and the side surface are continuous. In some embodiments, the area of the central terminal and the area of the outer terminal are configured to be subordinate. In some embodiments, the area of the central terminal and the area of the outer terminal are determined based on a threshold of the statistical likelihood of success of an interconnection weld or other assembly process at the cell array level.

[0009] In another aspect, an energy cell is disclosed. The energy cell has a top surface having a central terminal and an outer terminal, the first terminal and the second terminal being configured as substantially planar electrical contacts, the top surface including a pressure dissipation element configured to dissipate in a direction opposite to the bottom surface, a top surface, a side surface mechanically connected to the top surface, a bottom surface mechanically connected to the side surface, and an energy storage material within the top surface, the side surface, and the bottom surface.

[0010] In some embodiments, the upper surface is substantially circular. In some embodiments, the central terminal and the outer terminal substantially cover the upper surface. In some embodiments, the pressure dissipation element is defined to surround the first and second terminals. In some embodiments, the first portion of the upper surface is removed in response to dissipation in the opposite direction of the bottom surface. In some embodiments, at least the second portion of the upper surface remains undamaged in response to dissipation in the opposite direction of the bottom surface. In some embodiments, the central terminal and the outer terminal are separated by a terminal insulator gasket, and the terminal insulator gasket is an electrical insulator. In some embodiments, the central terminal is a cathode and the outer terminal is an anode. In some embodiments, the area of the central terminal and the area of the outer terminal are configured to be subordinate.

[0011] In some embodiments, the area of the central terminal and the area of the outer terminal are determined based on a threshold of the statistical likelihood of successful cell array level interconnect welding or other assembly processes. In some embodiments, the dissipation element defines an area surrounding at least one of the outer terminal or the central terminal for attaching at least one positive lead and one negative lead, and the at least one positive lead and one negative lead correspond to array level interconnect welding. In some embodiments, the at least one negative lead and positive lead are cut in response to dissipation in the opposite direction of the upper surface. In some embodiments, the upper surface and the side surface are continuous. In some embodiments, the upper surface is ferromagnetic enough to allow movement via magnetic adhesion by manufacturing equipment. In some embodiments, the bottom surface has an annular interface configured to form a base for the cell.

[0012] In another aspect, a battery system is disclosed. The battery system includes a plurality of cells, each cell having an upper surface with a central terminal and an outer terminal, where a first terminal and a second terminal are configured as electrical contacts, and the upper surface includes a dissipation element configured to disengage a portion of the upper surface in response to a pressure spike, the portion of the upper surface being defined by a region defined by the dissipation element, an upper surface, a side surface mechanically connected to the upper surface, a bottom surface mechanically connected to the side surface, and an energy storage material within the upper surface, the side surface, and the bottom surface, where the cells are interconnected by laser welding and aligned in a substantially planar configuration.

[0013] In another aspect, an energy storage device is disclosed. The energy storage device includes a first terminal, a second terminal, a pressure dissipation element, and a housing having a housing surface, where the housing surface includes the first terminal, the second terminal, and the pressure dissipation element, and an energy storage material disposed within the housing.

[0014] In some embodiments, the pressure dissipation element includes a material selected from the group consisting of a machined material, a degraded material, a formed material, and combinations thereof. In some embodiments, the pressure dissipation element includes a material selected from the group consisting of a punched material, a perforated material, a welded material, an etched material, a chemically treated material, an engraved material, and combinations thereof. In some embodiments, the pressure dissipation element has a dissipation surface thickness, the housing surface has a housing surface thickness, and the dissipation surface thickness is thinner than the housing surface thickness. In some embodiments, the housing surface includes an outer surface and an inner surface, and the position of the pressure dissipation element is selected from the group consisting of the outer surface, the inner surface, and combinations thereof. In some embodiments, the energy storage device further includes a terminal insulator gasket positioned between the first terminal and the second terminal.

[0015] In some embodiments, the housing surface comprises a top surface, a side surface, and a bottom surface. In some embodiments, the first terminal, the second terminal, and the pressure dissipation element are positioned on the top surface. In some embodiments, the first terminal and the second terminal are positioned on the top surface, and the pressure dissipation element is positioned on the bottom surface. In some embodiments, the first terminal and the second terminal are positioned on the top surface, and the pressure dissipation element is positioned on the side surface. In some embodiments, the top surface is substantially circular. In some embodiments, the bottom surface comprises a substantially annular surface.

[0016] In some embodiments, the first terminal is surrounded by the second terminal, and the pressure dissipation element surrounds the first terminal and the second terminal. In some embodiments, the first terminal and the second terminal are each substantially planar. In some embodiments, the housing is substantially cylindrical. In some embodiments, the first terminal and the second terminal together cover at least about 50% of the surface area of the top surface. In some embodiments, the first terminal and the second terminal together cover at least about 75% of the surface area of the top surface. In some embodiments, the first terminal and the second terminal are substantially flat. In some embodiments, the first terminal includes a first terminal shape selected from the group consisting of circular and annular shapes. In some embodiments, the second terminal includes an annular second terminal shape. In some embodiments, the width of the first terminal is about 5 - 15 mm. In some embodiments, the width of the second terminal is about 5 - 15 mm. In some embodiments, the aspect ratio of the first terminal size: the second terminal size is about 3:1 to about 1:3.

[0017] In some embodiments, the first terminal is a cathode terminal and the second terminal is an anode terminal. In some embodiments, the energy storage device further comprises a positive electrode lead in contact with the anode terminal and a negative electrode lead in contact with the cathode terminal. In some embodiments, the positive electrode lead and the negative electrode lead are welded to the anode terminal and the cathode terminal respectively. In some embodiments, the positive electrode lead and the negative electrode lead are laser welded to the anode terminal and the cathode terminal respectively. In some embodiments, a portion of the housing surface is substantially iron-based. In some embodiments, the pressure dissipation element includes a dissipation pressure of at least about 20 bar. In some embodiments, the energy storage device further comprises a housing cap. In some embodiments, the energy storage device further comprises a housing port.

[0018] In another aspect, an energy storage device is disclosed. The energy storage device comprises a first terminal, a second terminal that surrounds the first terminal, an insulating gasket positioned between the first terminal and the second terminal, a housing having a housing surface, and an energy storage material disposed within the housing. The housing surface comprises a top surface, a side surface, and a bottom surface. The top surface comprises the first terminal and the second terminal. The first terminal and the second terminal are each substantially planar.

[0019] In some embodiments, the first terminal protrudes from the top surface. In some embodiments, the second terminal is substantially at the same height as the top surface. In some embodiments, the first terminal and the second terminal together cover at least about 50% of the surface area of the top surface. In some embodiments, the width of the first terminal is about 5 - 15 mm. In some embodiments, the width of the second terminal is about 5 - 15 mm. In some embodiments, the aspect ratio of the first terminal size to the second terminal size is about 3:1 to about 1:3. In some embodiments, the energy storage device is a battery.

[0020] In another aspect, an energy storage device array is disclosed. The array comprises a plurality of energy storage devices, and the plurality of energy storage devices comprise energy storage devices.

[0021] In another aspect, an electric vehicle is disclosed. The electric vehicle comprises an energy storage device.

[0022] In another aspect, a process for manufacturing an energy storage device is disclosed. The process comprises forming a pressure dissipation element on a housing surface of a housing, wherein the housing surface comprises a first terminal and a second terminal; disposing an energy storage material within the housing; and attaching the energy storage material to the first terminal and the second terminal.

[0023] In another aspect, a process for manufacturing an energy storage device array is disclosed. The process comprises disposing an energy storage device within an array housing; contacting a first lead with a first terminal and a second lead with a second terminal; and attaching the first lead to the first terminal and the second lead to the second terminal. In some embodiments, the position of the battery is not adjusted after the energy storage device is disposed within the array housing. In some embodiments, attaching the first lead to the first terminal and the second lead to the second terminal comprises laser welding. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] These and other features, aspects, and advantages of the present disclosure are described with reference to the drawings of particular configurations, which are intended to schematically illustrate particular configurations and are not intended to limit the present disclosure.

[0025]

Figure 1A

[0026]

Figure 1B

[0027]

Figure 1C

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Figure 2A

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Figure 2B

[0030]

Figure 3

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Figure 4

[0032]

Figure 5

Best Mode for Carrying Out the Invention

[0033] Certain embodiments and examples are described herein, but those skilled in the art will understand that the present invention extends beyond the specifically disclosed embodiments and / or uses and their obvious modifications and equivalents. Accordingly, it is intended that the scope of the invention disclosed herein not be limited by any particular embodiment described herein.

[0034] Generally speaking, one or more aspects of the present disclosure relate to energy storage cells. More specifically, the present disclosure relates to energy storage cells designed to be integrated into large-scale vehicle and grid storage products. Exemplarily, in order to support such integration, in some embodiments, individual energy storage cells can correspond to cylindrical storage cells of various volumes and aspect ratios. The cylindrical storage cells have certain characteristics or configurations that further support integration. More specifically, in one aspect, in some embodiments, the cylindrical storage cells are concentric and have a top surface specifically configured to present substantially coplanar positive and negative terminals such that the surface area for welding the interconnections provides a statistically balanced result between the positive and negative terminals. In another aspect, in some embodiments, the central terminal interface (whether positive or negative) can be elevated relative to the surrounding geometry that includes the other terminal, a terminal insulator gasket that functions as an electrical insulator between the two terminals, or another element of the cell canister. In some embodiments, the top surface can include one or more components for calibrated dissipation during thermal runaway. In some embodiments, such components can correspond, by way of example, to terminal dissipation disks as described herein.

[0035] In another aspect, in some embodiments, the cylindrical storage cells include a side surface with a sleeve to electrically insulate the individual cells from each other and from auxiliary components within the cell array. Further, in some embodiments, the side surface functions, by way of example, to interface with a cooling system added as part of the cell array that functions as a primary conduit for extracting heat generated within the individual cells.

[0036] In yet another aspect, in some embodiments, the cylindrical storage cell design includes a bottom surface that selectively groups cell features or functions that in the prior art had to be incorporated either on the top or side surfaces. Such additional features can include features similar to, complementary to, or alternative to the top surface, including geometries for sealing the open end of an extruded or drawn cell can. Further, in some embodiments, the bottom surface can be reinforced such that forces generally referred to as pressure, pressure spikes, release forces, etc., that the cell experiences, such as those resulting from thermal runaway, prefer top surface release over bottom surface release.

[0037] In an exemplary embodiment, a particular combination of the above-described aspects of the top, side, and bottom surfaces of a cylindrical storage cell facilitates an improvement in the optimization of the functions implemented by each respective surface. For example, for a cylindrical storage cell, the functions or components presented on the top surface with respect to the positive and negative terminals can increase the surface area of the top surface corresponding to the positive and negative terminals, thereby facilitating welding of electrical interconnects via a manufacturing process such as laser welding. This can improve economic and performance characteristics. In another example, the utilization of a sleeve material having additional thermal conduction characteristics enables the establishment of cooling channels that optimize cost and performance in embodiments of a cell array. Those skilled in the art will understand that such configurations or combinations also facilitate additional examples and benefits. Further, those skilled in the art will understand that other storage cell implementations within the scope of this application can incorporate different combinations of the surface aspects presented herein.

[0038] Various energy storage cell designs attempt to optimize cost, package volume, mass, performance, durability, and manufacturing efficiency at the individual cell level. However, such local optimizations typically do not translate into system-level metric optimizations for an energy storage system in which the storage cells having cell arrays utilized, for example, in an electric vehicle or a grid energy storage system are integrated. The selection of a cell form factor provides an efficient and effective utilization for the resulting performance, cost, package volume, durability, and manufacturing efficiency of the battery pack. Three different form factors of pouch cells, prismatic cells, and cylindrical cells are most commonly used in large-scale product applications. In some embodiments, the cylindrical format provides decisive advantages in cost / manufacturing efficiency by a continuous motion assembly process of single parts and in packaging / durability by internal disassembly electrode stack material expansion forces. The cylindrical format can also generally improve performance by a shorter heat path length and volumetric energy density by the wound geometric shape of the electrode stack. Those skilled in the art will understand that the material and mechanical characteristics of individual cells, including the cell exterior, can affect the ability to integrate multiple cells to achieve the function of the battery pack in order to demonstrate the advantages of the cylindrical format at the level of the integrated battery pack. Thus, as described herein, specific features and functional configurations across various surfaces of individual cylindrical storage cells can provide additional product system-level optimizations of cost, package volume, mass, performance, durability, and manufacturing efficiency of the integrated cell array.

[0039] Although the present disclosure focuses on its use in energy storage systems, in some embodiments, a cylindrical energy storage cell design is utilized to improve any energy storage device of a cylindrical form factor (such as batteries, capacitors, etc.) where automated manufacturing of large array products sensitive to cost, volume, performance, and mass is a priority result. Those skilled in the art will understand that additional advantages or technical efficiencies may be associated with one or more aspects or combinations of aspects of the present application without limitation. Energy storage cell

[0040] FIG. 1A shows a cross-sectional side view of an exemplary cylindrical energy storage cell 100. The storage cell 100 may have a top surface 102, a side surface 104, and a bottom surface 106. The side surface 104 may comprise the cell wall of the storage cell 100. The cell dimensions (e.g., height and diameter, etc.) may be optimized to form a repeating pattern of the same voltage class across various energy storage systems such as vehicle battery platforms and energy grid networks at various bus voltages. The materials used in the construction of the storage cell 100 may be chemically and thermally compatible with both internal and external contacting materials in a given energy storage application. Although shown as a cylindrical embodiment in FIGS. 1A and 1B, in other embodiments, the energy storage cell 100 may have a non-cylindrical form such as a prismatic or pouch form factor.

[0041] Figure 1B shows a perspective view of an exemplary cylindrical energy storage cell 100. Side surface 104 can be part of a continuous structure forming the cell's structure. Top surface 102 and side surface 104 may be continuous (e.g., materially continuous, mechanically continuous, or any other form of adjacency or continuity). Similarly, bottom surface 106 and side surface 104 may be continuous. For example, the outer structure of the cell is often referred to as a "can," where the side surface can be referred to as the "can wall." Exemplarily, side surface 104 of the cell may be continuous with top surface 102 or bottom surface 106 to reduce the number or severity of mechanical and electrical weaknesses on the cell. For example, in embodiments where side surface 104 is continuous with top surface 102, the cell presents a locally homogeneous structure with respect to rigidity and strength. Such a cell structure may be more suitable for handling mechanical loads, pressures, or stresses applied to top surface 102 or experienced in other ways. This may also be advantageous for the assembly of the cell or the product in which the cell is used by eliminating mechanical weaknesses and related assembly errors. In some embodiments, top surface 102 or bottom surface 106 can be a housing cap added to energy storage cell 100 to form a housing enclosure for the energy storage material disposed therein.

[0042] Furthermore, as will be described below, top surface 102 can be used to handle a portion of the mechanical loads, pressures, or stresses applied to top surface 102 when the cell is deployed for use. Exemplarily, top surface 102 can be configured to enhance the tensile strength and rigidity, as well as the compressive strength and rigidity, for the integration of the product structure to react to the fixing force during the electrical interconnection process. More specifically, top surface 102 can be directly joined to the sheet such that an array of cells 100 creates a sandwich panel structure that provides sufficient strength and rigidity to support its own mass or, additionally, a product frame (such as a vehicle body). Note that although shown as circular in Figure 1B, top surface 102 can be of any other suitable shape (e.g., polygonal).

[0043] As described herein with respect to FIG. 1C, in some embodiments, the top surface 102 can include a dissipation element 210 that disconnects one or both of the cell array electrical interconnections 212, 214 and allows for the release of dissipated gas or other materials through an opening created at the break portion of the top surface, thereby releasing at least a portion of the top surface 102 from the cell 100. In some embodiments, the dissipation element 210 is illustratively defined as a circular seal that defines the outer perimeter of the top surface that disengages at least partially or completely from any remaining portion of the top surface 102. The dissipation element 210 can be composed of a material that provides sufficient weakness to cause the disengagement of a portion of the top surface 102 from the cell 100. In other embodiments, the dissipation element 210 can be formed using manufacturing techniques such as stamping to create a material or geometric weakness in a portion of the top surface 102 to facilitate the disengagement described herein. In other embodiments, the dissipation element 210 can be configured in other preferred shapes (e.g., elliptical, rhombic, square, rectangular, spiral, etc.) or combinations thereof to produce a non-uniform, asymmetric, or multi-element design. Although not shown in FIG. 1B, in some embodiments, the dissipation element 210 can be positioned on other surfaces of the cell 100. For example, in some embodiments, the dissipation element 210 can be positioned on the side surface 104, the bottom surface 106, and / or around the boundary between two surfaces (e.g., the top surface 102 and the side surface 104). FIG. 1B shows the dissipation element 210 positioned on the outer surface of the cell 100 surface, but in some embodiments, the dissipation element 210 can be additionally or alternatively positioned on an internal location surface of the cell 100.

[0044] In some embodiments, a sleeve can be applied to the outer surface of the storage cell 100. The sleeve can substantially surround at least the cylindrical side surface 104 of the cell 100. Exemplarily, the cylindrical side surface 104 is composed of a conductive material. In some embodiments, the sleeve can be composed of one or more bands that do not substantially surround the cylindrical side surface 104 of the cell, but rather partially expose the side surface 104 of the cell 100. These bands of the sleeve can be spaced equidistantly from each other along the height of the cylindrical side surface 104 of the cell, or can be disposed substantially proximate to the top surface 102 of the cell or the bottom surface 106 of the cell. When the sleeve comprises one or more bands, the sleeve enables an electrically insulated physical contact between the cell and other components (including other cells) while maintaining an opportunity for direct mechanical bonding to the side surface 104 of the cell 100.

[0045] In some embodiments, the sleeve can be an electrically insulating material. The sleeve can create an electrical barrier that electrically insulates each energy storage cell from other energy storage system components such as a product frame, other storage cells, and a cooling system. The sleeve can facilitate the structure or configuration of a plurality of storage cells 100 corresponding to a series voltage string having the maximum volume filling density of the battery cells 100. In this configuration, the sleeve alleviates unwanted electrical connectivity between individual cells and enables the cell array to eliminate the spacing gaps between the storage cells. Thus, the use of the sleeve can enable several advantages in an energy storage system, including but not limited to, improvement of the volumetric energy density, reduction of the internal void volume (which directly reduces the cost of structurally filled module and battery pack configurations), facilitation of a balanced distribution of thermal energy from an induced or uninduced thermal runaway (which reduces the likelihood of propagation to a module or package level safety event), enforcement of the cell spacing as a bumper, buffer or mechanical shim between cells, and enabling of electrical or thermal conductivity of adjacent components for application specific performance improvements.

[0046] Alternatively, the sleeve can be used as a bumper, buffer, or mechanical shim to physically enforce cell separation without itself functioning as a primary electrical insulating medium. By using the sleeve as a bumper or buffer to enforce the cell spacing, the movement and pitch of the cells can be reduced. In some embodiments, the sleeve can be a label for the cell and can contain information about the cell, such as regulatory information or important usage details.

[0047] In some embodiments, the sleeve is a single package of material. In some embodiments, the sleeve is a dual package of one or two materials. The dual package can be useful if the primary performance characteristics of one or both packages degrade over time. The dual package can be further useful in improving maintainability by creating a sliding interface layer that simplifies the removal of cells from the cell array and the replacement of cells within the cell array.

[0048] In other embodiments, the storage cell 100 may be manufactured without a sleeve such that the conductive sides are exposed. In such embodiments, during use in an energy storage system, the storage cell 100 can be arranged such that there is a distance between the storage cell 100 and other components of the energy storage system. If the distance between storage cells 100 in such embodiments is undesirable, cells within adjacent same-voltage clusters can be configured with reversed terminal polarities such that direct contact between the sides 104 results in a zero potential, thereby eliminating the importance of contact for constructing a series voltage stack.

[0049] Referring to FIG. 1B, side 104 may be designed to facilitate the passage of air, liquid, or passive cooling through sections of side 104 where no other competing functions exist. In some embodiments, side 104 may interface with active cooling channels or cooling components (e.g., heat sinks) provided as part of the manufacture of the cell array. Thus, side 104 and the sleeve (individually or in combination) may exist to have superior heat conduction paths compared to one or both of the other surfaces of storage cell 100. In some embodiments, storage cell 100 may be cooled via top surface 102 or bottom surface 106. Any subgroup of these interfaces may be cooled simultaneously, or all of them may be cooled together (e.g., immersion, phase change, etc.), or none of them may be cooled (depending on the passive / cell heat capacity). In some embodiments, side 104 may be able to sweep cylindrically around the cell. In some embodiments, side 104 may be curved near top surface 102 or bottom surface 106. Cooling side 104 can be used as an alternative to cooling top surface 102 and bottom surface 106. This may enable the design of top surface 102 and bottom surface 106 to be primarily designed for pressure dissipation, electrical terminal cell functions, and structural connections. Cooling side 104 may also be advantageous for maximizing the cell canister height that can be packaged within a fixed vehicle product height envelope, effectively minimizing the cell active material cost / mass overhead. Such a cooling configuration also enables the removal of the thermal management interface from typical abuse zones within the series load path for a structurally integrated energy storage system. This configuration can provide additional thermal benefits, for example, by minimizing the rate of heat leakage to the ambient environment such that the cell provides heat storage for warming the passenger compartment. In embodiments where side 104 is cooled, the sleeve may not need to be of high heat resistance.

[0050] Side 104 can be further used for the accurate positioning of the storage cell 100 within the energy storage system by aligning side 104 with complementary rigid components within the energy storage system. In some embodiments, the complementary components can be thermal components within the energy storage system.

[0051] Side 104 can have a thickness of from 0.1 to 2 mm. In some embodiments, side 104 can have a thickness of about, at most, or at most about 0.05 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, or 1.0 mm. Side 104 can have a thickness of about 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm or 2 mm, or a thickness of any value within the range between them. Side 104 can have a thickness of 0.05 mm. Thinner side 104 can be used to enable a higher volumetric energy density. If the cell size is longer or has longer electrodes, the wall (referring to side 104) may be thicker. Important factors in considering side thickness include mechanical strength against fatigue over time, resistance to side breakage from large hoop stresses due to internal pressure, and thermal balancing acting as a parallel resistor during cell cooling / heating.

[0052] The top surface 102 or the bottom surface 106 can be relatively thick compared to the side surface 104. One or more of the top surface 102 or the bottom surface 106 can have a thickness of 0.1 to 2 mm. In some embodiments, the top surface 102 or the bottom surface 106 can have a thickness of about, at least, or at least about 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, or 1.0 mm. The top surface 102 or the bottom surface 106 can have a thickness of about 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm or 2 mm, or any value within the range therebetween. In some embodiments, the top surface 102 can further have various thicknesses, particularly for defining the diffusion element 210, which can have a relatively thin surface (e.g., as a result of embossing) to facilitate breakage at the diffusion element 210.

[0053] A thicker top surface 102 or bottom surface 106 can provide additional substrate for electrical connection. A thicker top surface 102 or bottom surface 106 can be useful for stronger welding to the side surface 104, which optionally has a larger interconnect process window. A thicker top surface 102 or bottom surface 106 can be useful for allowing more heat transfer from the electrical joints during normal operation of the cell, thus allowing for higher thermal performance capabilities. A thicker top surface 102 or bottom surface 106 can be useful for manufacturing to contain more magnetic flux from material handling or assembly equipment during assembly of the cell and final product. This can allow for the manufacturing of taller cells and higher factory operating speeds. As mentioned above, in some embodiments, the configuration of the bottom surface 106 can be selected to promote forces experienced within the cell 100 (e.g., thermal runaway) being released through the top surface 102, such as the illustrated portion of the top surface 102 illustratively defined by the outer edge / perimeter corresponding to the dissipation element 210. Additionally, any portion of the upper surface 102 outside the outer edge / perimeter defined by the dissipation element 210 will not be released by the dissipation force or pressure spike and may be utilized to mechanically retain the internal contents or assist in the controlled or directed discharge of the dissipated material through the resulting orifice.

[0054] FIG. 1C shows the addition of two interconnects 212 and 214 that are respectively connected to the positive connection and the negative connection provided by the upper surface 120. In some embodiments, the coupling of the interconnects 212, 214 to the upper surface is specifically designed to cause the breakage of the dissipation element 210 to also completely sever at least one of the two electrical connections to the upper surface 102, providing a thermal runaway dissipation function. In one embodiment, the welding of the interconnects 212, 214 can be performed according to the maximum allowable strength to facilitate the disconnection of the interconnects 212, 214. In other embodiments, the interconnects 212, 214 can be scored or pre-configured such that the breakage of the dissipation element 210 and the resulting discharge of the upper surface 102 cause the interconnects to disconnect. For example, the interconnects 212, 214 can be made of a material such as aluminum that has a relatively low melting temperature that allows for the destruction of the interconnects 212, 214 in a thermal runaway dissipation scenario. In yet other embodiments, such embodiments or combinations of alternatives for causing the release of the interconnects 212, 214 can be utilized. Exemplarily, the interconnects 212, 214 are configured to separate both interconnects relatively simultaneously to eliminate the possibility of a post-runaway short circuit scenario.

[0055] Figure 2A shows the upper surface 102 of the storage cell 100. The upper surface 102 may include a conductive material configured as concentric positive and negative terminals, shown as central terminal 202 and outer terminal 204 in FIG. 2A. The central terminal 202 and the outer terminal 204 can be marked with text, symbols, colors, geometric features, etc. to enable identification of each terminal or the boundary of each terminal. In some embodiments, the central terminal can be surrounded by a terminal insulator gasket 206. The terminal insulator gasket 206 can function as an electrical insulator (or dielectric insulator) between the central terminal 202 and the outer terminal 204. The central terminal 202 and the outer terminal 204 can be joined to other components to supply power to other systems, subsystems, or components. The central terminal 202 and / or the outer terminal 204 can be externally configured to improve their suitability as electrical contacts. Such external configuration can improve the material compatibility, area, and thickness available for forming an electrical junction with the central terminal 202 and / or the outer terminal 204.

[0056] In some embodiments, the central terminal 202 is the positive terminal and the outer terminal 204 is the negative terminal. In other embodiments, the central terminal 202 is the negative terminal and the outer terminal 204 is the positive terminal. In some embodiments, the central terminal 202 can be a single solid conductive component that protrudes from the upper surface 102 (e.g., protrudes from the terminal insulator gasket 206 and / or the outer terminal 204), which minimizes interference with interconnecting components at the cell array level. The central terminal 202 may also be used as a gap setting mechanism for adhesives, sealants, or heat sink elements. The sleeve 108 can overlap the outer periphery of the upper surface 102 to prevent accidental bridging between the positive and negative terminals of adjacent storage cells within the energy storage system, or to enforce a minimum surface cross-sectional "creepage distance" from conductive components at different potentials such as a cooling system or a product frame.

[0057] In some embodiments, the top surface 102 can include a cell pressure relief element 210. The cell pressure relief element 210 can be designed to enable a storage cell 100 experiencing thermal runaway to mechanically break or sever its electrical connection to other cells in the cell array or to the energy storage system itself. Similarly, the cell pressure relief element 210 can separate one or both of the central terminal 202 and the outer terminal 204 from any combination of the remaining portion of the top surface 102, the walls of the cell 100, or the electrical connections to the interconnects 212, 214. The pressure relief element 210 on the top surface 102 can further improve the reproducibility of the cell failure scenario, particularly by directing hot gases, debris, and flames away from adjacent cells, sensitive components, and product users. By more deterministically directing these hazards, the probability of thermal runaway and injury propagation can be reduced.

[0058] The cell pressure relief element 210 can be sized large enough to surround both the central terminal 202 and the outer terminal 204. The cell pressure relief element 210 can be proximate to the edge of the top surface 102. One of ordinary skill in the art will understand that the area and shape of the cell pressure relief element 210 can be adjusted to balance manufacturing assembly results and runaway dissipation performance characteristics. For example, in some embodiments, the relief element 210 may not directly correspond to the outer edge of the top surface 102. Rather, the relief element 210 may be inserted from the edge of the top surface such that a portion of the top surface 102 remains as part of the cell with associated peeling or partial peeling related to the relief force or pressure spike. Further, the position and shape of the relief element 210 can further incorporate or account for the available surface area presented by the outer terminal 204, which can be included inside or outside the area defined by the relief element 210 to facilitate welding of leads to the outer terminal 204. When included within the area defined by the relief element 210, disengagement of the top surface 102 (or a portion thereof) increases the likelihood that both conductors are completely removed as described above.

[0059] The central terminal 202 and the outer terminal 204 of the upper surface 102 can be adjusted as a maximally flat and obstacle - free weldable area, including a substrate thickness and material suitable for providing a wide interconnect energy process window (converted to interconnect assembly gap generation robustness) while minimizing the risk of compromising the airtightness of the storage cell 100. On both opposing sides of each terminal weld, sufficient positive and negative terminal areas can be provided to simultaneously perform foil down - hold, welding area, and four - probe Kelvin interconnect verification tests. Since all the positive and negative cell terminals of the storage cell 100 are arranged in a common orientation on substantially the same plane, the electrical interconnections required for power supply and voltage sensing can also extend along a single plane (e.g., integrated as a foil sheet). Laser - welded interconnections along the common plane of the upper surface 102 can create conductive connections used to supply voltage and current with low heat loss, and can also reduce manufacturing and operating costs and connect voltage sensing and control electronics. As described above, the associated strength of the interconnect weld can be based on the maximum allowable weld strength that enables disconnection of the connection.

[0060] In some embodiments, the upper surface 102 can be made of iron or a magnetic material. In some embodiments, the central terminal 202 or the outer terminal 204 is made of iron or a magnetic material. In some embodiments, the portion of the upper surface 102 that is not the central terminal 202 or the outer terminal 204 includes iron or a magnetic material. Sufficient iron or magnetic material can be present on the upper surface 102 so that an assembly tool can be used to pick up the entire cell and battery assembly by magnetic attraction to the upper surface 102.

[0061] In some embodiments, the side surface 104 can be made of the same iron or magnetic material as the upper surface 102. Alternatively, the side surface 104 can be made of a different material. The side surface 104 can be made of a non - magnetic or non - iron material. The side surface 104 can be made of a lighter material (e.g., aluminum).

[0062] In an exemplary embodiment, the dimensions of the circular regions presented by the central terminal 202 and the outer terminal 204 can be determined based on a threshold of the statistical likelihood of a successful interconnect process (e.g., laser welding) at the cell array level. For example, in one embodiment, the threshold likelihood of success can be set to 99.9999% (4 sigma) or a maximum failure rate of 0.0001 or less. Even further, the dimensions of the circular regions presented by the central terminal 202 and the outer terminal 204 may be configured to be dependent. In one embodiment, the diameter of the central terminal 202 can be set in proportion to one-half (1 / 2) of the diameter of the outer terminal 204. In another embodiment, the flat conductive diameter of the central terminal 202 can be set to be approximately equal to the flat conductive radial width of the outer terminal 204. In some embodiments, the flatness or roughness (e.g., RMS) of the terminal (e.g., the central terminal 202 or the outer terminal 204) can be exactly, approximately, maximally, or maximally approximately 2μm, 5μm, 10μm, 20μm, 30μm, 40μm, 50μm, 60μm, 70μm, 80μm, 90μm, 100μm, 150μm, 200μm, 250μm, 300μm, 350μm, 400μm or 500μm, or any value in the range between them. In these embodiments, the flatness of the terminal can facilitate attachment (e.g., laser welding) to an external interface (e.g., a positive or negative electrode lead) during manufacturing. One of ordinary skill in the art will understand that other failure rates, thresholds, dependencies or proportionalities can be implemented for different storage cells, manufacturing environments, thermal system configurations, or desired cell arrays. Further, if additional features such as ports 208 for receiving internal materials or making physical connections are implemented on the top surface 102, the dimensions of the central terminal 202 or the outer terminal 204 can be adjusted accordingly to statistically re-adjust the results of the interconnect welding or other assembly processes, as shown in FIG. 2B. In embodiments where a relatively small portion of the surface of the outer terminal 204 is required for electrical interconnect, the remaining region can be utilized as an interface for cell terminal thermometry.

[0063] In some embodiments, the terminal insulator gasket 206 has a small radial width (e.g., 0.1 mm). The terminal insulator gasket 206 can be made thin enough to meet the electrical creepage distance requirements at a 4.2 V potential. Alternatively, the terminal insulator gasket can be configured to meet the electrical creepage distance requirements at 3.0 V, 3.2 V, 3.4 V, 3.6 V, 3.8 V, 4.0 V, 4.4 V, 4.6 V, 4.8 V, or 5.0 V. The thin terminal insulator can be useful for maximizing the electrical interface area on the top surface 102.

[0064] As shown in FIG. 2A, the central terminal 202 has a central width 302, the outer terminal 204 has an outer radial width 306, and the gasket 206 has a gasket radial width 304. As shown in FIG. 2A, the central width 302 is associated with the diameter of a circle formed by the central terminal 202 that ends at the gasket 206, while the outer radial width 306 and the gasket radial width 304 are, respectively, the exposed annular width portions of the outer terminal 204 and the gasket 206 as seen from the top of the cell that ends at the pressure dissipation element 210 or the outer terminal 204. In other embodiments, the radial width or the central width may be associated with the length of a side or a diagonal of a polygon (e.g., a square) or a polygonal ring. In some embodiments, the length of the central width 302 may be exactly, approximately, at least, or at least about, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 25 mm, 30 mm, 50 mm or 100 mm, or any value in the range between them. In some embodiments, the length of the gasket radial width 304 may be exactly, approximately, at most, or at most about, 0.05 mm, 0.06 mm, 0.07 mm, 0.08 mm, 0.09 mm, 0.1 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, 0.15 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.5 mm or 2 mm, or any value in the range between them. In some embodiments, the length of the outer radial width 306 may be exactly, approximately, at least, or at least about, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 25 mm, 30 mm, 50 mm or 100 mm, or any value in the range between them.Although not readily observable from FIG. 2A, in some embodiments, the ratio or aspect ratio between the central width 302 and the outer radial width 306 can be exactly, about, at least, at least about, at most, or at most about, 5:1, 4:1, 3:1, 2:1, 1.5:1, 1:1, 1:1.5, 1:2, 1:3, 1:4 or 1:5, or any value in the range between them.

[0065] As shown in FIG. 2B, port 208 has a port width 308, central terminal 202 has a central radial width 302, outer terminal 204 has an outer radial width 306, and gasket 206 has a gasket radial width 304. As shown in FIG. 2B, port width 308 is associated with the diameter of the circle of port 208 that ends at central terminal 202, while central radial width 302, outer radial width 306, and gasket radial width 304 are, respectively, the exposed annular width portions of central terminal 202, outer terminal 204, and gasket 206 as viewed from the top of the cell that ends at gasket 206, pressure dissipation element 210, or outer terminal 204. In other embodiments, the radial width may be associated with the length of a side or diagonal of a polygon (e.g., a square) or a polygonal annulus. In some embodiments, the length of central radial width 302 may be exactly, approximately, at least, or at least about, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 25 mm, 30 mm, 50 mm, or 100 mm, or any range of values therebetween. In some embodiments, the length of gasket radial width 304 may be exactly, approximately, at most, or at most about, 0.05 mm, 0.06 mm, 0.07 mm, 0.08 mm, 0.09 mm, 0.1 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, 0.15 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.5 mm, or 2 mm, or any range of values therebetween. In some embodiments, the length of outer radial width 306 may be exactly, approximately, at least, or at least about, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 25 mm, 30 mm, 50 mm, or 100 mm, or any range of values therebetween.Although not readily observable from FIG. 2B, in some embodiments, the ratio or aspect ratio between the central radial width 302 and the outer radial width 306 can be exactly, approximately, at least, at least about, at most, or at most about, 5:1, 4:1, 3:1, 2:1, 1.5:1, 1:1, 1:1.5, 1:2, 1:3, 1:4, or 1:5, or any value in the range between them.

[0066] FIG. 3 shows the bottom surface 106 of the storage cell 100. The bottom surface 106 can incorporate all storage cell features that do not need to be accessed or interfaced for the integration of the cell array or battery pack. For example, the bottom surface 106 can include all functions other than accommodating terminals, such as, but not limited to, geometric shapes for sealing the open side of the cell can and / or geometric shapes for calibrated dissipation during thermal runaway. By integrating all non-planar non-terminal features into the bottom surface 106, the top surface 102 may be able to reach the maximum electrical interface area, which can then optimize the results of the interconnect welding or other assembly processes.

[0067] FIG. 4 shows a cross-sectional side view structure of the top surface 102 and the bottom surface 106 of the cell enclosing the cell interior 410. The bottom surface can have ports 408 for receiving internal materials or making physical connections.

[0068] In some embodiments, the bottom surface 106 has one or more recessed portions 404 and a line contact base 406. The line contact base 406 is configured to enable the cell to rest stably on the bottom surface 106. The line contact base 406 can be an annular portion on the bottom surface 106 or substantially an annular portion with respect to the contact surface to provide stability for the cell 100. Alternatively, the line contact base 406 can be three or more contact points or regions on the bottom surface 106 configured to provide stability to the cell while the cell is at rest on the bottom surface 106. One or more recessed portions 404 can be used to shroud a sealing closure or the like on the bottom surface 106 or between the bottom surface 106 and the side surface 104. One or more recessed portions 404 can be used for other purposes related to the structural integrity of the cell and the bottom surface 106.

[0069] In some embodiments, the bottom surface 106 is not continuous with the side surface 104, whereby components (e.g., conductors and active materials) inside the cell can be installed and sealed following the bottom surface 106. For example, in some embodiments, a housing cap forming the bottom surface 106 can be installed and attached to the side surface 104. In some embodiments, the bottom surface 106 can include ports for receiving materials of the battery cell.

[0070] Having a top surface 102 that is not continuous in at least one direction (e.g., mechanically continuous, materially continuous, or any other form of adjacency or continuity) can also be advantageous for fine-tuning the pressure dissipation characteristics, almost independently of the constraints and trade-offs presented by the side surface 104 and the bottom surface 106. Additional or alternative subsequent optimizations to the pressure dissipation elements 210 on the top surface 102 can further improve the reproducibility of cell failure scenarios, particularly by further guiding high-temperature gases, debris, and flames away from adjacent cells, sensitive components, and product users. By more deterministically guiding these risks, the probability of thermal runaway and injury propagation can be reduced.

[0071] The perimeter of the bottom surface 106 may be recessed to accommodate some overlap of the sleeve so that quality defects or thickness variations in the sleeve, or contour variations in the rolled or welded canister edge, do not affect the cell alignment accuracy of the energy storage system. The configuration of the bottom surface 106 can simultaneously protect the sleeve from mechanical wear and abuse during handling and transportation during manufacturing operations and promote a larger contact area between the bottom surface 106 and adjacent components such as a strength-limiting adhesive.

[0072] Continuing to refer to FIG. 4, the central terminal 202 may comprise a solid piece of conductive material. The central terminal 202 may be separated from the outer terminal 204 via a terminal insulator gasket (e.g., a compression seal) 206. As described herein, the bottom surface 106 may have a recessed portion 404 where the sleeve can overlap. The central terminal 202 and the outer terminal 204 may include any material suitable for laser welding and welding of the internal cell structure (e.g., aluminum).

[0073] In some embodiments, the conductive side surface 104 may be continuous with the outer terminal 204 and may comprise an extruded or drawn aluminum grade for improved thermal conductivity, thermal diffusivity, welding interconnect yield, and weight energy density relative to conventionally used canister materials.

[0074] The disclosed energy storage cell design can be used with any internal structure suitable for an energy storage device. An example of a suitable internal design can include a first substrate, an inner separator, a second substrate, and an outer separator. The first substrate can be conductive. The inner separator can be electrically insulating and disposed (e.g., laminated on top of) the first substrate. The conductive second substrate can be further disposed (e.g., laminated on top of) the inner separator. The electrically insulating outer separator can be disposed (e.g., laminated on top of) the second substrate. When the first substrate, inner separator, second substrate, and outer separator are continuously laminated, the first substrate, inner separator, second substrate, and outer separator can be rolled around a central axis with the first substrate in the position closest to the central axis. In some embodiments, there is no outer separator. The rolled components can then be housed within the cylindrical energy storage cell design of the present disclosure together with an ion migration medium.

[0075] In some embodiments, the techniques described herein relate to an energy storage device. In some embodiments, the energy storage device includes a first terminal, a second terminal, an energy storage material disposed within a housing, and the housing, the housing having a housing surface that includes the first terminal and the second terminal. In some embodiments, the first terminal and / or the second terminal is substantially planar. In some embodiments, the housing of the energy storage device is substantially cylindrical.

[0076] In some embodiments, the energy storage device further comprises a pressure relief element. In some embodiments, the pressure element comprises a material selected from machined materials, degraded materials, formed materials, and / or combinations thereof. In some embodiments, the pressure relief element comprises a material selected from punched materials, perforated materials, welded materials, etched materials, chemically treated materials, engraved materials, and / or combinations thereof. In some embodiments, the pressure relief element has a relief surface thickness, the housing surface has a housing surface thickness, and the relief surface thickness is thinner than the housing surface thickness. In some embodiments, the housing surface includes an outer surface and an inner surface, and the position of the pressure relief element is selected from the group including the outer surface, the inner surface, and / or combinations thereof. In some embodiments, the pressure relief element may correspond to a portion of the housing surface (e.g., the upper surface) that is thinner than other portions of the surface. For example, in some embodiments, the pressure relief element may be structurally formed as one or more grooves and / or recessed regions of the surface. In some embodiments, the relief element may be positioned on the inner surface (e.g., inside the housing), the outer surface (e.g., outside the housing), the upper surface, the side surface, the bottom surface, or any combination thereof. In some embodiments, the pressure relief element includes a relief pressure (i.e., the pressure within the housing that exposes the pressure relief element to risk (e.g., partial, substantial, or complete rupture)) that is just, about, maximum, or up to about 15 bar, 20 bar, 21 bar, 22 bar, 23 bar, 24 bar, 25 bar, 26 bar, 27 bar, 28 bar, 29 bar, 30 bar, 31 bar, 32 bar, 35 bar, 40 bar, 45 bar, 50 bar, 55 bar, 60 bar, 65 bar, 70 bar, or 80 bar, or any value within a range therebetween.

[0077] In some embodiments, the first terminal and / or the second terminal have a terminal shape selected from a filled shape (e.g., circular) and an unfilled shape (e.g., frame shape or annular shape). In some embodiments, the second terminal surrounds the first terminal. In some embodiments, the pressure dissipation element surrounds the first and / or the second terminal. In some embodiments, the housing surface includes a top surface, a side surface, and a bottom surface, where the top surface includes the first terminal and the second terminal. In some embodiments, the first terminal and / or the second terminal are substantially planar. In some embodiments, the first terminal and / or the second terminal protrude from the top surface. In some embodiments, the first terminal and / or the second terminal are substantially at the same height as the top surface. In some embodiments, the first terminal and / or the second terminal cover exactly, approximately, at least, or at least approximately, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 92%, 95%, 98%, 99% or 100% of the surface area of the housing surface (e.g., the top surface), or any value within a range therebetween. In some embodiments, the first terminal has a width size (e.g., a central width or a radial width) of exactly, approximately, at least, or at least approximately, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 25 mm, 30 mm, 50 mm or 100 mm, or any value within a range therebetween. In some embodiments, the second terminal has a width size (e.g., a central width or a radial width) of exactly, approximately, at least, or at least approximately, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 25 mm, 30 mm, 50 mm or 100 mm, or any value within a range therebetween.In some embodiments, the aspect ratio of the first terminal size to the second terminal size is exactly, about, at least, at least about, at most, or at most about, 5:1, 4:1, 3:1, 2:1, 1.5:1, 1:1, 1:1.5, 1:2, 1:3, 1:4, or 1:5, or any value in the range therebetween. For example, if the central width or radial width of the first terminal is 10 mm and the central width or radial width of the second terminal is 15 mm, the aspect ratio of the first terminal size to the second terminal size is 1:1.5. In some embodiments, the first and / or second terminals are substantially flat. In some embodiments, the first and second terminals are in the same plane. In some embodiments, the flatness or roughness (e.g., RMS) of the terminals (e.g., the first terminal and / or the second terminal) is exactly, about, at most, or at most about, 2 μm, 5 μm, 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, 100 μm, 150 μm, 200 μm, 250 μm, 300 μm, 350 μm, 400 μm, or 500 μm, or any value in the range therebetween.

[0078] In some embodiments, the first terminal, the second terminal, and the pressure dissipation element are positioned on the top surface. In other embodiments, the first and second terminals are positioned on the top surface and the pressure dissipation element is positioned on the bottom surface. In yet other embodiments, the first and second terminals are positioned on the top surface and the pressure dissipation element is positioned on the side surface. In some embodiments, the top surface is substantially circular. In some embodiments, the bottom surface includes a substantially annular surface.

[0079] In some embodiments, the energy storage device further includes a terminal insulator gasket. In some embodiments, the terminal insulator gasket is positioned between the first terminal and the second terminal. In some embodiments, the terminal insulator gasket is positioned between the first terminal and the second terminal such that the first terminal and the second terminal do not physically and directly contact each other. In some embodiments, the insulator gasket covers a portion of the surface of the first and / or second terminal. In some embodiments, the length of the gasket radial width is exactly, approximately, maximally, or maximally approximately, 0.05 mm, 0.06 mm, 0.07 mm, 0.08 mm, 0.09 mm, 0.1 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, 0.15 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.5 mm or 2 mm, or any value in the range therebetween.

[0080] In some embodiments, the first terminal or the second terminal is a cathode terminal. In some embodiments, the first terminal or the second terminal is an anode terminal. In some embodiments, the energy storage device further includes a positive electrode lead in contact with the anode terminal and / or a negative electrode lead in contact with the cathode terminal. In some embodiments, the positive electrode lead and the negative electrode lead are attached (e.g., welded) to the anode terminal and the cathode terminal, respectively. In some embodiments, the welding can be selected from laser welding, ultrasonic bonding welding, resistance welding, and TIG welding. In some embodiments, the welding is laser welding.

[0081] In some embodiments, the energy storage device further includes a housing cap. In some embodiments, the housing cap forms the bottom surface of the housing. In some embodiments, the energy storage device further includes a housing port. In some embodiments, the housing port is positioned on the top surface and / or the bottom surface. In some embodiments, the housing port is surrounded by a first terminal, a second terminal, an insulating gasket, and / or a pressure dissipation element. In some embodiments, a portion of the housing surface is substantially iron-based. In some embodiments, the energy storage device is a battery. Product system

[0082] FIG. 5 shows an exemplary energy storage system 500 in which the storage cell 100 can be used within the cell array 530. In one embodiment, the storage cells 100 can be arranged as modules in a common orientation. In other embodiments, the array of cells may be arranged as modules in an alternating or staggered orientation. In some embodiments, the storage cells 100 can have sleeves 108 and be arranged directly adjacent to each other. In other embodiments, the storage cells 100 may not have sleeves 108 and thus may be arranged with some distance between each cell. In some embodiments, the storage cells 100 can be electrically interconnected via a lower voltage brick foil sheet 540, where the foil sheet 540 is laser welded to create electrical connections with the cells 100, sensing electronics, and the anode / cathode array terminals. In other embodiments, the foil sheet 540 may be completely omitted. In other embodiments, the storage cells 100 are interconnected via another means. The sides 104 of the storage cells 100 can be cooled using a thermal component 538. The cell array can be housed within a frame structure 502 and sealed with a lid 520.

[0083] The interconnection of 100 storage cells can also be configured to ensure the durability of the product under normal stress, but can be configured to disconnect from the terminals on the storage cells when under undesirable mechanical and thermal loads such as thermal runaway. The interconnection can be adjusted to different widths or thicknesses to disconnect from the terminals on the storage cells. To enable disconnection, other stress concentration shapes, such as welding patterns, shapes, footprint areas, power, and vias, can be added to the interconnection. Furthermore, the interconnection material can be composed of a material with a lower melting temperature.

[0084] In some embodiments, the techniques described herein relate to an energy storage device array. In some embodiments, the energy storage device array includes a plurality of energy storage devices, where each of the energy storage devices can be any of the energy storage devices described above. In some embodiments, the techniques described herein relate to an electric vehicle that includes an energy storage device such as any of the energy storage devices described above. Energy Storage Device Manufacturing Process

[0085] In some embodiments, the techniques described herein relate to a process for manufacturing an energy storage device such as cell 100. In some embodiments, the process for manufacturing an energy storage device can include disposing an energy storage material within a housing and attaching the energy storage material within the housing. In some embodiments, the process further includes forming a pressure dissipation element on the housing surface of the housing. In some embodiments, the housing surface includes a first terminal and a second terminal. In some embodiments, a cap is attached to the housing after the energy storage material is disposed within the housing. Energy Storage Device Array Manufacturing Process

[0086] In some embodiments, the techniques described herein relate to a process for manufacturing an energy storage device array, such as array 530. For example, a process for manufacturing an energy storage device array can include disposing at least one or a plurality of energy storage devices within an array housing, contacting a first lead to a first terminal of an energy storage device and a second lead to a second terminal of the energy storage device, and attaching the first lead to the first terminal of the energy storage device and the second lead to the second terminal of the energy storage device. In some embodiments, attaching includes welding (e.g., laser welding). In some embodiments, the position of the battery is not adjusted after the energy storage device is disposed within the array housing. The ability to attach leads to the energy storage devices within the array without adjustment can be enabled by using the terminals described herein, as shown, for example, by any one of FIGS. 1-5.

[0087] Although specific embodiments have been described, these embodiments are presented by way of example only and are not intended to limit the above disclosure to the exact forms or specific fields of use disclosed. Indeed, the novel methods and systems described herein can be embodied in a variety of other forms. Further, various omissions, substitutions, and changes can be made to the systems and methods described herein without departing from the spirit of the disclosure. Accordingly, various alternative embodiments and / or modifications to the disclosure, whether explicitly described or implied herein, are considered possible in light of the disclosure. Having thus described embodiments of the disclosure, those of ordinary skill in the art will recognize that changes in form and detail can be made without departing from the scope of the disclosure. The appended claims and their equivalents are intended to cover such forms or modifications as fall within the scope and spirit of the disclosure. Accordingly, the disclosure is limited only by the claims.

[0088] In the foregoing specification, the disclosure has been described with reference to specific embodiments. However, as will be understood by those skilled in the art, the various embodiments disclosed herein can be modified or otherwise implemented in various other ways without departing from the spirit and scope of the disclosure. Accordingly, this description should be regarded as illustrative only and is for the purpose of teaching those skilled in the art the manner of making and using the various embodiments of the disclosed cell assembly. It should be understood that the forms of the disclosure shown and described herein are to be construed as representative embodiments. Equivalent elements, materials, processes or steps may be substituted for those typically shown and described herein. Further, certain features of the disclosure may be utilized independently of the use of other features, as will be apparent to those skilled in the art after benefit of this description of the disclosure. Expressions such as "including", "comprising", "incorporating", "consisting of", "have", "is", etc., used to describe and claim the disclosure are to be construed in a non-exclusive manner, i.e., are intended to allow for the presence of items, components or elements not explicitly recited. References to the singular are also to be construed as relating to the plural.

[0089] Furthermore, the various embodiments disclosed herein should be construed in an exemplary and illustrative sense and should in no way be construed as limiting the disclosure. All references to joining (e.g., attaching, fixing, coupling, connecting, etc.) are used only to aid the reader's understanding of the disclosure and do not create limitations with respect to the position, orientation, or use of the systems and / or methods disclosed herein. Accordingly, references to joining, where present, should be construed broadly. Further, such references to joining do not necessarily mean that two elements are directly connected to each other.

[0090] Furthermore, the operations may be shown in the drawings or described herein in a particular order, but such operations need not be performed in the particular order shown or in a sequential order to achieve the desired results, nor do all the operations need to be performed. Other operations not illustrated or described may be incorporated into the exemplary methods and processes. Further, without limitation, all numerical terms such as "first," "second," "third," "primary," "secondary," "main," or any other ordinary and / or numerical terms should also be construed only as identifiers to assist the reader's understanding of the various elements, embodiments, variations, and / or modifications of the present disclosure, and in particular, should not give rise to any limitation with respect to the order or preference of one element, embodiment, variation, and / or modification over or with respect to another element, embodiment, variation, and / or modification.

[0091] It will also be understood that, depending on the particular application, one or more of the elements shown in the drawings / figures may also be implemented in a more separated or integrated manner, or in certain cases removed or rendered inoperable. Further, any signal hatching in the drawings / figures should be considered only as exemplary and not limiting, unless otherwise specified.

[0092] For purposes of the present disclosure, certain aspects, advantages, and novel features are described herein. It is not necessarily the case that all such advantages can be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the present disclosure may be embodied or implemented so as to achieve one advantage or group of advantages taught herein without necessarily achieving other advantages that may be taught or suggested herein.

[0093] Conditional language such as "can", "could", "might", or "may", unless otherwise specified or understood in another sense within the context in which it is used, generally is intended to convey that a particular embodiment includes a particular feature, element, and / or step, but that other embodiments do not. Thus, such conditional language generally is not intended to mean that a feature, element, and / or step is required in any way in one or more embodiments, or that one or more embodiments necessarily include logic for determining whether these features, elements, and / or steps are included in, or are to be performed in, any particular embodiment, regardless of user input or prompt.

[0094] Connective language such as the phrase "at least one of X, Y, and Z", unless otherwise specified, is understood in another sense within the context in which it is generally used to convey that an item, term, etc. can be either X, Y, or Z. Thus, such connective language generally is not intended to mean that a particular embodiment requires the presence of at least one of X, at least one of Y, and at least one of Z.

[0095] Degree language used herein, such as "approximately", "about", "generally", and "substantially", represents a value, quantity, or characteristic that still performs the desired function or achieves the desired result and is close to the recited value, quantity, or characteristic.

[0096] The scope of the present disclosure is not intended to be limited by the specific disclosure of embodiments in this section or elsewhere in this specification, but may be defined by the claims, as presented in this section or elsewhere in this specification, or as will be presented in the future. The language of the claims should be interpreted broadly based on the language used in the claims and not limited to the examples described in this specification or during the examination of the application, which should be construed as non-exclusive.

[0097] Although specific embodiments have been described, these embodiments are presented by way of example and are not intended to limit the scope of the present disclosure. Indeed, the novel methods and systems described herein may be embodied in various other forms. Further, various omissions, substitutions, and changes may be made to the systems and methods described herein without departing from the spirit of the present disclosure. The appended claims and their equivalents are intended to cover such forms or modifications as fall within the scope and spirit of the present disclosure. Accordingly, the scope of the present invention is defined only by reference to the appended claims.

Claims

1. The first terminal and The second terminal and Pressure relief element, A housing having a housing surface, wherein the housing surface includes the first terminal, the second terminal, and the pressure relief element, An energy storage material disposed within the housing, An energy storage device equipped with the following features.

2. The energy storage device according to claim 1, wherein the pressure relief element includes a material selected from the group consisting of machined material, degraded material, molded material, and combinations thereof.

3. The energy storage device according to claim 1 or 2, wherein the pressure relief element includes a material selected from the group consisting of punched material, perforated material, welded material, etched material, chemically treated material, engraved material, and combinations thereof.

4. The energy storage device according to claim 1 or 2, wherein the pressure dissipation element has a dissipation surface thickness, the housing surface has a housing surface thickness, and the dissipation surface thickness is thinner than the housing surface thickness.

5. The energy storage device according to claim 1 or 2, wherein the housing surface comprises an outer surface and an inner surface, and the position of the pressure relief element is selected from the group consisting of the outer surface, the inner surface, and combinations thereof.

6. The energy storage device according to claim 1 or 2, further comprising a terminal insulating gasket positioned between the first terminal and the second terminal.

7. The energy storage device according to claim 1 or 2, wherein the housing surface comprises a top surface, a side surface, and a bottom surface.

8. The energy storage device according to claim 7, wherein the first terminal, the second terminal, and the pressure relief element are positioned on the upper surface.

9. The energy storage device according to claim 7, wherein the first terminal and the second terminal are positioned on the upper surface and the pressure relief element is positioned on the bottom surface.

10. The energy storage device according to claim 7, wherein the first terminal and the second terminal are positioned on the upper surface and the pressure relief element is positioned on the side surface.

11. The energy storage device according to claim 7, wherein the upper surface is substantially circular.

12. The energy storage device according to claim 7, wherein the bottom surface comprises a substantially annular surface.

13. The energy storage device according to claim 1 or 2, wherein the first terminal is surrounded by the second terminal, and the pressure relief element surrounds the first terminal and the second terminal.

14. The energy storage device according to claim 1 or 2, wherein the first terminal and the second terminal are each substantially planar.

15. The energy storage device according to claim 1 or 2, wherein the housing is substantially cylindrical.

16. The energy storage device according to claim 1 or 2, wherein the first terminal and the second terminal together cover at least 50% of the surface area of ​​the upper surface.

17. The energy storage device according to claim 1 or 2, wherein the first terminal and the second terminal together cover at least 75% of the surface area of ​​the upper surface.

18. The energy storage device according to claim 1 or 2, wherein the first terminal and the second terminal are substantially flat.

19. The energy storage device according to claim 1 or 2, wherein the first terminal includes a first terminal shape selected from the group consisting of circular and annular shapes.

20. The energy storage device according to claim 1 or 2, wherein the second terminal includes an annular second terminal shape.

21. The energy storage device according to claim 1 or 2, wherein the width of the first terminal is 5 to 15 mm.

22. The energy storage device according to claim 1 or 2, wherein the width of the second terminal is 5 to 15 mm.

23. The energy storage device according to claim 1 or 2, wherein the aspect ratio of the first terminal size to the second terminal size is 3:1 to 1:

3.

24. The energy storage device according to claim 1 or 2, wherein the first terminal is a cathode terminal and the second terminal is an anode terminal.

25. The energy storage device according to claim 24, further comprising a positive lead in contact with the anode terminal and a negative lead in contact with the cathode terminal.

26. The energy storage device according to claim 25, wherein the positive electrode lead and the negative electrode lead are welded to the anode terminal and the cathode terminal, respectively.

27. The energy storage device according to claim 26, wherein the positive electrode lead and the negative electrode lead are laser-welded to the anode terminal and the cathode terminal, respectively.

28. The energy storage device according to claim 1 or 2, wherein a portion of the housing surface is substantially iron-based.

29. The energy storage device according to claim 1 or 2, wherein the pressure relief element includes a relief pressure of at least 20 bar.

30. The energy storage device according to claim 1 or 2, further comprising a housing cap.

31. The energy storage device according to claim 1 or 2, further comprising a housing port.

32. First terminal and A second terminal, wherein the second terminal surrounds the first terminal, An insulating gasket positioned between the first terminal and the second terminal, A housing having a housing surface, Energy storage material disposed within the housing, Equipped with, The housing surface comprises a top surface, side surfaces, and bottom surface. The upper surface is provided with the first terminal and the second terminal, An energy storage device in which the first terminal and the second terminal are each substantially planar.

33. The energy storage device according to claim 32, wherein the first terminal protrudes from the upper surface.

34. The energy storage device according to claim 32 or 33, wherein the second terminal is substantially the same height as the top surface.

35. The energy storage device according to claim 32 or 33, wherein the first terminal and the second terminal together cover at least 50% of the surface area of ​​the upper surface.

36. The energy storage device according to claim 32 or 33, wherein the width of the first terminal is 5 to 15 mm.

37. The energy storage device according to claim 32 or 33, wherein the width of the second terminal is 5 to 15 mm.

38. The energy storage device according to claim 32 or 33, wherein the aspect ratio of the first terminal size to the second terminal size is 3:1 to 1:

3.

39. The energy storage device according to any one of claims 1, 2, 32, and 33, wherein the energy storage device is a battery.

40. An energy storage device array comprising a plurality of energy storage devices, wherein the plurality of energy storage devices comprises an energy storage device according to any one of claims 1, 2, 32, and 33.

41. An electric vehicle comprising an energy storage device according to any one of claims 1, 2, 32, and 33.

42. A step of forming a pressure relief element on the housing surface of a housing, wherein the housing surface comprises a first terminal and a second terminal, The steps include: arranging energy storage material within the housing; Steps include attaching the energy storage material to the first terminal and the second terminal, A process for manufacturing energy storage devices, including the process itself.

43. The steps of arranging the energy storage device according to any one of claims 1, 2, 32, and 33 within an array housing, The steps include bringing the first lead into contact with the first terminal and the second lead into contact with the second terminal, The steps include attaching the first lead to the first terminal and the second lead to the second terminal, A process for manufacturing energy storage device arrays, including the process itself.

44. The process according to claim 43, wherein the position of the battery is not adjusted after the energy storage device is disposed within the array housing.

45. The process according to claim 43, wherein attaching the first lead to the first terminal and the second lead to the second terminal includes laser welding.

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