Separator assembly and method for use in energy storage devices

Abstract

The present invention provides a separator assembly and method for use in an energy storage device, including a separator layer and a support tape. [Effect] The separator assembly 100A, utilizing support tapes 150A, 175A such as a barrier layer and / or coil core layer, prevents electrode buckling and provides additional support to protect the separator layer 105A from wear-related electrode buckling and puncture over the life of the energy storage device.

Description

[Technical Field]

[0001] [Cross-reference of related applications] This application claims priority to U.S. Patent Application No. 18 / 979,006, filed on 12 December 2024, entitled “SEPARATOR ASSEMBLIES FOR USE IN ENERGY STORAGE DEVICES, AND METHODS THEREOF,” which is incorporated herein by reference in its entirety for all purposes. [Background technology]

[0002] Electrode buckling and short circuits due to wear-related problems are typical failures known to occur throughout the lifespan of energy storage devices. Currently, energy storage devices are manufactured by fitting or inserting solid rigid materials (e.g., sacrificial mandrels, core pins) to provide protection against electrode buckling during use or cycling. However, solid rigid materials constitute a large portion of the energy storage device's core, resulting in a lack of design flexibility and increased manufacturing time and cost.

[0003] Therefore, an improved energy storage device having a separator assembly is desired. [Overview of the Initiative]

[0004] For the purpose of summarizing the advantages achieved beyond the present invention and the prior art, specific purposes and advantages of the present invention are described herein. Not all such purposes or advantages can be achieved in any particular embodiment of the present invention. Therefore, for example, those skilled in the art will recognize that the present invention can be embodied or practiced in a manner that achieves or optimizes one advantage or set of advantages taught herein, without necessarily achieving other purposes or advantages that may be taught or suggested herein.

[0005] In one embodiment, an energy storage device is described. The energy storage device comprises an electrode assembly comprising: a cathode including a cathode front edge; an anode including an anode front edge and an anode overhang region extending beyond the cathode front edge; and a separator assembly disposed between the cathode and the anode, wherein the separator assembly comprises a separator layer, a coil core support tape, and a barrier layer support tape, the separator layer comprising a cathode-facing surface and an anode-facing surface; the coil core support tape comprising a coil support layer and a coil adhesive layer, the coil adhesive layer disposed directly above the separator layer, the coil support layer comprising a metallic material selected from the group consisting of copper, aluminum, magnesium, or a combination thereof; the coil core support tape disposed above the anode front edge; the barrier layer support tape comprising a barrier support layer and a barrier adhesive layer, the barrier adhesive layer disposed directly above the separator layer, and the barrier layer support tape disposed above the cathode front edge; an electrolyte; and a housing in which the electrode assembly and the electrolyte are disposed.

[0006] In another embodiment, an electrode assembly for an energy storage device is described. The electrode assembly comprises a cathode, an anode, and a separator assembly disposed between the cathode and the anode, wherein the separator assembly comprises a separator layer including a cathode-facing surface and an anode-facing surface, and a support tape including a support layer and an adhesive layer, the adhesive layer being located directly above the separator layer.

[0007] In some embodiments, the anode includes an anode overhang region. In some embodiments, the support layer includes a barrier layer, and the adhesive layer is positioned on the cathode-facing surface. In some embodiments, the barrier layer includes a barrier layer thickness of about 5 to 20 μm. In some embodiments, the barrier layer includes a polyimide material.

[0008] In some embodiments, the support layer includes a coil core layer, and at least a portion of the adhesive layer is positioned on the anode-facing surface. In some embodiments, the coil core layer includes a material selected from the group consisting of metals, polymers, and combinations thereof. In some embodiments, the metal is selected from the group consisting of copper, aluminum, magnesium, or combinations thereof. In some embodiments, the coil core layer includes a coil core layer thickness of about 75 to 125 μm. In some embodiments, the coil core layer is positioned on the anode-facing surface.

[0009] In some embodiments, the electrode assembly further comprises an additional separator assembly, which is positioned on the cathode on the side of the cathode opposite to the separator assembly. In some embodiments, the additional separator assembly includes an additional support layer. In some embodiments, the support layer is aligned with the leading edge of the anode or the leading edge of the cathode. In some embodiments, the support layer overlaps the leading edge of the anode or the leading edge of the cathode by about 10–20 mm. In some embodiments, the anode overhangs by about 40–60 mm from the leading edge of the cathode. In some embodiments, the support layer overlaps the leading edge of the anode overhang region by about 10–20 mm. In some embodiments, the anode or cathode has a rigidity of at least about 2 GPa.

[0010] In another embodiment, an energy storage device is described. The energy storage device comprises an electrode assembly, an electrolyte, and a housing in which the electrode assembly and the electrolyte are disposed.

[0011] In some embodiments, the method includes positioning a separator assembly between the cathode and the anode. In some embodiments, the method further includes positioning a support tape on the cathode-facing surface at a tape positioning speed of at least about 3 m / s. In some embodiments, the method further includes positioning a support tape on the anode-facing surface at a tape positioning speed of at least about 3 m / s.

[0012] In another aspect, a method of preparing a wound electrode assembly is described. The method includes preparing an electrode assembly and winding the electrode assembly to form a wound electrode assembly.

[0013] In another aspect, a method of forming an energy storage device is described. The method includes preparing a wound electrode assembly and disposing the wound electrode assembly and an electrolyte within a housing. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] [Figure 1A] FIG. 15 is a schematic view showing a separator assembly having a support tape according to some embodiments.

[0015] [Figure 1B] FIG. 21 is another schematic view showing a separator assembly having a support tape according to some embodiments.

[0016] [Figure 1C] FIG. 27 is another schematic view showing a separator assembly having a support tape according to some embodiments. >

[0017] [Figure 1D] FIG. 33 is another schematic view showing a separator assembly having a support tape according to some embodiments.

[0018] [Figure 2A] FIG. 39 is a schematic view showing a separator assembly having a barrier layer support tape according to some embodiments.

[0019] [Figure 2B] FIG. 45 is another schematic view showing a separator assembly having a barrier layer support tape according to some embodiments.

[0020] [Figure 2C]Schematic diagram showing a separator assembly having a coil core support tape according to some embodiments.

[0021] [Figure 2D] Another schematic diagram showing a separator assembly having a coil core support tape according to some embodiments.

[0022] [Figure 3A] Schematic diagram showing an electrode assembly having a separator assembly according to some embodiments.

[0023] [Figure 3B] Another schematic diagram showing an electrode assembly having a separator assembly according to some embodiments.

[0024] [Figure 3C] Another schematic diagram showing an electrode assembly having a separator assembly according to some embodiments.

[0025] [Figure 3D] Another schematic diagram showing an electrode assembly having a separator assembly according to some embodiments.

[0026] [Figure 3E] Another schematic diagram showing an electrode assembly having a separator assembly according to some embodiments.

[0027] [Figure 3F] Another schematic diagram showing an electrode assembly having a separator assembly according to some embodiments.

[0028] [Figure 4A] Schematic diagram showing a wound electrode assembly according to some embodiments.

[0029] [Figure 4B]This is another schematic diagram showing a wound electrode assembly according to several embodiments.

[0030] [Figure 4C] This is another schematic diagram showing a wound electrode assembly according to several embodiments.

[0031] [Figure 5A] These are top views of wound electrode assemblies according to several embodiments.

[0032] [Figure 5B] This is an enlarged top view of the wound electrode assembly shown in Figure 5A, according to several embodiments.

[0033] [Figure 6] This is a top view of a portion of a wound electrode assembly magnified on the leading edge of the cathode, according to several embodiments.

[0034] However, it should be clearly understood that the examples and drawings are for illustrative purposes only and do not necessarily limit the scope of the present invention. [Modes for carrying out the invention]

[0035] While certain preferred embodiments and examples are disclosed below, the subject matter of the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and / or uses, as well as their modifications and equivalents. Therefore, the appended claims are not limited by any of the specific embodiments described below. For example, in any method or process disclosed herein, the movement or operation of the method or process may be performed in any suitable order, and is not necessarily limited to any specific disclosed order. For this reason, various operations can be described as a number of separate operations in a manner that may be helpful in understanding a particular embodiment. However, the order of description should not be construed as meaning that these operations are order-dependent. Furthermore, the structures, systems, and / or devices described herein may be embodied as integrated components or as separate components. For the purpose of comparing various embodiments, specific aspects and advantages of these embodiments are described. Not all such aspects or advantages are necessarily achieved by any particular embodiment. Therefore, for example, various embodiments may be performed to achieve or optimize one advantage or group of advantages taught herein, without necessarily achieving other aspects or advantages that may similarly be taught or suggested herein.

[0036] An energy storage device comprising a separator assembly is described herein. Typically, an energy storage device comprises an electrode assembly, an electrolyte, and a housing in which the electrode assembly and the electrolyte are disposed. The electrode assembly generally includes a cathode, an anode, and a separator positioned between the cathode and the anode. To save time and cost associated with the manufacture of the energy storage device and to protect the device from electrode buckling and short circuits, a separator assembly comprising a separator layer and support tape is described herein.

[0037] A separator assembly may include a separator layer and a support tape. The support tape (e.g., coil core support tape, barrier layer support tape) may include a support layer (e.g., coil support layer or coil core layer, barrier support layer or barrier layer) and an adhesive layer (e.g., coil adhesive layer, barrier adhesive layer). A coil core support tape including a coil support layer and a coil adhesive layer may be used to protect the energy storage device from electrode buckling. A barrier layer support tape including a barrier support layer and a barrier adhesive layer can be used to protect the separator layer from puncture, thereby preventing short circuits of the electrodes. Separator Assembly

[0038] Figures 1A to 1D are schematic diagrams showing separator assemblies in various configurations. Separator assemblies, including separator layers and support tapes, can be manufactured or formed in various configurations. For example, Figure 1A is a schematic diagram of separator assembly 100A. As shown in Figure 1A, separator assembly 100A includes a separator layer 105A and cathode-facing surfaces 115A and anode-facing surfaces 125A of the separator layer 105A. Separator assembly 100A further includes a barrier layer support tape 150A and a coil core support tape 175A. The barrier layer support tape 150A and the coil core support tape 175A are positioned along the length of the separator layer 105A without contacting or overlapping each other. The barrier layer support tape 150A includes a barrier adhesive layer 155A positioned on the cathode-facing surface 115A of the separator layer 105A. The barrier layer support tape 150A also includes a barrier support layer 160A positioned on the side of the barrier adhesive layer 155A opposite to the cathode-facing surface 115A. The coil core support tape 175A includes a coil adhesive layer 180A positioned on the anode-facing surface 125A of the separator layer 105A. The coil core support tape 175A also includes a coil support layer 185A positioned on the side of the coil adhesive layer 180A opposite to the anode-facing surface 125A.

[0039] Figure 1B is another schematic diagram of separator assembly 100B. As shown in Figure 1B, separator assembly 100B includes a separator layer 105B and cathode-facing surfaces 115B and anode-facing surfaces 125B of separator layer 105B. Separator assembly 100B further includes a barrier layer support tape 150B and a coil core support tape 175B. The barrier layer support tape 150B and the coil core support tape 175B are positioned along the length of separator layer 105B without contacting or overlapping each other. The barrier layer support tape 150B includes a barrier adhesive layer 155B positioned on the cathode-facing surface 115B of separator layer 105B. The barrier layer support tape 150B also includes a barrier support layer 160B positioned on the surface of the barrier adhesive layer 155B opposite to the cathode-facing surface 115B. The coil core support tape 175A includes a coil adhesive layer 180B positioned on the cathode-facing surface 115B of the separator layer 105B. The coil core support tape 175B also includes a coil support layer 185B positioned on the surface of the coil adhesive layer 180B opposite to the cathode-facing surface 115B.

[0040] Figure 1C is another schematic diagram of the separator assembly 100C. As shown in Figure 1C, the separator assembly 100C includes a separator layer 105C and cathode-facing surfaces 115C and anode-facing surfaces 125C of the separator layer 105C. The separator assembly 100C further includes a barrier layer support tape 150C and a coil core support tape 175C. The barrier layer support tape 150C and the coil core support tape 175C are positioned along the length of the separator layer 105C without contacting or overlapping each other. The barrier layer support tape 150C includes a barrier adhesive layer 155C positioned on the anode-facing surface 125C of the separator layer 105C. The barrier layer support tape 150C also includes a barrier support layer 160C positioned on the surface of the barrier adhesive layer 155C opposite to the anode-facing surface 125C. The coil core support tape 175C includes a coil adhesive layer 180C positioned on the anode-facing surface 125C of the separator layer 105C. The coil core support tape 175C also includes a coil support layer 185C positioned on the surface of the coil adhesive layer 180C opposite to the anode-facing surface 125C.

[0041] Figure 1D is another schematic diagram of the separator assembly 100D. As shown in Figure 1D, the separator assembly 100D includes a separator layer 105D and cathode-facing surfaces 115D and anode-facing surfaces 125D of the separator layer 105D. The separator assembly 100D further includes a barrier layer support tape 150D and a coil core support tape 175D. The barrier layer support tape 150D and the coil core support tape 175D are positioned along the length of the separator layer 105D without contacting or overlapping each other. The barrier layer support tape 150D includes a barrier adhesive layer 155D positioned on the anode-facing surface 125D of the separator layer 105D. The barrier layer support tape 150D also includes a barrier support layer 160D positioned on the surface of the barrier adhesive layer 155D opposite to the anode-facing surface 125D. The coil core support tape 175D includes a coil adhesive layer 180D positioned on the cathode-facing surface 115D of the separator layer 105D. The coil core support tape 175D also includes a coil support layer 185D positioned on the surface of the coil adhesive layer 180D opposite to the cathode-facing surface 115D.

[0042] Figures 2A to 2D are schematic diagrams showing separator assemblies in various configurations. Separator assemblies, including separator layers and support tapes, can be manufactured or formed in various configurations. For example, Figure 2A is a schematic diagram of separator assembly 200A. As shown in Figure 2A, separator assembly 200A includes a separator layer 205A and cathode-facing surfaces 215A and anode-facing surfaces 225A of the separator layer 205A. Separator assembly 200A further includes a barrier layer support tape 250A arranged along the length of the separator layer 205A. The barrier layer support tape 250A includes a barrier adhesive layer 255A positioned on the cathode-facing surface 215A of the separator layer 205A. The barrier layer support tape 250A also includes a barrier support layer 260A positioned on the surface of the barrier adhesive layer 255A opposite to the cathode-facing surface 215A.

[0043] Figure 2B is another schematic diagram of the separator assembly 200B. As shown in Figure 2B, the separator assembly 200B includes a separator layer 205B and cathode-facing surfaces 215B and anode-facing surfaces 225B of the separator layer 205B. The separator assembly 200B further includes a barrier layer support tape 250B positioned along the length of the separator layer 205B. The barrier layer support tape 250B includes a barrier adhesive layer 255B positioned on the anode-facing surface 225B of the separator layer 205B. The barrier layer support tape 250B also includes a barrier support layer 260B positioned on the surface of the barrier adhesive layer 255B opposite to the anode-facing surface 225B.

[0044] Figure 2C is another schematic diagram of the separator assembly 200C. As shown in Figure 2C, the separator assembly 200C includes a separator layer 205C and cathode-facing surfaces 215C and anode-facing surfaces 225C of the separator layer 205C. The separator assembly 200C further includes a coil core support tape 275C arranged along the length of the separator layer 205C. The coil core support tape 275C includes a coil adhesive layer 280C positioned on the anode-facing surface 225C of the separator layer 205C. The coil core support tape 275C also includes a coil support layer 285C positioned on the surface of the coil adhesive layer 280C opposite to the anode-facing surface 225C.

[0045] Figure 2D is another schematic diagram of the separator assembly 200D. As shown in Figure 2D, the separator assembly 200D includes a separator layer 205D and cathode-facing surfaces 215D and anode-facing surfaces 225D of the separator layer 205D. The separator assembly 200D further includes a coil core support tape 275D arranged along the length of the separator layer 205D. The coil core support tape 275D includes a coil adhesive layer 280D positioned on the cathode-facing surface 215D of the separator layer 205D. The coil core support tape 275D also includes a coil support layer 285D positioned on the surface of the coil adhesive layer 280D opposite to the cathode-facing surface 215D.

[0046] In some embodiments, the separator assembly includes one or more support tapes. In some embodiments, one or more support tapes may be positioned on the cathode-facing surface of the separator layer. In some embodiments, one or more support tapes may be positioned on the anode-facing surface of the separator layer. In some embodiments, the support tapes may be positioned on the separator layer such that the support tapes do not come into contact with and / or overlap each other.

[0047] In some embodiments, the support tape may be tapered. In some embodiments, the edges of the support tape may be tapered. In some embodiments, the support tape may be porous. In some embodiments, the support tape may be perforated to reduce the weight of the electrode assembly and to facilitate the flow of gas and / or electrolyte.

[0048] In some embodiments, the support tape includes a barrier layer and an adhesive layer (e.g., a barrier adhesive layer). In some embodiments, the barrier adhesive layer is resistant to electrolytes. In some embodiments, the barrier adhesive layer adheres to the separator layer during winding. In some embodiments, the barrier adhesive layer is positioned on the cathode-facing surface. In some embodiments, the barrier adhesive layer is positioned on the anode-facing surface.

[0049] In some embodiments, the barrier layer includes a barrier layer that is 3 μm, 4 μm, 5 μm, 6 μm, 7 μm, 8 μm, 9 μm, 10 μm, 11 μm, 12 μm, 13 μm, 14 μm, 15 μm, 16 μm, 17 μm, 18 μm, 19 μm, 20 μm, 21 μm, 22 μm, 23 μm, 24 μm, 25 μm, 30 μm, 35 μm, 40 μm, 45 μm, and 50 μm, or any range between them, approximately these values, at least these values, or at least approximately these values. In some embodiments, the barrier layer includes a barrier layer thickness of about 5 to 20 μm.

[0050] In some embodiments, the barrier layer includes a length of 1 mm, 2 mm, 4 mm, 6 mm, 8 mm, 10 mm, 12 mm, 14 mm, 16 mm, 18 mm, 20 mm, 22 mm, 24 mm, 26 mm, 28 mm, 30 mm, 32 mm, 34 mm, 36 mm, 38 mm, 40 mm, 42 mm, 44 mm, 46 mm, 48 mm, 50 mm, 52 mm, 54 mm, 56 mm, 58 mm, and 60 mm, or any range between these values, approximately these values, at least these values, or at least approximately these values. In some embodiments, the barrier layer includes a width of 40 mm, 42 mm, 44 mm, 46 mm, 48 mm, 50 mm, 52 mm, 54 mm, 56 mm, 58 mm, 60 mm, 62 mm, 64 mm, 66 mm, 68 mm, 70 mm, 72 mm, 74 mm, 76 mm, 78 mm, 80 mm, 82 mm, 84 mm, 86 mm, 88 mm, 90 mm, 92 mm, 94 mm, 96 mm, 98 mm, 100 mm, 102 mm, 104 mm, 106 mm, 108 mm, and 110 mm, or any range between these values, approximately these values, at least these values, or at least approximately these values.

[0051] In some embodiments, the barrier layer includes a Young's modulus that is 0.2GPa, 0.4GPa, 0.6GPa, 0.8GPa, 1GPa, 1.2GPa, 1.4GPa, 1.6GPa, 1.8GPa, 2GPa, 2.2GPa, 2.4GPa, 2.6GPa, 2.8GPa, 3GPa, 3.2GPa, 3.4GPa, 3.6GPa, 3.8GPa, 4GPa, 4.2GPa, 4.4GPa, 4.6GPa, 4.8GPa, and 5GPa, or any range between these values, approximately these values, at least these values, or at least approximately these values.

[0052] In some embodiments, the barrier layer comprises a polymer material. In some embodiments, the polymer is selected from the group consisting of polyimide, polyethylene, polypropylene, or a combination thereof. In some embodiments, the barrier layer comprises a polyimide material.

[0053] In some embodiments, the support layer includes a coil core layer and an adhesive layer (e.g., a coil adhesive layer). In some embodiments, the coil adhesive layer is resistant to electrolytes. In some embodiments, the coil adhesive layer adheres to the separator layer during winding. In some embodiments, the coil adhesive layer is positioned on the anode-facing surface. In some embodiments, the coil adhesive layer is positioned on the cathode-facing surface.

[0054] In some embodiments, the coil core layer is 40μm, 50μm, 60μm, 70μm, 71μm, 72μm, 73μm, 74μm, 75μm, 76μm, 77μm, 78μm, 79μm, 80μm, 81μm, 82μm, 83μm, 84μm, 85μm, 86μm, 87μm, 88μm, 89μm, 90μm, 91μm, 92μm, 93μm, 94μm, 95μm, 96μm, 97μm, 98μm, 99μm, 100μm, 101μm, 102μm, 103μm, 104μm, 105μm, 106μm, 107μm, 108μm, 109μm, 110μm, 111μm, The coil core layer thickness includes values ​​of 112 μm, 113 μm, 114 μm, 115 μm, 116 μm, 117 μm, 118 μm, 119 μm, 120 μm, 121 μm, 122 μm, 123 μm, 124 μm, 125 μm, 126 μm, 127 μm, 128 μm, 129 μm, 130 μm, 140 μm, 150 μm, 160 μm, 170 μm, 180 μm, 190 μm, 200 μm, 210 μm, 220 μm, and 230 μm, or any range between them, approximately these values, at least these values, or at least approximately these values. In some embodiments, the coil core layer includes a coil core layer thickness of about 75 to 125 μm.

[0055] In some embodiments, the coil core layer is 20mm, 22mm, 24mm, 26mm, 28mm, 30mm, 32mm, 34mm, 36mm, 38mm, 40mm, 42mm, 44mm, 46mm, 48mm, 50mm, 52mm, 54mm, 56mm, 58mm, 60mm, 62mm, 64mm, 66mm, 68mm, 70mm, 72mm, 74mm, 76mm, 78mm, 80mm, 82mm, 84mm, 86mm, 88mm, 90mm, 92mm, 94mm, 96mm, 98mm, 100mm, 102mm, 1 04mm, 106mm, 108mm, 110mm, 112mm, 114mm, 116mm, 118mm, 120mm, 122mm, 124mm, 126mm, 128mm, 130mm, 132mm, 134mm, 136mm, 138mm, 140mm, 142 mm, 144mm, 146mm, 148mm, 150mm, 152mm, 154mm, 156mm, 158mm, 160mm, 162mm, 164mm, 166mm, 168mm, 170mm, 172mm, 174mm, 176mm, 178mm, 180mm, 182mm, 184mm, 186mm, 188mm, 190mm, 192mm, 194mm, 196mm, 198mm, 200mm, 202mm, 204mm, 206mm, 208mm, 210mm, 212mm, 214mm, 216mm, 218mm, 22 0mm, 222mm, 224mm, 226mm, 228mm, 230mm, 232mm, 234mm, 236mm, 238mm, 240mm, 242mm, 244mm, 246mm, 248mm, 250mm, 252mm, 254mm, 256mm, 258mm , including lengths that are 260mm, 262mm, 264mm, 266mm, 268mm, 270mm, 272mm, 274mm, 276mm, 278mm, 280mm, 282mm, 284mm, 286mm, 288mm, 290mm, 292mm, 294mm, 296mm, 298mm, 300mm, 302mm, 304mm, 306mm, 308mm, and 310mm, or any range between them, approximately these values, at least these values, or at least approximately these values.In some embodiments, the coil core layer includes a width of 40 mm, 42 mm, 44 mm, 46 mm, 48 mm, 50 mm, 52 mm, 54 mm, 56 mm, 58 mm, 60 mm, 62 mm, 64 mm, 66 mm, 68 mm, 70 mm, 72 mm, 74 mm, 76 mm, 78 mm, 80 mm, 82 mm, 84 mm, 86 mm, 88 mm, 90 mm, 92 mm, 94 mm, 96 mm, 98 mm, 100 mm, 102 mm, 104 mm, 106 mm, 108 mm, and 110 mm, or any range between these values, approximately these values, at least these values, or at least approximately these values.

[0056] In some embodiments, the coil core layer is 2GPa, 4GPa, 6GPa, 8GPa, 10GPa, 12GPa, 14GPa, 16GPa, 18GPa, 20GPa, 22GPa, 24GPa, 26GPa, 28GPa, 30GPa, 32GPa, 34GPa, 36GPa, 38GPa, 40GPa, 42GPa, 44GPa, 46GPa, 48GPa, 50GPa, 52GPa, 54GPa, 56GPa, 58GPa, 60GPa, 62GPa, 64GPa, 66GPa, 68GPa, 70GPa, 72GPa, 74GPa, 76GPa, 78GPa , 80GPa, 82GPa, 84GPa, 86GPa, 88GPa, 90GPa, 92GPa, 94GPa, 96GPa, 98GPa, 100GPa, 102GPa, 104GPa, 106GPa, 108GPa, 110GPa, 112GPa, 114GPa, 116GPa, 118GPa, 120GPa, 122GPa, 124GPa, 126GPa, 128GPa, 130GPa, 132GPa, 134GPa, 136GPa, 138GPa, 140GPa, 142GPa, 144GPa, 146GPa, 148GPa, 150GPa, 152GPa , 154GPa, 156GPa, 158GPa, 160GPa, 162GPa, 164GPa, 166GPa, 168GPa, 170GPa, 172GPa, 174GPa, 176GPa, 178GPa, 180GPa, 182GPa, 184GPa, 186GPa, 188G Pa, 190GPa, 192GPa, 194GPa, 196GPa, 198GPa, 200GPa, 202GPa, 204GPa, 206GPa, 208GPa, 210GPa, 212GPa, 214GPa, 216GPa, 218GPa, 220GPa, 222GPa, 224 GPa, 226GPa, 228GPa, 230GPa, 232GPa, 234GPa, 236GPa, 238GPa, 240GPa, 242GPa, 244GPa, 246GPa, 248GPa, 250GPa, 252GPa, 254GPa, 256GPa, 258GPa, 2 60GPa, 262GPa, 264GPa, 266GPa, 268GPa, 270GPa, 272GPa, 274GPa, 276GPa, 278GPa, 280GPa, 282GPa, 284GPa, 286GPa, 288GPa, 290GPa, 292GPa, 294GPa,The stiffness includes values ​​of 296 GPa, 298 GPa, and 300 GPa, or any range between them, approximately these values, at least these values, or at least approximately these values.

[0057] In some embodiments, the coil core layer comprises a material selected from the group consisting of metals, anodized metals, polymers, and combinations thereof. In some embodiments, the coil core layer comprises a metal laminated or placed between nonconductive polymers. In some embodiments, the coil core layer comprises a metal stable at the anode potential, cathode potential, and / or stray potential. In some embodiments, the metal is selected from the group consisting of copper, aluminum, magnesium, stainless steel, or combinations thereof. In some embodiments, the stainless steel may include elements such as iron, chromium, molybdenum, carbon, nickel, nitrogen, manganese, silicon, titanium, vanadium, copper, and combinations thereof. In some embodiments, the polymer is selected from the group consisting of polyimide, polyethylene, polypropylene, or combinations thereof. Electrode assembly including separator assembly

[0058] Figures 3A to 3F are schematic diagrams showing electrode assemblies in various configurations. Electrode assemblies, including cathode, anode, and separator assemblies, can be manufactured or formed in various configurations. For example, Figure 3A is a schematic diagram of electrode assembly 300A. As shown in Figure 3A, electrode assembly 300A includes a first separator assembly 305A, a cathode 315A, a second separator assembly 320A, and an anode 335A. The first separator assembly 305A includes a first separator layer 307A and a first barrier layer support tape 309A. The first barrier layer support tape 309A includes a barrier adhesive layer 310A positioned on the cathode-facing surface 308A of the first separator layer 307A. The first barrier layer support tape 309A also includes a barrier support layer 311A ​​positioned on the surface of the barrier adhesive layer 310A opposite to the cathode-facing surface 308A of the first separator layer 307A. The second separator assembly 320A includes a second separator layer 325A, a second barrier layer support tape 312A, and a coil core support tape 330A. The second separator layer 325A includes a cathode-facing surface 322A and an anode-facing surface 324A. The second barrier layer support tape 312A includes a barrier adhesive layer 313A positioned on the cathode-facing surface 322A of the second separator layer 325A. The second barrier layer support tape 309A also includes a barrier support layer 314A positioned on the surface of the barrier adhesive layer 313A opposite to the cathode-facing surface 322A of the second separator layer 325A. The cathode 315A includes a cathode leading edge 317A and is positioned between the first barrier layer support tape 309A and the second barrier layer support tape 312A. The coil core support tape 330A includes a coil adhesive layer 331A positioned on the anode-facing surface 324A of the second separator layer 325A. The coil core support tape 330A also includes a coil support layer 332A positioned on the surface of the coil adhesive layer 331A opposite to the anode-facing surface 324A of the second separator layer 325A. The anode 335A positioned on the coil support layer 332A includes an anode leading edge 337A and an anode overhang region 339A, which is measured by the distance between the anode leading edge 337A and the cathode leading edge 317A.The electrode assembly 300A further includes an anode wrap portion 340A, which is the anode portion between the end portion of the coil core support tape 330A and the cathode leading edge 317A.

[0059] Figure 3B is another schematic diagram of electrode assembly 300B. As shown in Figure 3B, electrode assembly 300B includes a first separator assembly 305B, a cathode 315B, a second separator assembly 320B, and an anode 335B. The first separator assembly 305B includes a first separator layer 307B and a first barrier layer support tape 309B. The first barrier layer support tape 309B includes a barrier adhesive layer 310B positioned on the surface of the first separator layer 307B opposite to the cathode-facing surface 308B. The first barrier layer support tape 309B also includes a barrier support layer 311B positioned on the surface of the barrier adhesive layer 310B opposite to the first separator layer 307B. The second separator assembly 320B includes a second separator layer 325B, a second barrier layer support tape 312B, and a coil core support tape 330B. The second separator layer 325B includes a cathode-facing surface 322B and an anode-facing surface 324B. The second barrier layer support tape 312B includes a barrier adhesive layer 313B positioned on the cathode-facing surface 322B of the second separator layer 325B. The second barrier layer support tape 309B also includes a barrier support layer 314B positioned on the surface of the barrier adhesive layer 313B opposite to the cathode-facing surface 322B of the second separator layer 325B. The cathode 315B includes a cathode leading edge 317B and is positioned between the first barrier layer support tape 309B and the second barrier layer support tape 312B. The coil core support tape 330B includes a coil adhesive layer 331B positioned on the anode-facing surface 324B of the second separator layer 325B. The coil core support tape 330B also includes a coil support layer 332B positioned on the surface of the coil adhesive layer 331B opposite to the anode-facing surface 324B of the second separator layer 325B. The anode 335B positioned on the coil support layer 332B includes an anode front edge 337B and an anode overhang region 339B, measured by the distance between the anode front edge 337B and the cathode front edge 317B. The electrode assembly 300B further includes an anode wrap portion 340B, which is the anode portion between the end portion of the coil core support tape 330B and the cathode front edge 317B.

[0060] Figure 3C is another schematic diagram of electrode assembly 300C. As shown in Figure 3C, electrode assembly 300C includes a first separator assembly 305C, a cathode 315C, a second separator assembly 320C, and an anode 335C. The first separator assembly 305C includes a first separator layer 307C, a first barrier layer support tape 309C, and a coil core support tape 330C. The first barrier layer support tape 309C includes a barrier adhesive layer 310C positioned on the cathode-facing surface 308C. The first barrier layer support tape 309C also includes a barrier support layer 311C positioned on the surface of the barrier adhesive layer 310C opposite to the cathode-facing surface 308C of the first separator layer 307C. The second separator assembly 320C includes a second separator layer 325C and a second barrier layer support tape 312C. The second separator layer 325C includes a cathode-facing surface 322C and an anode-facing surface 324C. The second barrier layer support tape 312C includes a barrier adhesive layer 313C positioned on the cathode-facing surface 322C of the second separator layer 325C. The second barrier layer support tape 309C also includes a barrier support layer 314C positioned on the surface of the barrier adhesive layer 313C opposite to the cathode-facing surface 322C of the second separator layer 325C. The cathode 315C includes a cathode leading edge 317C and is positioned between the first barrier layer support tape 309C and the second barrier layer support tape 312C. The coil core support tape 330C includes a coil adhesive layer 331C and is positioned on the surface of the first separator layer 307C opposite to the cathode-facing surface 308C. The coil core support tape 330C also includes a coil support layer 332C positioned on the surface of the coil adhesive layer 331C opposite to the first separator layer 307C. The anode 335C, positioned on the anode-facing surface 324C of the second separator layer 325C, includes an anode leading edge 337C and an anode overhang region 339C, which is measured by the distance between the anode leading edge 337C and the cathode leading edge 317C.

[0061] Figure 3D is another schematic diagram of electrode assembly 300D. As shown in Figure 3D, electrode assembly 300D includes a first separator assembly 305D, a cathode 315D, a second separator assembly 320D, and an anode 335D. The first separator assembly 305D includes a first separator layer 307D and a coil core support tape 330D. The coil core support tape 330D includes a coil adhesive layer 331D positioned on the surface of the first separator layer 307D opposite to the cathode-facing surface 308D. The coil core support tape 330D also includes a coil support layer 332D positioned on the surface of the coil adhesive layer 331D opposite to the first separator layer 307D. The second separator assembly 320D includes a second separator layer 325D and a barrier layer support tape 312D. The second separator layer 325D includes a cathode-facing surface 322D and an anode-facing surface 324D. The barrier layer support tape 312D includes a barrier adhesive layer 313D positioned on the cathode-facing surface 322D of the second separator layer 325D. The barrier layer support tape 312D also includes a barrier support layer 314D positioned on the surface of the barrier adhesive layer 313D opposite to the cathode-facing surface 322D of the second separator layer 325C. The cathode 315D includes a cathode leading edge 317D and is positioned between the first separator layer 307D and the barrier layer support tape 312D. The anode 335D, positioned on the anode-facing surface 324D of the second separator layer 325D, includes an anode leading edge 337D and an anode overhang region 339D, which is measured by the distance between the anode leading edge 337D and the cathode leading edge 317D.

[0062] Figure 3E is another schematic diagram of electrode assembly 300E. As shown in Figure 3E, electrode assembly 300E includes a first separator assembly 305E, a cathode 315E, a second separator assembly 320E, and an anode 335E. The first separator assembly 305E includes a first separator layer 307E and a first barrier layer support tape 309E. The first barrier layer support tape 309E includes a barrier adhesive layer 310E positioned on the cathode-facing surface 308E of the first separator layer 307E. The first barrier layer support tape 309E also includes a barrier support layer 311E positioned on the surface of the barrier adhesive layer 310E opposite to the cathode-facing surface 308E of the first separator layer 307E. The second separator assembly 320E includes a second separator layer 325E, a second barrier layer support tape 312E, and a coil core support tape 330E. The second separator layer 325E includes a cathode-facing surface 322E and an anode-facing surface 324E. The second barrier layer support tape 312E includes a barrier adhesive layer 313E positioned on the cathode-facing surface 322E of the second separator layer 325E. The second barrier layer support tape 309E also includes a barrier support layer 314E positioned on the surface of the barrier adhesive layer 313E opposite to the cathode-facing surface 322E of the second separator layer 325E. The cathode 315E includes a cathode leading edge 317E and is positioned between the first barrier layer support tape 309E and the second barrier layer support tape 312E. The coil core support tape 330E includes a coil adhesive layer 331E positioned on the cathode-facing surface 322E of the second separator layer 325E. The coil core support tape 330E also includes a coil support layer 332E positioned on the surface of the coil adhesive layer 331E opposite to the cathode-facing surface 322E of the second separator layer 325E. The anode 335E positioned on the anode-facing surface 324E of the second separator layer 325E includes an anode leading edge 337E and an anode overhang region 339E, which is measured by the distance between the anode leading edge 337E and the cathode leading edge 317E.

[0063] Figure 3F is another schematic diagram of the electrode assembly 300F. As shown in Figure 3F, the electrode assembly 300F includes a first separator assembly 305F, a cathode 315F, a second separator assembly 320F, and an anode 335F. The first separator assembly 305F includes a first separator layer 307F and a first barrier layer support tape 309F. The first barrier layer support tape 309F includes a barrier adhesive layer 310F positioned on the surface of the first separator layer 307F opposite to the cathode-facing surface 308F. The first barrier layer support tape 309F also includes a barrier support layer 311F positioned on the surface of the barrier adhesive layer 310F opposite to the first separator layer 307F. The second separator assembly 320F includes a second separator layer 325F, a second barrier layer support tape 312F, and a coil core support tape 330F. The second separator layer 325F includes a cathode-facing surface 322F and an anode-facing surface 324F. The second barrier layer support tape 312F includes a barrier adhesive layer 313F positioned on the cathode-facing surface 322F. The second barrier layer support tape 309F also includes a barrier support layer 314F positioned on the surface of the barrier adhesive layer 313F opposite to the cathode-facing surface 322F. The cathode 315F includes a cathode leading edge 317F and is positioned between the first barrier layer support tape 309F and the second barrier layer support tape 312F. The coil core support tape 330F includes a coil adhesive layer 331F positioned on the cathode-facing surface 322F of the second separator layer 325F. The coil core support tape 330F also includes a coil support layer 332F positioned on the surface of the coil adhesive layer 331F opposite to the cathode-facing surface 322F of the second separator layer 325F. The anode 335F positioned on the anode-facing surface 324F of the second separator layer 325F includes an anode leading edge 337F and an anode overhang region 339F, which is measured by the distance between the anode leading edge 337F and the cathode leading edge 317F.

[0064] Figures 4A to 4C are schematic diagrams showing wound electrode assemblies in various configurations. A wound electrode assembly, including a cathode, anode, and separator assembly, can be manufactured or formed in various configurations. For example, Figure 4A is a schematic diagram of a wound electrode assembly 400A. As shown in Figure 4A, the wound electrode assembly 400A includes an anode 405A, a cathode 415A, and a coil core support tape 430A. The coil core support tape 430A is located closest to the core of the wound electrode assembly 400A. The leading edge of the anode 410A is positioned between the coil core support tapes 430A, and the leading edge of the cathode 420A is positioned between the anodes 410A.

[0065] Figure 4B is another schematic diagram of the wound electrode assembly 400B. As shown in Figure 4B, the wound electrode assembly 400B includes an anode 405B, a cathode 415B, and a coil core support tape 430B. The coil core support tape 430B is located closest to the core of the wound electrode assembly 400B. The leading edges of the anode 410B and the cathode 420B are positioned between the coil core support tapes 430B.

[0066] Figure 4C is another schematic diagram of the wound electrode assembly 400C. As shown in Figure 4C, the wound electrode assembly 400C includes an anode 405C, a cathode 415C, and a coil core support tape 430C. The coil core support tape 430C is located closest to the core of the wound electrode assembly 400C. The leading edge of anode 410C is positioned between the coil core support tape 430C and anode 405C, and the leading edge of cathode 420C is positioned between anodes 405C and anode 420C.

[0067] In some embodiments, the separator assembly may be positioned between the barrier layer and the coil core layer. In some embodiments, the separator assembly may be positioned between the barrier layer and the cathode. In some embodiments, the separator assembly may be positioned between the coil core layer and the barrier layer. In some embodiments, the separator assembly may be positioned between the barrier layer and the anode. In some embodiments, the separator assembly may be positioned between the coil core layer and both the barrier layer on the cathode-facing side and the anode on the anode-facing side.

[0068] In some embodiments, the electrode assembly may include an additional separator assembly. In some embodiments, the additional separator assembly is positioned on the cathode on the cathode side opposite to the separator assembly. In some embodiments, the additional separator assembly is positioned on the anode on the anode side opposite to the separator assembly. In some embodiments, the additional separator assembly includes an additional support layer.

[0069] In some embodiments, the support layer is aligned with the anode front edge (e.g., the anode front edge) and / or the cathode front edge (e.g., the cathode front edge). In some embodiments, the support layer overlaps the anode front edge and / or the cathode front edge by 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, 21 mm, 22 mm, 23 mm, 24 mm, 25 mm, 26 mm, 27 mm, 28 mm, 29 mm, and 30 mm, or any range between these values, approximately these values, at least these values, or at least approximately these values. In some embodiments, the support layer overlaps the anode front edge and / or the cathode front edge by about 10 to 20 mm.

[0070] In some embodiments, the support layer overlaps the leading edge of the anode overhang region by 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, 21 mm, 22 mm, 23 mm, 24 mm, 25 mm, 26 mm, 27 mm, 28 mm, 29 mm, and 30 mm, or any range between these values, approximately these values, at least these values, or at least approximately these values. In some embodiments, the support layer overlaps the leading edge of the anode overhang region by approximately 10 to 20 mm.

[0071] In some embodiments, the anode protrudes from the leading edge of the cathode region by 30 mm, 31 mm, 32 mm, 33 mm, 34 mm, 35 mm, 36 mm, 37 mm, 38 mm, 39 mm, 40 mm, 41 mm, 42 mm, 43 mm, 44 mm, 45 mm, 46 mm, 47 mm, 48 mm, 49 mm, 50 mm, 51 mm, 52 mm, 53 mm, 54 mm, 55 mm, 56 mm, 57 mm, 58 mm, 59 mm, 60 mm, 61 mm, 62 mm, 63 mm, 64 mm, 65 mm, 66 mm, 67 mm, 68 mm, 69 mm, and 70 mm, or any range in between, approximately these values, at least these values, or at least approximately these values. In some embodiments, the anode protrudes about 40 to 60 mm from the leading edge of the cathode. Electrode film material and electrode film

[0072] Electrode film mixtures and electrode films formed using materials are described herein. In some embodiments, the components of the active layer or electrode film may include particles such as composite materials. The particles for forming the active layer or electrode film can be combined with materials to provide an electrode film mixture. In some embodiments, the active layer or electrode film may be formed from an electrode film mixture such that the weight percentages of the components of the active layer or electrode film and the weight percentages of the components of the electrode film mixture are substantially the same.

[0073] The active material (e.g., cathode active material, anode active material) can be used for preparing electrode films and / or electrodes for energy storage devices.

[0074] In some embodiments, the active material is a cathode active material. In some embodiments, the cathode active material is selected from at least one of metal oxides, metal sulfides, sulfur-carbon composites, lithium metal oxides, and materials containing sulfur. In some embodiments, the cathode active material is selected from lithium iron phosphate (i.e., LiFePO4 or "LFP"), lithium manganese iron phosphate (e.g., LiMn 0.6 Fe 0.4 PO4 or "LMFP"), lithium nickel manganese cobalt oxide (i.e., LiNi x Mn y Co 1-x-y O2 or "NMC"), lithium nickel cobalt aluminum oxide (i.e., LiNi x Co y Al z O2 or "NCA"), lithium manganese oxide ("LMO"), lithium nickel manganese oxide ("LNMO"), lithium cobalt oxide ("LCO"), lithium titanate ("LTO"), or combinations thereof. In some embodiments, the cathode active material includes at least two of LFP, LMFP, NMC, NCA, LMO, LNMO, LCO, LTO, and combinations thereof. In some embodiments, the cathode active material is an iron phosphate-based active material. In some embodiments, the iron phosphate-based active material includes LiFePO4 (i.e., "lithium iron phosphate" and "LFP") and LiMn 1-x Fe x PO4 (i.e., "lithium manganese iron phosphate" and "LMFP") (e.g., LiMn 0.6 Fe 0.4 PO4 or LiMn 0.8 Fe 0.2 PO4). In some embodiments, the iron phosphate-based active material includes LFP. In some embodiments, the iron phosphate-based active material includes LMFP. In some embodiments, the iron phosphate-based active material includes LFP and / or LMFP.

[0075] In some embodiments, the active material is an anode active material. In some embodiments, the anode active material may include, for example, an insert material (such as carbon, graphite, and / or graphene), an alloying / dealloying material (such as silicon, silicon oxide, tin, and / or tin oxide), a metallic alloy or compound (such as Si-Al and / or Si-Sn), and / or a conversion material (such as manganese oxide, molybdenum oxide, nickel oxide, and / or copper oxide). The anode active material may be used alone or mixed together to form a multiphase material (such as Si-C, Sn-C, SiOx-C, SnOx-C, Si-Sn, Si-SiOx, Sn-SnOx, Si-SiOx-C, Sn-SnOx-C, Si-Sn-C, SiOx-SnOx-C, Si-SiOx-Sn, Sn-SiOx-SnOx, etc.). Anode active materials include common natural graphite, synthetic or artificial graphite, surface-modified graphite, spherical graphite, flake graphite, and blends or combinations of these types of graphite, metallic elements and their compounds, as well as metal-C composites for anodes.

[0076] In some embodiments, the electrode film contains an amount of active material that is approximately 70% by weight, 75% by weight, 80% by weight, 85% by weight, 86% by weight, 87% by weight, 88% by weight, 89% by weight, 90% by weight, 91% by weight, 92% by weight, 93% by weight, 94% by weight, 95% by weight, 96% by weight, 97% by weight, 98% by weight, 98.5% by weight, 99% by weight, 99.5% by weight, 99.8% by weight, or 99.9% by weight, or any range of values ​​between these, or is approximately these values, at least these values, or at least approximately these values.

[0077] In some embodiments, the electrode film includes a carbon material configured to reversibly insert lithium ions. In some embodiments, the lithium-inserted carbon is selected from graphitic carbon, graphite, hard carbon, soft carbon, and combinations thereof. For example, the electrode film of an electrode may include a binder material, one or more of graphitic carbon, graphite, graphene-containing carbon, hard carbon, and soft carbon, as well as a conductivity-enhancing material. In some embodiments, the electrode is mixed with lithium metal and / or lithium ions. In some embodiments, the electrode includes a total amount of carbon material that is approximately 20% by weight, 15% by weight, 10% by weight, 9% by weight, 8% by weight, 7% by weight, 6% by weight, 5% by weight, 4% by weight, 3% by weight, 2% by weight, 1% by weight, or any range of values ​​between these, or is approximately these values, or is at most these values, or is at most approximately these values.

[0078] In some embodiments, the electrode film includes a conductive additive. In some embodiments, the conductive additive may include a conductive carbon additive such as carbon black. In some embodiments, the conductive additive may include a conductive carbon additive. In some embodiments, the conductive carbon additive includes carbon nanotubes such as carbon black, single-walled carbon nanotubes (SWCNTs), and multi-walled carbon nanotubes (MWCNTs). In some embodiments, the electrode film contains a total amount of the conductive additive that is 10% by weight, 9% by weight, 8% by weight, 7% by weight, 6% by weight, 5% by weight, 4% by weight, 3% by weight, 2% by weight, 1% by weight, 0.5% by weight, 0.25% by weight, 0.1% by weight, or any value in between, or is approximately one of these values, or is at most one of these values, or is at most approximately one of these values. In some embodiments, each of the conductive additives is in an amount that is 10% by weight, 9% by weight, 8% by weight, 7% by weight, 6% by weight, 5% by weight, 4% by weight, 3% by weight, 2% by weight, 1% by weight, 0.5% by weight, 0.25% by weight, 0.1% by weight, or any value in between, or is approximately one of these values, or is at most one of these values, or is at most one of these values. In some embodiments, the conductive additive is carbon black.

[0079] In some embodiments, the electrode film includes a binder or binder material. In some embodiments, the binder may include polytetrafluoroethylene (PTFE), polyolefins, polyalkylenes, polyethers, styrene-butadiene, polysiloxane copolymers and polysiloxanes, branched polyethers, polyvinyl ethers, carboxymethylcellulose (CMC), copolymers thereof, and / or combinations thereof. In some embodiments, the polyolefin may include polyethylene (PE), polypropylene (PP), polyvinylidene fluoride (PVDF), copolymers thereof, and / or combinations thereof. For example, the binder may include polyvinylidene chloride, poly(phenylene oxide) (PPO), polyethylene-block-poly(ethylene glycol), poly(ethylene oxide) (PEO), poly(phenylene oxide) (PPO), polyethylene-block-poly(ethylene glycol), polydimethylsiloxane (PDMS), polydimethylsiloxane-coalkylmethylsiloxane, copolymers thereof, and / or combinations thereof. In some embodiments, the binder may include a thermoplastic material. In some embodiments, the binder comprises a fibrillable and / or fibrillable polymer. In certain embodiments, the binder comprises, essentially comprises, or comprises a single fibrillable and / or fibrillable binder such as PTFE. In some embodiments, the electrode film comprises a binder in a range of values ​​of about 1% by weight, 2% by weight, 3% by weight, 4% by weight, 5% by weight, 6% by weight, 7% by weight, 8% by weight, 9% by weight, 10% by weight, or any range of values ​​in between, or a binder with approximately these values, or a binder with up to approximately these values.

[0080] In some embodiments, the electrode film may be a wet-processed electrode film. In some embodiments, the electrode film is prepared by a wet or slurry-based electrode manufacturing process. In some embodiments, the electrode film of the Disclosure may be a dry-processed electrode film. In some embodiments, the electrode film is prepared by a dry electrode manufacturing process. As used herein, a dry electrode manufacturing process may refer to a process that forms a dry electrode film without the use of solvents, or substantially without them. For example, the components of an active layer or electrode film, including a carbon material and a binder, may include, consist of, or essentially consist of dry particles. A combination of dry particles for forming an active layer or electrode film can be provided to provide a dry particle active layer mixture. In some embodiments, the active layer or electrode film may be formed from a dry particle active layer mixture such that the weight percentages of the components of the active layer or electrode film and the weight percentages of the components of the dry particle active layer mixture are substantially the same. In some embodiments, an active layer or electrode film formed from a dry particle active layer mixture using a dry manufacturing process may not contain, or substantially contain, any processing additives such as solvents and the resulting solvent residues. In some embodiments, the resulting active layer or electrode film is a self-supporting film formed by dry processing from a dry particle mixture. In some embodiments, the resulting active layer or electrode film is a self-supporting film formed by dry processing from a dry particle mixture. The process for forming the active layer or electrode film may include fibrillating a fibrillable binder component(s) such that the film contains a fibrillating binder. In further embodiments, the self-supporting active layer or electrode film may be formed in the absence of a current collector. In further embodiments, the active layer or electrode film may include a fibrillated polymer matrix such that the film is self-supporting. It is conceivable that a matrix, grid, or web of fibrils can be formed to provide a mechanical structure to the electrode film.

[0081] In some embodiments, the electrode film is placed on a current collector to form an electrode. In some embodiments, the current collector may include a metallic material such as aluminum, nickel, copper, or a combination thereof. In some embodiments, the current collector may include a pure metal. In some embodiments, the current collector may include a metallized polymer film or a metal-coated polymer film. In some embodiments, the polymer may include polyethylene terephthalate (PET), biaxially oriented polypropylene (BOPP), or a combination thereof. In some embodiments, the metal coating may include aluminum. In some embodiments, coating the final electrode film mixture may involve forming a uniform electrode film mixture coating. In some embodiments, the current collector may include a thickness of 200 μm, 100 μm, 50 μm, 40 μm, 30 μm, 20 μm, 15 μm, 10 μm, 5 μm, or any range between these values, approximately these values, up to these values, or up to approximately these values. Electrodes and energy storage devices

[0082] An energy storage system or device includes a positive electrode (i.e., cathode), a negative electrode (i.e., anode), a separator or separator assembly disposed between them, and an electrolyte disposed within a housing. Each electrode includes an electrode film disposed on a current collector. In some embodiments, the current collector is foil. In some embodiments, the current collector is aluminum foil, copper foil, or a combination thereof. In some embodiments, the current collector may include a metallic material such as aluminum, nickel, copper, or a combination thereof. In some embodiments, the current collector includes a pure metal. In some embodiments, the current collector includes a metallized polymer film or a metal-coated polymer film. In some embodiments, the polymer includes polyethylene terephthalate (PET), biaxially oriented polypropylene (BOPP), or a combination thereof. In some embodiments, the metal coating includes aluminum. In some embodiments, coating the final electrode film mixture includes forming a uniform electrode film mixture coating. In some embodiments, the current collector has a thickness of 200 μm, 100 μm, 50 μm, 40 μm, 30 μm, 20 μm, 15 μm, 10 μm, 5 μm, or any range between these values, approximately these values, at most these values, or at most approximately these values. In some embodiments, an active layer is disposed on both sides of the current collector.

[0083] In some embodiments, the electrode is a double-sided electrode. In some embodiments, the double-sided electrode includes two electrode films. In some embodiments, the double-sided electrode may include a current collector, an upper electrode film, and a lower electrode film. In some embodiments, each of the two electrode films may have any suitable shape, size, and thickness.

[0084] In some embodiments, the electrodes (e.g., anode, cathode) are 2GPa, 4GPa, 6GPa, 8GPa, 10GPa, 12GPa, 14GPa, 16GPa, 18GPa, 20GPa, 22GPa, 24GPa, 26GPa, 28GPa, 30GPa, 32GPa, 34GPa, 36GPa, 38GPa, 40GPa, 42GPa, 44GPa, 46GPa, 48GPa, 50GPa, 52GPa, 54GPa, 56GPa, 58GPa, 60GPa, 62GPa, 64GPa, 66GPa, 68GPa, 70GPa, 72GPa, 74GPa, 7 6GPa, 78GPa, 80GPa, 82GPa, 84GPa, 86GPa, 88GPa, 90GPa, 92GPa, 94GPa, 96GPa, 98GPa, 100GPa, 102GPa, 104GPa, 106GPa, 108GPa, 110GPa, 112GPa, 114GP a, 116GPa, 118GPa, 120GPa, 122GPa, 124GPa, 126GPa, 128GPa, 130GPa, 132GPa, 134GPa, 136GPa, 138GPa, 140GPa, 142GPa, 144GPa, 146GPa, 148GPa, 150G Pa, 152GPa, 154GPa, 156GPa, 158GPa, 160GPa, 162GPa, 164GPa, 166GPa, 168GPa, 170GPa, 172GPa, 174GPa, 176GPa, 178GPa, 180GPa, 182GPa, 184GPa, 186 GPa, 188GPa, 190GPa, 192GPa, 194GPa, 196GPa, 198GPa, 200GPa, 202GPa, 204GPa, 206GPa, 208GPa, 210GPa, 212GPa, 214GPa, 216GPa, 218GPa, 220GPa, 22 2GPa, 224GPa, 226GPa, 228GPa, 230GPa, 232GPa, 234GPa, 236GPa, 238GPa, 240GPa, 242GPa, 244GPa, 246GPa, 248GPa, 250GPa, 252GPa, 254GPa, 256GPa, 2 58GPa, 260GPa, 262GPa, 264GPa, 266GPa, 268GPa, 270GPa, 272GPa, 274GPa, 276GPa, 278GPa, 280GPa, 282GPa, 284GPa, 286GPa, 288GPa, 290GPa, 292GPa,The stiffness includes values ​​of 294 GPa, 296 GPa, 298 GPa, and 300 GPa, or any range between them, approximately these values, at least these values, or at least approximately these values. In some embodiments, the electrodes (e.g., anode, cathode) include a stiffness of at least about 2 GPa.

[0085] In some embodiments, the energy storage device includes a separator, an anode electrode, a cathode electrode, an electrolyte, and a housing, wherein the electrolyte, separator, anode electrode, and cathode electrode are arranged within the housing, and the separator is positioned between the anode electrode and the cathode electrode. In some embodiments, the energy storage device is formed by arranging the electrolyte, separator, anode electrode, and cathode electrode described herein within a housing, and the separator is positioned between the anode electrode and the cathode electrode.

[0086] The electrode assembly includes a cathode, an anode, and a separator positioned between the anode and the cathode. In some embodiments, the electrode assembly is a wound electrode (i.e., rolled electrode) assembly (e.g., a jelly roll). In some embodiments, the energy storage device is selected from the group consisting of cylindrical energy storage devices, stacked prismatic energy storage devices, and helically wound prismatic energy storage devices.

[0087] Normalized circularity can be used to identify and / or correlate relatively weak core spots (e.g., spots that may cause electrode buckling) in wound electrode assemblies. The normalized circularity of a non-ideal helix is ​​defined as the minimum ratio between the non-ideal (actual) geometric shape and the ideal geometric shape at each point, according to the following formula:

number

[0088] The geometric shape of a non-ideal (actual) spiral is given by measured Cartesian and polar coordinates (x,y,θ,r), while the geometric shape of an ideal spiral is derived from the Archimedean spiral according to r = αθ + β. The geometric shape of a spiral (ideal or non-ideal) can be characterized by curvature (K), such as the following polar curvature parameterization.

number

[0089] In some embodiments, the electrode assembly is 0.7, 0.705, 0.71, 0.715, 0.72, 0.725, 0.73, 0.735, 0.74, 0.745, 0.75, 0.76, 0.77, 0.78, 0.79, 0.8, 0.805, 0.81, 0.815, 0.82, 0.825, 0.83, 0.835, 0.84, 0.845, 0.85, 0.86, 0 Includes normalized circularity values ​​that are 0.87, 0.88, 0.89, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, 0.99, 1, 1.05, 1.1, 1.15, 1.2, or any range between them, approximately these values, at least these values, or at least approximately these values.

[0090] The electrodes disclosed herein can be used in energy storage devices. In some embodiments, the energy storage device includes a separator, an anode electrode, a cathode electrode, an electrolyte, and a housing, wherein the electrolyte, separator, anode electrode, and cathode electrode are arranged within the housing, and the separator is positioned between the anode electrode and the cathode electrode. In some embodiments, the energy storage device is formed by arranging the electrolyte, separator, anode electrode, and cathode electrode described herein within the housing, with the separator positioned between the anode electrode and the cathode electrode. In some embodiments, the energy storage device includes an anode electrode positioned between two cathode electrodes. In some embodiments, the anode electrode and / or cathode electrode includes a molded electrode film. In some embodiments, the energy storage device is a lithium-ion battery. In some embodiments, the energy storage device may be a battery, a capacitor, a capacitor-battery hybrid, a fuel cell, or a combination thereof. In some embodiments, the energy storage system or energy storage device may be used in electromobility. In some embodiments, the energy storage device can be used in vehicles including hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), and / or electric vehicles (EVs). In some embodiments, the energy storage device used in vehicles including hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), and / or electric vehicles (EVs) reduces greenhouse gas emissions.

[0091] In some embodiments, the energy storage device is charged with a suitable lithium-containing electrolyte. For example, the energy storage device may include a lithium salt and a solvent such as a non-aqueous solvent or an organic solvent. Generally, the lithium salt contains a redox-stable anion. In some embodiments, the anion may be monovalent. In some embodiments, the lithium salt can be selected from lithium hexafluoride phosphate (LiPF6), lithium bis(trifluoromethanesulfonyl)imide (LiFSI), lithium tetrafluoroborate (LiBF4), lithium perchlorate (LiClO4), lithium bis(trifluoromethanesulfonyl)imide (LiN(SO2CF3)2), lithium trifluoromethanesulfonate (LiSO3CF3), lithium bis(oxalato)borate (LiB(C2O4)2), lithium bis(fluorosulfonyl)imide (LiN(SO2F)2), lithium difluoro(oxalato)borate (LiC2BF2O4), and combinations thereof. In some embodiments, the electrolyte may include a quaternary ammonium cation and an anion selected from the group consisting of hexafluorophosphate, tetrafluoroborate, and iodide. In some embodiments, the salt concentration may be about 0.1 mol / L(M) to about 5 M, about 0.2 M to about 3 M, or about 0.3 M to about 2 M. In further embodiments, the salt concentration of the electrolyte may be about 0.7 M to about 2 M. In certain embodiments, the salt concentration of the electrolyte may be about 0.2 M, about 0.3 M, about 0.4 M, about 0.5 M, about 0.6 M, about 0.7 M, about 0.8 M, about 0.9 M, about 1 M, about 1.1 M, about 1.2 M, 1.3 M, 1.4 M, 1.5 M, or values ​​in between.

[0092] In some embodiments, the energy storage device may include a liquid solvent. The solvent does not need to dissolve all components of the electrolyte, nor does it need to completely dissolve any component. In further embodiments, the solvent may be an organic solvent. In some embodiments, the solvent may include one or more functional groups selected from dioxathiolane (e.g., 1,3,2-dioxathiolane-2,2-dioxide (i.e., "DTD")), carbonates, ethers and / or esters. In some embodiments, the solvent may include a carbonate. In further embodiments, the carbonate may be selected from cyclic carbonates, e.g., ethylene carbonate (EC), propylene carbonate (PC), vinylethylene carbonate (VEC), vinylene carbonate (VC), fluoroethylene carbonate (FEC) and combinations thereof, or acyclic carbonates, e.g., dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC), 1,3-propensultone (PRS) and combinations thereof. In some embodiments, the solvent may include an ester. In some embodiments, the ester is selected from methyl acetate (MA), methyl propionate (MP), ethyl acetate (EA), methyl butyrate (MB), and combinations thereof. In some embodiments, the solvent may include EC, PC, VEC, VC, FEC, DMC, DEC, EMC, MA, MP, EA, MB, and combinations thereof. In some embodiments, the solvent may include EC, DMC, DEC, EMC, MA, and combinations thereof. In some embodiments, the solvent may include EC, DMC, EMC, and combinations thereof. In some embodiments, the solvent may include an EC:DMC:EMC ratio of 10-30:0-90:0-70.

[0093] In some embodiments, one or more solvents can be used at concentrations of 30% by weight, 35% by weight, 40% by weight, 45% by weight, 50% by weight, 55% by weight, 60% by weight, 65% by weight, 70% by weight, 75% by weight, 80% by weight, 85% by weight, or 90% by weight, or any range of values ​​between these, approximately these values, at least these values, or at least approximately these values. In some embodiments, the solvent is used as an additive in the electrolyte system at concentrations of 0.1% by weight, 0.2% by weight, 0.3% by weight, 0.4% by weight, 0.5% by weight, 0.6% by weight, 0.7% by weight, 0.8% by weight, 0.9% by weight, 1% by weight, 1.1% by weight, 1.2% by weight, 1.3% by weight, 1.4% by weight, 1.5% by weight, 1.6% by weight, 1.7% by weight, 1.8% by weight, 1.9% by weight, 2% by weight, 2.1% by weight It can be used at concentrations of 2.2 wt%, 2.3 wt%, 2.4 wt%, 2.5 wt%, 2.6 wt%, 2.7 wt%, 2.8 wt%, 2.9 wt%, 3 wt%, 4 wt%, 5 wt%, 6 wt%, 7 wt%, 8 wt%, 9 wt%, or 10 wt%, or any range of values ​​in between, or approximately these values, or at most these values, or at most approximately these values. For example, in some embodiments, the amount of additive in the electrolyte is one of the ranges of 0.1–10 wt%, 1–6 wt%, 2–5 wt%, 0.1–6 wt%, 2–8 wt%, 2–3 wt%, or 1–4 wt%, or approximately these ranges.

[0094] In some embodiments, the energy storage device is constructed such that one electrode (e.g., the anode) is larger than and overhangs the other electrode (e.g., the cathode). One electrode may overhang the other in the winding direction and / or non-winding direction of the electrode assembly. Such electrode overhangs can avoid yield losses. In some embodiments, if there is no or substantially no overlap and / or mixing of the separator and the molded electrode film (e.g., the cathode electrode film), the boundary of the molded electrode film is easier to identify, and therefore the ability to form a counter electrode (e.g., the anode electrode) with an overhang is improved.

[0095] A method for preparing an electrode assembly may include placing a separator assembly between the cathode and the anode. In some embodiments, a method for preparing an electrode assembly may include placing a support tape on the cathode-facing surface at a tape placement speed of 3 m / s, 4 m / s, 5 m / s, 6 m / s, 7 m / s, 8 m / s, 9 m / s, 10 m / s, 11 m / s, 12 m / s, 13 m / s, 14 m / s, 15 m / s, 16 m / s, 17 m / s, 18 m / s, 19 m / s, and 20 m / s, or any range between these values, approximately these values, at least these values, or at least approximately these values. In some embodiments, a method for preparing an electrode assembly may include placing a support tape on the anode-facing surface at a tape placement speed that is 3 m / s, 4 m / s, 5 m / s, 6 m / s, 7 m / s, 8 m / s, 9 m / s, 10 m / s, 11 m / s, 12 m / s, 13 m / s, 14 m / s, 15 m / s, 16 m / s, 17 m / s, 18 m / s, 19 m / s, and 20 m / s, or any range between them, approximately these values, at least these values, or at least approximately these values.

[0096] A method for preparing a wound electrode assembly includes preparing an electrode assembly and rolling the electrode assembly to form a wound electrode assembly. A method for forming an energy storage device includes preparing a wound electrode assembly and placing the wound electrode assembly and electrolyte inside a housing. [Examples]

[0097] Exemplary embodiments of the present disclosure, including processes, materials, and / or resulting products, are described in the following examples.

[0098] Figures 5A and 5B show top perspective views of the wound electrode assembly. As shown in Figure 5A, the wound electrode assembly 500A includes an anode 505A having a leading edge of an anode 510A positioned between coil core layers 530A. The wound electrode assembly 500A further includes a cathode 520A and its leading edge cathode 525A. Figure 5B is a magnified version of Figure 5A and shows the wound electrode assembly 500B. The wound electrode assembly 500B includes an anode wrap 535 portion of the anode 505B positioned between the end of the coil core layer 530B and the cathode 520B, which acts as an additional support against electrode buckling.

[0099] As shown in Figure 6, a portion of the wound electrode assembly 600 is enlarged at the leading edge of the cathode 625. The wound electrode assembly 600 has an anode 605 and a coil core layer 630. A separator layer 615 is positioned between the anode 605 and the cathode 620. The separator layer includes an anode-facing surface 613 and a cathode-facing surface 617. The anode 605 is positioned on the anode-facing surface 613 of the separator layer 615. The coil core layer 630 is positioned on the anode 605 to prevent electrode buckling of the core of the wound electrode assembly. The wound electrode assembly 600 further includes a barrier layer 650 positioned on the cathode-facing surface 617 of the separator layer 615 to protect the separator layer from electrode puncture and short circuits.

[0100] While specific embodiments of the present invention have been described, these embodiments are presented only as examples and are not intended to limit the scope of this disclosure. In fact, the novel methods and systems described herein can be embodied in a variety of other forms. Furthermore, various omissions, substitutions, and modifications can be made to the systems and methods described herein without departing from the spirit of this disclosure. The appended claims and their equivalents are intended to encompass forms or modifications that fall within the scope and spirit of this disclosure. Accordingly, the scope of the present invention is defined solely by reference to the appended claims.

[0101] Features, materials, properties, or groups described in relation to a particular aspect, embodiment, or example should be understood to be applicable to any other aspect, embodiment, or example described in this section or elsewhere in this specification, provided that they do not conflict. All features and / or any steps of any method or process disclosed herein (including any appended claims, abstract, and drawings) may be combined in any combination, except for any combination in which at least some of such features and / or steps are mutually exclusive. Protection is not limited to the details of any aforementioned embodiment. Protection extends to any novel features or any novel combination of features disclosed herein (including any appended claims, abstract, and drawings), or any novel steps or any novel combination of any steps of any method or process disclosed herein.

[0102] Furthermore, certain features described in this disclosure in the context of separate embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented separately or in any suitable combination of sub-features in multiple embodiments. Furthermore, while features may be described above as acting in a particular combination, one or more features from a claimed combination may, in some cases, be removed from the combination, and the combination may be claimed as a combination of sub-features or a variation of a combination of sub-features.

[0103] Furthermore, while operations may be shown in the drawings or described herein in a specific order, such operations do not need to be performed in the specific order shown or in a sequential order to achieve the desired result, nor do all operations need to be performed. Other operations not shown or described may be incorporated into exemplary methods and processes. For example, one or more additional operations may be performed before, after, simultaneously with, or in between any of the described operations. Furthermore, operations may be rearranged or reordered in other embodiments. Those skilled in the art will understand that in some embodiments, the actual steps performed in the illustrated and / or disclosed processes may differ from those shown in the drawings. Depending on the embodiment, certain steps among the steps described above may be omitted, or other steps may be added. Furthermore, the features and attributes of the particular embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of this disclosure. Also, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and the described components and systems may generally be integrated together in a single product or packaged in multiple products. For example, any of the components of the energy storage system described herein may be provided separately or as an integrated unit (e.g., packaged together or mounted together) to form the energy storage system.

[0104] For the purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not all such advantages can necessarily be achieved according to any particular embodiment. Therefore, for example, a person skilled in the art will recognize that this disclosure can be implemented or carried out in a manner that achieves one advantage or set of advantages as taught herein, without necessarily achieving other advantages that can be taught or suggested herein.

[0105] Conditional language such as “can,” “could,” “might,” or “may” is generally intended to convey that a particular embodiment includes certain features, elements, and / or steps, but other embodiments do not, unless otherwise specified or understood in the context in which they are used. Therefore, such conditional language is generally not intended to imply that features, elements, and / or steps are required in one or more embodiments, or that one or more embodiments necessarily include logic for determining, with or without user input or facilitation, whether these features, elements, and / or steps are included in or performed within any particular embodiment.

[0106] The phrase "at least one of X, Y, and Z" is generally understood in its context to mean that an item, term, etc., may be one of X, Y, or Z, unless otherwise specified. Therefore, such a phrase is not generally intended to imply that a particular embodiment requires the presence of at least one X, at least one Y, and at least one Z.

[0107] As used herein, the terms “approximately,” “about,” “generally,” and “substantially” refer to values, quantities, or characteristics close to the stated values, quantities, or characteristics that still perform the desired function or achieve the desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to quantities less than 10%, less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the stated quantity, depending on the desired function or desired result.

[0108] The scope of this disclosure is not intended to be limited by any specific disclosure of preferred 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 presented in the future. The language of the claims should be interpreted broadly on the basis of the language adopted in the claims, and not limited to the examples described herein or during the examination of an application, and the examples should be interpreted as non-exclusive.

Claims

1. An energy storage device, An electrode assembly, wherein the electrode assembly is The cathode including the leading edge of the cathode, An anode including an anode leading edge and an anode overhang region extending beyond the cathode leading edge, The system comprises a separator assembly disposed between the cathode and the anode, The separator assembly includes a separator layer, a coil core support tape, and a barrier layer support tape. The separator layer includes a cathode-facing surface and an anode-facing surface, The coil core support tape comprises a coil support layer and a coil adhesive layer, the coil adhesive layer is positioned directly above the separator layer, the coil support layer comprises a metallic material selected from the group consisting of copper, aluminum, magnesium, or a combination thereof, and the coil core support tape is positioned above the anode leading edge. The electrode assembly comprises a barrier support tape including a barrier support layer and a barrier adhesive layer, wherein the barrier adhesive layer is positioned directly above the separator layer and the barrier support tape is positioned above the cathode leading edge. Electrolytes, A housing in which the electrode assembly and the electrolyte are disposed within the housing, An energy storage device equipped with the following features.

2. An electrode assembly for an energy storage device, Cathode and, A-scatter, A separator assembly disposed between the cathode and the anode, wherein the separator assembly comprises a separator layer including a cathode-facing surface and an anode-facing surface, and a support tape including a support layer and an adhesive layer, wherein the adhesive layer is disposed directly above the separator layer. An electrode assembly comprising:

3. The electrode assembly according to claim 2, wherein the anode includes an anode overhang region.

4. The electrode assembly according to claim 2 or 3, wherein the support layer includes a barrier layer and the adhesive layer is disposed on the cathode-facing surface.

5. The electrode assembly according to claim 4, wherein the barrier layer includes a barrier layer thickness of 5 to 20 μm.

6. The electrode assembly according to claim 4, wherein the barrier layer comprises a polyimide material.

7. The electrode assembly according to claim 2 or 3, wherein the support layer includes a coil core layer and at least a portion of the adhesive layer is disposed on the anode-facing surface.

8. The electrode assembly according to claim 7, wherein the coil core layer comprises a material selected from the group consisting of metals, polymers, and combinations thereof.

9. The electrode assembly according to claim 8, wherein the metal is selected from the group consisting of copper, aluminum, magnesium, or a combination thereof.

10. The electrode assembly according to claim 7, wherein the coil core layer includes a coil core layer thickness of 75 to 125 μm.

11. The electrode assembly according to claim 7, wherein the coil core layer is disposed on the anode-facing surface.

12. The electrode assembly according to claim 2 or 3, further comprising an additional separator assembly, wherein the additional separator assembly is positioned on the cathode on the side of the cathode opposite to the separator assembly.

13. The electrode assembly according to claim 12, wherein the additional separator assembly includes an additional support layer.

14. The electrode assembly according to claim 3, wherein the support layer is aligned with the leading edge of the anode or the leading edge of the cathode.

15. The electrode assembly according to claim 14, wherein the support layer overlaps the leading edge of the anode or the leading edge of the cathode by 10 to 20 mm.

16. The electrode assembly according to claim 14 or 15, wherein the anode protrudes by 40 to 60 mm from the leading edge of the cathode.

17. The electrode assembly according to claim 14 or 15, wherein the support layer overlaps the leading edge of the anode overhang region by 10 to 20 mm.

18. The electrode assembly according to claim 2 or 3, wherein the anode or cathode has a rigidity of at least 2 GPa.

19. An energy storage device, The electrode assembly according to claim 2 or 3, Electrolytes, A housing in which the electrode assembly and the electrolyte are disposed within the housing, An energy storage device equipped with the following features.

20. A method for preparing the electrode assembly according to claim 2, comprising arranging the separator assembly between the cathode and the anode.

21. The method according to claim 20, further comprising positioning the support tape on the cathode-facing surface at a tape positioning speed of at least 3 m / s.

22. The method according to claim 20 or 21, further comprising positioning the support tape on the anode-facing surface at a tape positioning speed of at least 3 m / s.

23. A method for preparing a wound electrode assembly, A step of preparing the electrode assembly according to the method of claim 20 or 21, The process of winding the electrode assembly to form a wound electrode assembly, Methods that include...

24. A method for forming an energy storage device, A step of preparing the wound electrode assembly according to the method of claim 23, The steps include placing the wound electrode assembly and electrolyte inside the housing, Methods that include...

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