Electrode assembly and secondary battery

Abstract

Embodiments of secondary batteries having electrode assemblies are provided. The secondary battery may include an electrode assembly having a stacked series of layers having an offset between electrode layers and counter electrode layers in the stacked series of unit cell members. A primary restraint system may be provided for a group of restraints, the primary restraint system having first and second primary growth restraints separated from each other in a longitudinal direction and connected by at least one primary connecting member, and a secondary restraint system including first and second secondary growth restraints separated in a second direction and connected by members of the stacked series of layers. The primary restraint system may at least partially restrict growth of the electrode assembly in the longitudinal direction, and the secondary restraint system may at least partially restrict growth in a second direction orthogonal to the longitudinal direction.

Description

Technical Field

[0001] This disclosure generally relates to electrode assemblies used in energy storage devices such as secondary batteries. Background Technology

[0002] A rocking chair or plug-in secondary battery is a type of energy storage device in which carrier ions, such as lithium ions, sodium ions, potassium ions, calcium ions, or magnesium ions, move between positive and negative electrodes via an electrolyte. A secondary battery may comprise a single cell, or two or more cells electrically coupled to form a battery. Each cell includes a positive electrode, a negative electrode, a microporous separator, and an electrolyte.

[0003] In a rocking chair battery cell, both the positive and negative electrodes consist of materials in which carrier ions are inserted and extracted. When the battery discharges, carrier ions are extracted from the negative electrode and inserted into the positive electrode. When the battery is charged, the reverse process occurs: carrier ions are extracted from the positive electrode and inserted into the negative electrode.

[0004] One ongoing challenge as carrier ions move between electrodes is the fact that the electrodes tend to expand and contract with repeated charging and discharging of the battery. This expansion and contraction during cycling often causes problems with battery reliability and cycle life because electrical short circuits and battery failures can occur when the electrodes expand. Another potential problem is that misalignment of the electrodes, for example, due to physical or mechanical stress on the battery during manufacturing, use, or transportation, can lead to battery short circuits and failures.

[0005] Therefore, it remains necessary to control the expansion and contraction of the electrodes during battery cycling to improve battery reliability and cycle life. Electrode alignment and structure also need to be controlled to improve the battery's mechanical stability without excessively increasing its footprint.

[0006] Furthermore, a reliable and efficient method for manufacturing such a battery is still needed. That is, an efficient manufacturing method is needed to provide a battery with electrode assemblies that have carefully controlled alignment and whose expansion is controlled during battery cycling. Summary of the Invention

[0007] One aspect of this disclosure relates to a secondary battery for cycling between a state of charge and a state of discharge, the secondary battery comprising a battery casing, an electrode assembly, and an assembly of lithium ions within the battery casing, and electrode restraints, wherein...

[0008] (a) The electrode assembly has mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y, and z axes of a hypothetical three-dimensional Cartesian coordinate system, a first longitudinal end surface and a second longitudinal end surface separated from each other in the longitudinal direction, and a region surrounding the longitudinal axis A of the electrode assembly. EA A transverse surface connects the first longitudinal end surface and the second longitudinal end surface, the transverse surface having opposing first and second regions located on opposite sides of the longitudinal axis and separated in a first direction orthogonal to the longitudinal axis, the electrode assembly having a maximum width W measured in the longitudinal direction. EA The maximum length L defined by the transverse surface and measured in the transverse direction EA and the maximum height H defined by the transverse surface and measured in the vertical direction. EA Wherein, the maximum length L EA and the maximum width W EA With the maximum height H EA The ratio should be at least 2:1

[0009] (b) The electrode assembly includes a series of layers stacked within the electrode assembly in a stacking direction parallel to the longitudinal axis, wherein the stacked series of layers includes a negative electrode active material layer group, a negative electrode current collector layer group, a separator material layer group, a positive electrode active material layer group, and a positive electrode current collector material layer group, wherein

[0010] (i) Each component in the negative electrode active material layer group has a length L E Height H E and width W E The length L E The Freette diameter of the negative electrode active material layer, measured in the lateral direction between the first and second opposing lateral end surfaces of the negative electrode active material layer, and the height H E The Freette diameter of the negative electrode active material layer, measured in the vertical direction between the first and second opposing vertical end surfaces of the negative electrode active material layer, and the width W E Corresponding to the Freette diameter of the negative electrode active material layer measured in the longitudinal direction between the first and second opposing surfaces of the negative electrode active material layer, where L E With H E and W E The ratio should be at least 5:1;

[0011] (ii) Each component in the positive electrode active material layer group has a length L C Height H C and width W CThe length L C The Freette diameter of the positive electrode active material layer, measured in the lateral direction between the first and second opposing lateral end surfaces of the positive electrode active material layer, and the height H C The Freette diameter of the positive electrode active material layer, measured in the vertical direction between the first and second opposing vertical end surfaces of the positive electrode active material layer, and the width W C Corresponding to the Freette diameter of the positive electrode active material layer measured in the longitudinal direction between the first and second opposing surfaces of the positive electrode active material layer, where L C With H C and W C The ratio should be at least 5:1

[0012] (iii) The components of the negative electrode active material layer group include particulate material having at least 60 wt% negative electrode active material, less than 20 wt% conductive additive, and binder material, wherein the negative electrode active material includes silicon-containing material.

[0013] (c) The assembly of electrode constraints comprises a primary constraint system and a secondary constraint system, wherein

[0014] (i) The primary constraint system includes first and second growth constraint members and at least one primary connecting member, the first and second primary growth constraint members being separated from each other in the longitudinal direction, and the at least one primary connecting member connecting the first and second primary growth constraint members to at least partially restrict the growth of the electrode assembly in the longitudinal direction, and

[0015] (ii) The secondary constraint system includes first and second secondary growth constraint members separated in a second direction and connected by components of the stacked series of layers, wherein the secondary constraint system at least partially restricts the growth of the electrode assembly in the second direction, orthogonal to the longitudinal direction, during the secondary battery cycle.

[0016] (iii) The primary constraint system maintains a pressure on the electrode assembly in the stacking direction that exceeds the pressure maintained on the electrode assembly in each of two directions perpendicular to each other and perpendicular to the stacking direction, and

[0017] (d) The electrode assembly comprises a group of unit cells, wherein each unit cell comprises a unit cell portion of a first member of the electrode current collector layer group, a member of the separator group that is ion-permeable to the carrier ions, a first member of the electrode active material layer group, a unit cell portion of a first member of the counter electrode current collector group, and a first member of the counter electrode active material layer group, wherein, (aa) the first member of the electrode active material layer group is located near a first side of the separator, and the first member of the counter electrode material layer group is located near a opposite second side of the separator, (bb) the separator electrically isolates the first member of the electrode active material layer group from the first member of the counter electrode active material layer group, and carrier ions are exchanged primarily between the first member of the electrode active material layer group and the first member of the counter electrode active material layer group via the separator of each such unit cell during cycling between the charged state and the discharged state of the battery, and (cc) within each unit cell,

[0018] a. The first vertical end surfaces of the electrode and the counter electrode active material layer are located on the same side of the electrode assembly, and the median vertical position of the first opposing vertical end surfaces of the electrode active material is along the length L of the electrode active material layer in the XZ plane. E The 2D drawing depicts the surface of the first vertical end, E. VP1 The median vertical position of the first relatively vertical end surface of the counter electrode active material layer along the length L of the counter electrode active material layer in the XZ plane. C The 2D drawing depicts the surface of the first vertical end, CE. VP1 Wherein, for the length L of the first pair of electrode active material layers C At least 60% of: (i) the figure E measured in the vertical direction VP1 and CE VP1 The separation distance S between them Z1 The absolute value is 1000μm≥|S Z1 |≥5μm, (ii) for the first vertical end surface between the electrode and the counter electrode active material layer, the first vertical end surface of the counter electrode active material layer is disposed inward relative to the first vertical end surface of the electrode active material layer.

[0019] b. The second vertical end surfaces of the electrode and counter electrode active material layers are located on the same side of the electrode assembly and are respectively opposite to the first vertical end surfaces of the electrode and counter electrode active material layers. The median vertical position of the second opposite vertical end surfaces of the electrode active material layers is along the length L of the electrode active material layer in the XZ plane. E The 2D drawing depicts the second vertical end surface diagram E. VP2 The median vertical position of the second relatively vertical end surface of the counter electrode active material layer along the length L of the counter electrode active material layer in the XZ plane. C The 2D drawing depicts the second vertical end surface CE. VP2 Wherein, for the length L of the active material layer of the counter electrode C At least 60% of: (i) the figure E measured in the vertical direction VP2 and CE VP2 The separation distance S between them Z2 The absolute value is 1000μm≥|S Z2 |≥5μm, and (ii) for the second vertical end surface of the electrode and the counter electrode active material layer, the second vertical end surface of the counter electrode active material layer is disposed inward relative to the second vertical end surface of the electrode active material layer.

[0020] Another aspect of this disclosure relates to a secondary battery for cycling between a charged state and a discharged state, the secondary battery comprising a battery casing, an electrode assembly and an assembly of carrier ions within the battery casing, and electrode confinement elements, wherein...

[0021] (a) The electrode assembly has mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y, and z axes of a hypothetical three-dimensional Cartesian coordinate system, a first longitudinal end surface and a second longitudinal end surface separated from each other in the longitudinal direction, and a region surrounding the longitudinal axis A of the electrode assembly. EA A transverse surface connects the first longitudinal end surface and the second longitudinal end surface, the transverse surface having opposing first and second regions located on opposite sides of the longitudinal axis and separated in a first direction orthogonal to the longitudinal axis, the electrode assembly having a maximum width W measured in the longitudinal direction. EA The maximum length L defined by the transverse surface and measured in the transverse direction EA and the maximum height H defined by the transverse surface and measured in the vertical direction. EA Wherein, the maximum length L EA And / or the maximum width W EA Greater than the maximum height HEA ,

[0022] (b) The electrode assembly includes a series of layers stacked within the electrode assembly in a stacking direction parallel to the longitudinal axis, wherein the stacked series of layers includes a negative electrode active material layer group, a negative electrode current collector layer group, a separator material layer group, a positive electrode active material layer group, and a positive electrode current collector material layer group, wherein

[0023] (i) Each component in the negative electrode active material layer group has a length L E Height H E and width W E The length L E The Freette diameter of the negative electrode active material layer, measured in the lateral direction between the first and second opposing lateral end surfaces of the negative electrode active material layer, and the height H E The Freette diameter of the negative electrode active material layer, measured in the vertical direction between the first and second opposing vertical end surfaces of the negative electrode active material layer, and the width W E Corresponding to the Freette diameter of the negative electrode active material layer measured in the longitudinal direction between the first and second opposing surfaces of the negative electrode active material layer, wherein the L E With the H E and the W E The ratio should be at least 5:1;

[0024] (ii) Each component in the positive electrode material layer group has a length L C Height H C and width W C The length L C The Freette diameter of the positive electrode active material layer, measured in the lateral direction between the first and second opposing lateral end surfaces of the positive electrode active material layer, and the height H C The Freette diameter of the positive electrode active material layer, measured in the vertical direction between the first and second opposing vertical end surfaces of the positive electrode active material layer, and the width W C Corresponding to the Freette diameter of the positive electrode active material layer measured in the longitudinal direction between the first and second opposing surfaces of the positive electrode active material layer, where L C With H C and W C The ratio should be at least 5:1

[0025] (iii) The components of the negative electrode active material layer group include particulate material having at least 60 wt% negative electrode active material, less than 20 wt% conductive additive, and binder material.

[0026] (c) The assembly of electrode constraints comprises a primary constraint system and a secondary constraint system, wherein

[0027] (i) The primary constraint system includes first and second growth constraint members and at least one primary connecting member, the first and second primary growth constraint members being separated from each other in the longitudinal direction, and the at least one primary connecting member connecting the first and second primary growth constraint members to at least partially restrict the growth of the electrode assembly in the longitudinal direction, and

[0028] (ii) The secondary constraint system includes first and second secondary growth constraint members separated in a second direction and connected by components of the stacked series of layers, wherein the secondary constraint system at least partially restricts the growth of the electrode assembly in the second direction, orthogonal to the longitudinal direction, during the secondary battery cycle.

[0029] (iii) The primary constraint system maintains a pressure on the electrode assembly in the stacking direction that exceeds the pressure maintained on the electrode assembly in each of two directions perpendicular to each other and perpendicular to the stacking direction, and

[0030] (d) The stacked series of layers includes layers having opposing end surfaces spaced apart from each other in the transverse direction, wherein, due to the elongation and shrinkage of the layers at the opposing end surfaces, the multiple opposing end surfaces of the layers exhibit plastic deformation and fracture oriented in the transverse direction.

[0031] Other aspects, features, and embodiments of this disclosure will be discussed in part and will be apparent in part from the following description and drawings. Attached Figure Description

[0032] Figure 1A This is a perspective view of one embodiment of a constraint system used with electrode assemblies.

[0033] Figure 1B This is a schematic diagram of one embodiment of a three-dimensional electrode assembly for a secondary battery.

[0034] Figure 1C yes Figure 1B Insertion cross-sectional view of the electrode assembly.

[0035] Figure 1D It is along Figure 1B The line E in the middle is intercepted Figure 1B A cross-sectional view of the electrode assembly.

[0036] Figure 2A This is a schematic diagram of one embodiment of a three-dimensional electrode assembly.

[0037] Figures 2B to 2C This is a schematic diagram of one embodiment of a three-dimensional electrode assembly, illustrating the anode structure group components in constrained and extended configurations.

[0038] Figures 3A to 3H Exemplary embodiments of electrode assemblies in different shapes and sizes are shown.

[0039] Figure 4A It shows along Figure 1A The cross-section of an embodiment of the electrode assembly is shown along line A-A', and elements of the primary and secondary growth constraint systems are further illustrated.

[0040] Figure 4B It shows along Figure 1A The diagram shows a cross-section of an embodiment of the electrode assembly taken by line B-B', and further illustrates the elements of the primary and secondary growth constraint systems.

[0041] Figure 4C It shows along Figure 1A The diagram shows a cross-section of an embodiment of the electrode assembly taken by line B-B', and further illustrates the elements of the primary and secondary growth constraint systems.

[0042] Figure 5 It shows along Figure 1A The cross-section of an embodiment of the electrode assembly is shown by line A-A1'.

[0043] Figure 6A An embodiment of a porous secondary growth constraint on an electrode assembly is shown in top view, as well as an embodiment for adhering the secondary growth constraint to the electrode assembly.

[0044] Figure 6B An embodiment of a porous secondary growth constraint on an electrode assembly is shown in top view, and another embodiment for adhering the secondary growth constraint to the electrode assembly is shown.

[0045] Figure 7 It shows along Figure 1A The cross-section of the electrode assembly embodiment shown by line A-A' further includes a set of electrode constraints, including an embodiment of a primary constraint system and an embodiment of a secondary constraint system.

[0046] Figures 8A to 8B A force diagram according to one embodiment is shown, illustrating the force applied to the electrode assembly by a group of electrode restraints, and the force applied by the electrode structure during repeated cycles of a battery containing the electrode assembly.

[0047] Figure 9A It shows along Figure 1AThe cross-section of an embodiment of the electrode assembly shown by line A-A' further includes an assembly of electrode constraints, including an embodiment of a primary growth constraint system and an embodiment of a secondary growth constraint system, wherein the electrode backbone is used to assemble the assembly of electrode constraints.

[0048] Figure 9B It shows along Figure 1A The cross-section of an embodiment of the electrode assembly shown by line A-A' further includes an assembly of electrode constraints, including an embodiment of a primary growth constraint system and an embodiment of a secondary growth constraint system, wherein an electrode current collector is used to assemble the assembly of electrode constraints.

[0049] Figure 10 An exploded view of an embodiment of an energy storage device or secondary battery utilizing a group of growth constraints is shown.

[0050] Figures 11A to 11C The diagram illustrates the vertical offset and / or separation distance S between the vertical end surfaces of the electrode and the counter electrode active material layer. Z1 and S Z2 Examples of implementations.

[0051] Figures 12A to 12C The diagram illustrates the lateral offset and / or separation distance S between the lateral end surfaces of the electrode and the counter electrode active material layer. X1 and S X2 Examples of implementations.

[0052] Figures 13A to 13B The height H of the active material layer of the electrode and / or counter electrode is shown based on its Ferrette diameter. E H C and length L E L C Examples of implementations.

[0053] Figures 14A to 14H A cross-section in the ZY plane is shown of an embodiment of a unit cell having electrode and counter electrode active material layers, wherein the two have and do not have vertical offset and / or separation distances.

[0054] Figures 15A to 15F A cross-section in the YX plane is shown of an embodiment of a unit cell having electrode and counter electrode active material layers, wherein the two have and do not have lateral offset and / or separation distances.

[0055] Figures 16A to 16B An embodiment of an electrode assembly having electrode and / or counter electrode busbars is shown. Figure 16A '-16B' indicates Figure 16A -16F represents the various cross-sections taken in the XY plane.

[0056] Figure 17 An embodiment of a secondary battery with an alternating arrangement of electrode and counter electrode structures is shown.

[0057] Figures 18A to 18B A cross-section in the ZY plane is shown of an embodiment of an electrode assembly with auxiliary electrodes.

[0058] Figure 19 This is a schematic diagram of the negative electrode unit before and after the current collector end is exposed after the end of the negative electrode unit is removed, and it shows the plastic deformation at the current collector end due to the removal of the end portion at the current collector end.

[0059] Other aspects, embodiments, and features of the subject matter of the invention will become apparent from the following detailed description when considered in conjunction with the accompanying drawings. The drawings are schematic and not intended to be drawn to scale. For clarity, not every element or component is labeled in every drawing, nor does every element or component of every embodiment of the subject matter of the invention illustrate the invention, and the illustrations are not essential for those skilled in the art to understand the subject matter of the invention. Detailed Implementation

[0060] definition

[0061] Unless the context clearly indicates otherwise, the terms “a,” “an,” and “the” (i.e., the singular) used herein refer to a plural number of objects. For example, in one instance, references to “electrode” include a single electrode and multiple similar electrodes.

[0062] As used herein, “about” and “approximately” mean a value plus or minus 10%, 5%, or 1%. For example, in one instance, about 250 μm would include 225 μm to 275 μm. As a further example, in one instance, about 1000 μm would include 900 μm to 1100 μm. Unless otherwise indicated, all figures representing quantities (e.g., measurements, etc.) used in the specification and claims should be understood to be modified by the term “about” in all cases. Therefore, unless indicated to the contrary, the numerical parameters set forth in the following specification and appended claims are approximate values. Each numerical parameter should be interpreted at least according to the number of significant figures reported and by applying common rounding techniques.

[0063] In the context of secondary batteries, the term "anode" as used in this article refers to the negative electrode in a secondary battery.

[0064] As used in this article, "anodic activity" refers to materials suitable for use as anodes in secondary batteries.

[0065] In the context of secondary batteries, "cathode" as used in this article refers to the positive electrode in a secondary battery.

[0066] As used in this article, "cathode activity" refers to the material of the cathode suitable for secondary batteries.

[0067] In the context of the state of a secondary battery, the term "state of charge" as used herein refers to a secondary battery that has been charged to at least 75% of its rated capacity. For example, a battery can be charged to at least 80% of its rated capacity, at least 90% of its rated capacity, or even at least 95% of its rated capacity, such as 100% of its rated capacity.

[0068] As used in this article, "C-rate" refers to a measure of the discharge rate of a secondary battery and is defined as the discharge current divided by the theoretical current draw, at which the battery will output its nominal rated capacity in one hour. For example, 1C indicates the discharge current that allows the battery to discharge in one hour, 2C indicates the discharge current that allows the battery to discharge in 1 / 2 hour, C / 2 indicates the discharge current that allows the battery to discharge in 2 hours, and so on.

[0069] In the context of secondary battery status, “state of discharge” as used herein refers to a secondary battery being discharged to less than 25% of its rated capacity. For example, a battery can be discharged to less than 20% of its rated capacity, such as less than 10% of its rated capacity, or even less than 5% of its rated capacity, such as 0% of its rated capacity.

[0070] As used herein in the context of cycling a secondary battery between states of charge and state of discharge, "cycle" refers to charging and / or discharging the battery to move it through a cycle from a first state (i.e., a state of charge or discharge) to a second state opposite to the first state (i.e., a state of charge if the first state is a state of discharge, and a state of discharge if the first state is a state of charge), and then moving the battery back to the first state to complete the cycle. For example, when in a charging cycle, a single cycle of a secondary battery between states of charge and state of discharge may include charging the battery from a state of discharge to a state of charge, and then discharging it back to a state of discharge to complete the cycle. When in a discharging cycle, a single cycle may also include discharging the battery from a state of charge to a state of discharge, and then charging it back to a state of charge to complete the cycle.

[0071] As used herein with respect to electrode assemblies, electrode active material layers, and / or counter electrode active material layers, the "Ferret diameter" is defined as the distance between two parallel planes of a confining structure (i.e., the electrode active material layer of an electrode assembly and / or the counter electrode active material layer), measured in a direction perpendicular to the two planes. For example, the Ferret diameter of an electrode assembly in the longitudinal direction is the distance between two parallel planes confining the electrode assembly, measured in the longitudinal direction, perpendicular to that longitudinal direction. As another example, the Ferret diameter of an electrode assembly in the transverse direction is the distance between two parallel planes confining the electrode assembly, measured in the transverse direction, perpendicular to that transverse direction. As yet another example, the Ferret diameter of an electrode assembly in the vertical direction is the distance between two parallel planes confining the electrode assembly, measured in the vertical direction, perpendicular to that vertical direction. As yet another example, the Ferret diameter of an electrode active material layer in the transverse direction is the distance between two parallel planes confining the electrode active material layer, measured in the transverse direction, perpendicular to that transverse direction. As yet another example, the Freret diameter of the electrode active material layer in the vertical direction is the distance measured vertically between two parallel planes of the electrode active material layer, which are perpendicular to the vertical direction. As yet another example, the Freret diameter of the counter electrode active material layer in the transverse direction is the distance measured horizontally between two parallel planes of the counter electrode active material layer, which are perpendicular to the transverse direction. As yet another example, the Freret diameter of the counter electrode active material layer in the vertical direction is the distance measured vertically between two parallel planes of the counter electrode active material layer, which are perpendicular to the vertical direction.

[0072] As used herein, "longitudinal axis," "lateral axis," and "vertical axis" refer to axes that are perpendicular to each other (i.e., each axis is orthogonal to the others). For example, the "longitudinal axis," "lateral axis," and "vertical axis" as used herein are analogous to a Cartesian coordinate system used to define a three-dimensional aspect or orientation. Therefore, the description of elements of the subject matter of this invention herein is not limited to one or more specific axes used to describe the three-dimensional orientation of the elements. In other words, when referring to the three-dimensional aspects of the subject matter of this invention, the axes can be interchangeable.

[0073] As used in this paper, "vertical direction," "lateral direction," and "vertical direction" refer to mutually perpendicular directions (i.e., each direction is orthogonal to the others). For example, the "vertical direction," "lateral direction," and "vertical direction" used in this paper can generally be parallel to the longitudinal axis, lateral axis, and vertical axis of a Cartesian coordinate system used to define a three-dimensional aspect or orientation, respectively.

[0074] In the context of cycling between the states of charge and discharge of a secondary battery, the term "repeated cycle" as used herein refers to more than one cycle from a state of discharge to a state of charge, or from a state of charge to a state of discharge. For example, a repeated cycle between a state of charge and a state of discharge may include at least two cycles from a state of discharge to a state of charge, such as charging from a state of discharge to a state of charge, discharging back to a state of discharge, charging again to a state of charge, and finally discharging back to a state of discharge. As another example, at least two repeated cycles between a state of charge and a state of discharge may include discharging from a state of charge to a state of discharge, charging back to a state of charge, discharging again to a state of discharge, and finally charging back to a state of charge. As yet another example, a repeated cycle between a state of charge and a state of discharge may include at least five cycles, or even at least ten cycles from a state of discharge to a state of charge. With further examples, a repeated cycle between a state of charge and a state of discharge may include at least 25, 50, 100, 300, 500, and even 1000 cycles from a state of discharge to a state of charge.

[0075] In the context of secondary batteries, the term "rated capacity" refers to the capacity of a secondary battery to output a specified current over a given period of time, measured under standard temperature conditions (25°C). For example, rated capacity can be measured in ampere-hours (AHs), either by determining the current output for a specified time period or by determining the time during which the current can be output for a specified current period and then multiplying the current by the time. For instance, for a battery rated at 20 AHs, if the current is specified as 2 AHs for the rating, the battery can be understood as one that will provide that current output for 10 hours continuously; conversely, if the time is specified as 10 hours for the rating, the battery can be understood as one that will output 2 AHs over a 10-hour period. Specifically, the rated capacity of a secondary battery can be given as the rated capacity at a specified discharge current, such as the C-rate, where the C-rate is a measure of the rate at which the battery is discharged relative to its capacity. For example, a 1C rate indicates the discharge current that allows the battery to discharge in 1 hour, a 2C rate indicates the discharge current that allows the battery to discharge in 1 / 2 hour, a C / 2 rate indicates the discharge current that allows the battery to discharge in 2 hours, and so on. Therefore, for example, a battery rated at 20 amp-hours at a 1C rate will provide a discharge current of 20 amps for 1 hour, a battery rated at 20 amp-hours at a 2C rate will provide a discharge current of 40 amps for half an hour, and a battery rated at 20 amp-hours at a C / 2 rate will provide a discharge current of 10 amps for 2 hours.

[0076] The term "maximum width" (W) used in this article in the context of electrode assembly dimensions EA This corresponds to the maximum width of the electrode assembly as measured from a relative point on the longitudinal end surface of the electrode assembly in the longitudinal direction.

[0077] The term "maximum length" (L) used in this article in the context of electrode assembly dimensions EA This corresponds to the maximum length of the electrode assembly measured from a relative point on the transverse surface of the electrode assembly in the transverse direction.

[0078] The term "maximum height" (H) used in this article in the context of electrode assembly dimensions EA This corresponds to the maximum height of the electrode assembly as measured from a relative point on the lateral surface of the electrode assembly in the lateral direction.

[0079] As used in this paper, "centroid" refers to the geometric center of a planar object, which is the arithmetic mean position of all points in the object. In n-dimensional space, the centroid is the average position of all points in all coordinate directions of the object. To describe the centroid of the objects in this paper, for example, negative and positive pole sub-units, as well as negative and positive active material layers, the objects can be effectively regarded as 2-D objects such that the centroid is effectively the same as the centroid of the object. For example, the centroid of a positive or negative pole sub-unit, or the centroid of a positive or negative active material layer, can be effectively the same as its centroid.

[0080] Detailed description

[0081] Typically, various aspects of this disclosure are directed to, for example, Figure 1B and 2A The energy storage device 100 (such as a secondary battery 102) and its manufacturing method are shown, the secondary battery 102 cycling between charging and discharging states. The secondary battery 102 includes a battery casing 104, electrode assemblies 106, and ion carriers, and may also contain a non-aqueous liquid electrolyte within the battery casing. The secondary battery 102 may also include a set of electrode restraints 108 that restrict the growth of the electrode assemblies 106. The growth of the restrained electrode assemblies 106 may be a macroscopic increase in one or more dimensions of the electrode assemblies 106.

[0082] Various aspects of this disclosure also provide reduced offset and / or separation distances in the vertical and lateral directions of the electrode active material layer and the counter electrode active material layer, which can improve the storage capacity of the secondary battery without unduly increasing the risk of short circuits or failures, as described in detail below. Various aspects of this disclosure may also provide methods for manufacturing secondary batteries and / or manufacturing high-energy-density structures and configurations of secondary batteries with reduced footprints.

[0083] Furthermore, in some embodiments, various aspects of this disclosure include a three-dimensional constraint structure, which provides particular advantages when incorporated into an energy storage device 100 such as a battery, capacitor, fuel cell, etc. In one embodiment, the constraint structure has a configuration and / or structure selected to resist at least one of the growth, enlargement, and / or expansion of the electrode assembly 106, which could otherwise occur when the secondary battery 102 cycles repeatedly between a charging state and a discharging state. Specifically, during the transition from a discharging state to a charging state, carrier ions (e.g., one or more of lithium, sodium, potassium, calcium, and magnesium) move between the positive and negative electrodes in the battery. Upon reaching the electrode, the carrier ions can then be intercalated or alloyed into the electrode material, thereby increasing the size and volume of the electrode. Conversely, the transition from a charging state to a discharging state can result in ion deintercalation or dealloying, causing the electrode to shrink. Such alloying and / or intercalation, as well as dealloying and / or deintercalation, can lead to significant changes in the volume of the electrode. In yet another embodiment, the transport of carrier ions away from the electrode can increase the size of the electrode, for example, by increasing the electrostatic repulsion of the remaining material layer (e.g., using LCO and some other materials). Other mechanisms that can lead to an increase in the size of the secondary battery 102 may include, for example, the formation of an SEI on the electrodes, the decomposition of the electrolyte and other components, or even gas formation. Therefore, the repeated expansion and contraction of the electrodes during charging and discharging, as well as other enlargement mechanisms, can cause strain in the electrode assembly 106, which can degrade the performance of the secondary battery and ultimately even lead to its failure.

[0084] refer to Figures 2A to 2C The effects of repeated expansion and / or contraction of the electrode assembly 106 according to embodiments of the present disclosure can be described. Figure 2A An embodiment of a three-dimensional electrode assembly 106 is shown, having a group of electrode structures 110 and a group of counter electrode structures 112 (e.g., a group of anode structures and a group of cathode structures, respectively). The three-dimensional electrode assembly 106 in this embodiment provides an alternating set of electrode structures 110 and counter electrode structures 112, which are interleaved and, Figure 2A In the embodiment shown, a longitudinal axis A parallel to the Y-axis is provided. EA A transverse axis parallel to the X-axis (not shown), and a vertical axis parallel to the Z-axis (not shown). The X, Y, and Z axes shown herein are arbitrary axes, used only to illustrate a basis set in which the axes are perpendicular to each other in reference space, and do not in any way limit the structures herein to a particular orientation. During charge and discharge cycles of the secondary battery 102 having electrode assembly 106, carrier ions travel between the electrode and counter electrode structures 110 and 112, respectively, typically in a direction parallel to the Y-axis, such as... Figure 2AAs shown in the embodiments illustrated, it can be embedded in one or more of the electrode materials of electrode structure 110 and counter electrode structure 112 located in the direction of travel. The effect of carrier ion embedding and / or alloying into the electrode material can... Figures 2B to 2C As seen in the illustrated embodiment. Specifically, Figure 2B An embodiment of an electrode assembly 106 in which the electrode structure 110 is in a relatively unexpanded state is shown, for example, before the secondary battery 106 repeatedly cycles between a charging state and a discharging state. For comparison, Figure 2C An embodiment of an electrode assembly 106 having an electrode structure 110 after a predetermined number of cycles of repeated cycling in a secondary battery is shown. As illustrated, the size of the electrode structure 110 can be significantly increased in the stacking direction (e.g., the Y direction) due to carrier ion intercalation and / or alloying into the electrode material or other mechanisms as described above. The size of the electrode structure 110 can also be significantly increased in another direction, for example, in the Z direction (…). Figure 2C (Not shown in the image). Furthermore, the increased size of the electrode structure 110 can lead to deformation of the internal structures of the electrode assembly, such as deformation of the counter electrode structure 112 and the spacer 130 within the assembly, to accommodate the expansion of the electrode structure 110. The expansion of the electrode structure 110 can ultimately cause the electrode assembly 106 to bulge and / or warp at its longitudinal ends, such as... Figure 2C As shown in the illustrated embodiment (and in other directions, such as the top and bottom surfaces in the Z direction). Therefore, due to the insertion and deintercalation of carrier ions during the charging and discharging process, the electrode assembly 106 according to one embodiment may exhibit significant expansion and contraction along the longitudinal direction (Y-axis) and other axes of the assembly 106.

[0085] Therefore, in one embodiment, a primary growth constraint system 151 is provided to mitigate and / or reduce at least one of the growth, expansion, and / or enlargement of the electrode assembly 106 in the longitudinal direction (i.e., in the direction parallel to the Y-axis), such as in, for example Figure 1AAs shown in the diagram. For example, the primary growth constraint system 151 may include a structure configured to constrain growth by opposing expansions at longitudinal end surfaces 116, 118 of the electrode assembly 106. In one embodiment, the primary growth constraint system 151 includes first and second primary growth constraint members 154, 156, which are longitudinally separated from each other and operate with at least one primary connecting member 162 that connects the first and second primary growth constraint members 154, 156 together to suppress growth of the electrode assembly 106. For example, the first and second primary growth constraint members 154, 156 may at least partially cover the first and second longitudinal end surfaces 116, 118 of the electrode assembly 106 and may operate with connecting members 162, 164 that connect the primary growth constraint members 154, 156 to each other to resist and suppress any growth of the electrode assembly 106 that occurs during repeated charge and / or discharge cycles. Further discussion of embodiments and operation of the primary growth constraint system 151 is provided below in more detail.

[0086] Furthermore, the repeated cycles of charging and discharging of the secondary battery 102 not only affect the longitudinal direction of the electrode assembly 106 (e.g., Figure 2A The Y-axis in the model can induce growth and strain, and as described above, this can also be induced in directions orthogonal to the longitudinal direction, such as in the transverse and vertical directions (e.g., respectively). Figure 2A Growth and strain are induced in the X and Z axes (in the model). Furthermore, in some embodiments, including a primary growth constraint system 151 to suppress growth in one direction may even exacerbate growth and / or enlargement in one or more other directions. For example, when the primary growth constraint system 151 is configured to suppress growth of the electrode assembly 106 in the longitudinal direction, the embedding of carrier ions during charge and discharge cycles and the resulting increase in electrode structure can induce strain in one or more other directions. Specifically, in one embodiment, the strain resulting from the combination of electrode growth / enlargement and longitudinal growth constraint can cause the electrode assembly 106 to grow and strain in the vertical direction (e.g., the X and Z axes). Figure 2A On the Z-axis (as shown), or even in the lateral direction (e.g., Figure 2A Bending or other faults on the X-axis (as shown).

[0087] Therefore, in one embodiment of this disclosure, the secondary battery 102 includes not only a primary growth constraint system 151 but also at least one secondary growth constraint system 152, which can operate together with the primary growth constraint system 151 to suppress the growth of the electrode assembly 106 along multiple axes of the electrode assembly 106. For example, in one embodiment, the secondary growth constraint system 152 can be configured to interlock with or otherwise cooperate with the primary growth constraint system 151, thereby suppressing the overall growth of the electrode assembly 106 to improve the performance of the secondary battery having the electrode assembly 106 and the primary and secondary growth constraint systems 151 and 152, respectively, and to reduce its failure rate. Further discussion of embodiments of the interrelationship between the primary and secondary growth constraint systems 151 and 152, and their operation in suppressing the growth of the electrode assembly 106, is provided below in more detail.

[0088] As described above, constraining the growth of electrode assembly 106 means that the overall macroscopic increase in one or more dimensions of electrode assembly 106 is constrained. That is, the overall growth of electrode assembly 106 can be constrained such that even if volume changes of one or more electrodes within electrode assembly 106 may occur at a smaller (e.g., microscopic) scale during charge and discharge cycles, the increase of one or more dimensions of electrode assembly 106 along the (X, Y, and Z axes) can be controlled. Microscopic changes in electrode volume can be observed, for example, via scanning electron microscopy (SEM). While this set of electrode constraints 108 is able to suppress the growth of some individual electrodes at the microscopic level, some growth may still occur, although this growth can at least be constrained. The volume changes of individual electrodes during charge / discharge, while potentially small at the microscopic level for each individual electrode, still have the additional effect that results in a relatively large volume change of the entire electrode assembly 106 at the macroscopic level during cycles between charge and discharge states, which may cause strain within electrode assembly 106.

[0089] According to one embodiment, the electrode active material used in the electrode structure 110 corresponding to the anode of the electrode assembly 106 includes a material that expands when carrier ions are inserted into the electrode active material during the charging of the secondary battery 102. For example, the electrode active material may include an anode active material that accepts carrier ions (e.g., by intercalating or alloying the carrier ions in an amount sufficient to produce a volume increase in the electrode active material) during the charging of the secondary battery. For example, in one embodiment, when the secondary battery 102 is charged from a discharged state to a charged state, the electrode active material may include a material having a capacity to accept more than one mole of carrier ions per mole of electrode active material. As another example, the electrode active material may include a material having a capacity to accept 1.5 moles or more of carrier ions per mole of electrode active material, such as 2.0 moles or more of carrier ions per mole of electrode active material, or even 2.5 moles or more of carrier ions per mole of electrode active material, such as 3.5 moles or more of carrier ions per mole of electrode active material. The carrier ions accepted by the electrode active material may be at least one of lithium, potassium, sodium, calcium, and magnesium. Examples of electrode active materials that provide such volume change through expansion include one or more of silicon (e.g., SiO), aluminum, tin, zinc, silver, antimony, bismuth, gold, platinum, germanium, palladium, and their alloys and compounds. For example, in one embodiment, the electrode active material may include a silicon-containing material in particulate form, such as one or more of particulate silicon, particulate silicon oxide, and mixtures thereof. In yet another embodiment, the electrode active material may include a material exhibiting small or even negligible volume change. For example, in one embodiment, the electrode active material may include a carbon-containing material such as graphite. In yet another embodiment, the electrode structure includes a lithium layer that serves as the electrode active material layer.

[0090] Another embodiment of this disclosure may include an energy storage device 100 including electrode assembly 106, such as a secondary battery 102 and / or a structure therefor, which does not include a restraint system, or is restrained by a restraint system other than the set of electrode restraints 108 described herein.

[0091] Electrode assembly

[0092] Reference again Figure 1B and Figure 2A In one embodiment, the electrode assembly 106 includes a group of electrode structures 110, a group of counter electrode structures 112, and an electrically insulating separator 130 that electrically insulates the electrode structures 110 from the counter electrode structures 112. In one example, such as Figure 1B As shown, the electrode assembly includes a series of stacked layers 800, which include alternately arranged electrode structures 110 and counter electrode structures. Figure 1C It is shown that has Figure 1BAn illustration of the secondary battery with electrode assembly 106, and Figure 1D Is a Figure 1B The cross-section of the secondary battery of electrode assembly 106. As yet another example, in... Figure 2A In the illustrated embodiment, the electrode assembly 106 includes an interdigitated electrode assembly 106 having interdigitated electrode and counter electrode structures.

[0093] Furthermore, as used herein, for each embodiment of a material or structure described using the term "electrode," such as "electrode structure" or "electrode active material," it should be understood that such structure and / or material may correspond in some embodiments to a "negative electrode" structure and / or material, such as "negative electrode structure" or "negative electrode active material." Similarly, as used herein, for each embodiment of a material or structure described using the term "counter electrode," such as "counter electrode structure" or "counter electrode active material," it should be understood that such structure and / or material may correspond in some embodiments to a "positive electrode" structure and / or material, such as "positive electrode structure" or "positive electrode active material." That is, where appropriate, any embodiment described with respect to an electrode and / or counter electrode may correspond to the same embodiment in which the electrode and / or counter electrode are specifically negative and / or positive electrodes, including their respective structures and materials.

[0094] In one embodiment, the electrode structure 110 includes an electrode active material layer 132, an electrode backbone 134 supporting the electrode active material layer 132, and an electrode current collector 136. The electrode current collector may be an ion-porous current collector to allow ions to pass through, such as... Figure 7 As illustrated in the embodiments shown. For example, in one embodiment, electrode structure 110 may include an anode structure having an anode active material layer, an anode backbone, and an anode current collector. In yet another embodiment, as... Figure 1B As shown, electrode structure 110 may include an anode structure having an anode current collector 136 and an anode active material layer 132. For example, the anode current collector 136 may include an anode current collector layer disposed between one or more anode active material layers. In yet another embodiment, electrode structure 110 may include a single-layer material, such as a lithium sheet electrode. Similarly, in one embodiment, counter electrode structure 112 includes a counter electrode active material layer 138, a counter electrode current collector 140, and a counter electrode backbone 141 supporting one or more of the counter electrode current collector 140 and / or the counter electrode active material layer 138, for example in... Figure 7As shown in the embodiments illustrated. For example, in one embodiment, the counter electrode structure 112 may include a cathode structure comprising a cathode active material layer, a cathode current collector, and a cathode backbone. In yet another embodiment, the counter electrode structure 110 may include a cathode structure having a cathode current collector 140 and a cathode active material layer 138, such as... Figure 1B As shown. The electrically insulating microporous separator 130 allows carrier ions to pass through during charging and / or discharging to travel between the electrode structure 110 and the counter electrode structure 112 in the electrode assembly 106. Furthermore, it should be understood that the electrode and counter electrode structures 110 and 112 are not limited to the specific embodiments and structures described herein, and other configurations, structures, and / or materials other than those specifically described herein can be provided to form the electrode structure 110 and the counter electrode structure 112. For example, the electrode and counter electrode structures 110, 112 can be provided in a form in which the electrode and counter electrode structures substantially lack any electrode and / or counter electrode backbones 134, 141, as... Figure 1B In cases where, for example, the regions of the electrode and / or counter electrode structures 110, 112 that would otherwise contain the backbone are instead made of electrode active material and / or counter electrode active material.

[0095] according to Figure 1B and 2A In the illustrated embodiment, the components of groups 110 and 112 of the electrode and counter electrode structures are arranged in an alternating order, the direction of which corresponds to the stacking direction D. The electrode assembly 106 according to this embodiment further includes mutually perpendicular longitudinal, transverse, and vertical axes, with longitudinal axis A... EA This typically corresponds to or is parallel to the stacking direction D of the components in the electrode and counter-electrode structure group. For example... Figure 2A As shown in the embodiment, the longitudinal axis A EA The axes are shown as corresponding to the Y-axis, the horizontal axis as corresponding to the X-axis, and the vertical axis as corresponding to the Z-axis. (Although this document references...) Figure 2A This description is intended to describe various features, including dimensions and axes for the secondary battery and electrode assembly; however, it should be understood that this description also applies to embodiments depicted in other figures herein, including... Figures 1B to 1D Examples of implementations.

[0096] Furthermore, the electrode assembly 106 has a maximum width W measured in the longitudinal direction (i.e., along the y-axis). EA The maximum length L defined by the transverse surface and measured in the transverse direction (i.e., along the x-axis). EA And the maximum height H, which is also defined by the transverse surface and measured in the vertical direction (i.e., along the z-axis). EA Maximum width W EAThis can be understood as corresponding to the maximum width of the electrode assembly 106 measured from relative points on the longitudinal end surfaces 116, 118, where the electrode assembly is widest in the longitudinal direction. For example, refer to... Figure 2A In an embodiment of electrode assembly 106, the maximum width W EA This can be understood as simply corresponding to the width of component 106 measured in the longitudinal direction. However, reference Figure 3H As can be seen from the embodiment of electrode assembly 106 shown, the maximum width W EA The width of the electrode assembly, measured from two opposing points 300a and 300b at its widest point in the longitudinal direction, is the opposite of the width measured from opposing points 301a and 301b at the narrowest point of the electrode assembly 106. Similarly, the maximum length L EA This can be understood as the maximum length of the electrode assembly measured from a relative point on the lateral surface 142 of the electrode assembly 106, which is at its longest point in the lateral direction. (Refer to again...) Figure 2A In the embodiment described, the maximum length L EA This can be simply understood as the length of the electrode assembly 106, while Figure 3H In the embodiment shown, the maximum length L EA The length of the electrode assembly, measured from two opposite points 302a and 302b at its longest point in the lateral direction, corresponds to the length measured from opposite points 303a and 303b at its shortest point. Along a similar line, the maximum height H... EA This can be understood as the maximum height of the electrode assembly measured from a relative point on the transverse surface 143 of the electrode assembly at its highest point in the vertical direction. That is, in Figure 2A In the embodiment shown, the maximum height H EA Simply put, it's the height of the electrode assembly. Although not in Figure 3H The illustrated embodiment specifically shows that, however, if the electrode assembly has different heights at points in one or more of the longitudinal and transverse directions, the maximum height H of the electrode assembly is... EA This will be understood as corresponding to the height of the electrode assembly measured from two relative points at its highest point in the vertical direction, in contrast to the height measured from a relative point at the shorter end of the electrode assembly. This is consistent with the maximum width W. EA and maximum length L EA Similarly, the maximum length L of the electrode assembly 106 is described. EA Maximum width W EA and maximum height H EAThe design can vary depending on the energy storage device 100 and its intended use. For example, in one embodiment, the electrode assembly 106 may include a maximum length L typical of conventional secondary battery sizes. EA Maximum width W EA and maximum height H EA As another example, in one embodiment, the electrode assembly 106 may include a maximum length L typical of thin-film battery dimensions. EA Maximum width W EA and maximum height H EA .

[0097] In some embodiments, size L is selected. EA W EA and H EA To provide a maximum height H that is greater than that along the vertical axis (Z-axis) EA The maximum length L along the horizontal axis (X-axis) EA And / or the maximum width W along the longitudinal axis (Y-axis) EA Electrode assembly 106. For example, in Figure 2A In the embodiment shown, size L is selected. EA W EA and H EA An electrode assembly 106 is provided with a maximum dimension having a transverse axis (X-axis) orthogonal to the electrode structure stacking direction D, and a longitudinal axis (Y-axis) coinciding with the electrode structure stacking direction D. That is, a maximum length L... EA and / or maximum width W EA It can be greater than the maximum height H EA For example, in one embodiment, the maximum length L EA With maximum height H EA The ratio can be at least 2:1. As another example, in one embodiment, the maximum length L EA With maximum height H EA The ratio can be at least 5:1. As another example, in one embodiment, the maximum length L EA With maximum height H EA The ratio can be at least 10:1. As another example, in one embodiment, the maximum length L EA With maximum height H EA The ratio can be at least 15:1. As another example, in one embodiment, the maximum length L EA With maximum height H EA The ratio can be at least 20:1. Different ratios in different dimensions can allow for optimal configuration within the energy storage device to maximize the amount of active material, thereby increasing energy density.

[0098] In some embodiments, the maximum width W can be selected.EA To provide a height greater than the maximum height H EA The width of the electrode assembly 106. For example, in one embodiment, the maximum width W EA With maximum height H EA The ratio can be at least 2:1. As another example, in one embodiment, the maximum width W EA With maximum height H EA The ratio can be at least 5:1. As another example, in one embodiment, the maximum width W EA With maximum height H EA The ratio can be at least 10:1. As another example, in one embodiment, the maximum width W EA With maximum height H EA The ratio can be at least 15:1. As another example, in one embodiment, the maximum width W EA With maximum height H EA The ratio can be at least 20:1.

[0099] According to one embodiment, the maximum width W can be selected. EA With the maximum length L EA The ratio is adjusted so that it remains within a predetermined range to provide an optimal configuration. For example, in one embodiment, the maximum width W... EA With the maximum length L EA The ratio can range from 1:5 to 5:1. As another example, in one embodiment, the maximum width W EA With the maximum length L EA The ratio can range from 1:3 to 3:1. As yet another example, in one embodiment, the maximum width W EA With the maximum length L EA The ratio can be in the range of 1:2 to 2:1.

[0100] exist Figure 1B and 2A In the illustrated embodiment, the electrode assembly 106 has a first longitudinal end surface 116 and an opposing second longitudinal end surface 118, the second longitudinal end surface 118 being along the longitudinal axis A. EA Separated from the first longitudinal end surface 116. The electrode assembly 106 further includes a transverse surface 142, which at least partially surrounds the longitudinal axis A. EA And connects the first and second longitudinal end surfaces 116, 118. In one embodiment, the maximum width W EA It is along the longitudinal axis A EA The dimensions measured from the first longitudinal end surface 116 to the second longitudinal end surface 118. Similarly, the maximum length L EAThe transverse surface 142 may be defined, and in one embodiment, it may be a dimension measured from opposing first and second regions 144 of the transverse surface 142 along a transverse axis orthogonal to the longitudinal axis. In one embodiment, the maximum height H EA It can be defined by the transverse surface 142 and can be measured from the opposite first and second regions 148, 150 of the transverse surface 142 along a vertical axis orthogonal to the longitudinal axis.

[0101] For clarity, Figure 2A The illustrated embodiment shows only four electrode structures 110 and four counter electrode structures 112, and in Figure 1B Only a limited number of electrode structures 110 and counter electrode structures are shown. In one embodiment, the alternation order of the components of the electrode and counter electrode structure groups 110 and 112 can each include any number of components from each group, depending on the energy storage device 100 and its intended use, and the alternation order of the components of the electrode and counter electrode structure groups 110 and 112 can be staggered, for example, as... Figure 2AAs shown. As another example, in one embodiment, each member of the electrode structure group 110 may be located between two members of the counter electrode structure group 112, except when the alternating sequence terminates along the stacking direction D. As another example, in one embodiment, each member of the counter electrode structure group 112 may be located between two members of the electrode structure group 110, except when the alternating sequence terminates along the stacking direction D. As another example, in one embodiment, and more generally, the electrode structure group 110 and the counter electrode structure group 112 each have N members, each of the N-1 electrode structure members 110 is located between two counter electrode structure members 112, each of the N-1 counter electrode structure members 112 is located between two electrode structure members 110, and N is at least 2. As another example, in one embodiment, N is at least 4. As another example, in one embodiment, N is at least 5. As another example, in one embodiment, N is at least 10. As another example, in one embodiment, N is at least 25. As another example, in one embodiment, N is at least 50. As another example, in one embodiment, N is at least 100 or more. In one embodiment, the components of the electrode and / or counter electrode group extend sufficiently from an imaginary backplate (e.g., a plane substantially coinciding with the surface of the electrode assembly) to have a surface area greater than twice the geometric footprint (i.e., projection) of the components in the backplate (ignoring porosity). In some embodiments, the ratio of the surface area of ​​the non-layered (i.e., three-dimensional) electrode and / or counter electrode structure to its geometric footprint in the imaginary backplate can be at least about 5, at least about 10, at least about 50, at least about 100, and / or even at least about 500. However, this ratio is typically between about 2 and about 1000. In one such embodiment, the components of the electrode group are inherently non-layered. As another example, in one such embodiment, the components of the counter electrode group are inherently non-layered. As another example, in one such embodiment, the components of both the electrode group and the counter electrode group are inherently non-layered.

[0102] According to one embodiment, the electrode assembly 106 has longitudinal ends 117, 119, at which it terminates. According to one embodiment, the alternating sequence of the electrode and counter electrode structures 110, 112 in the electrode assembly 106 terminates symmetrically along the longitudinal direction; for example, electrode structure 110 terminates at each end 117, 119 of the electrode assembly 106 in the longitudinal direction, or counter electrode structure 112 terminates at each end 117, 119 of the electrode assembly 106 in the longitudinal direction. In another embodiment, the alternating sequence of the electrode 110 and counter electrode structure 112 may terminate asymmetrically along the longitudinal direction; for example, electrode structure 110 terminates at longitudinal axis A. EA One end 117, and the counter electrode structure 112 terminate at the longitudinal axis AEA The other end 119. According to yet another embodiment, the electrode assembly 106 may terminate by having one or more substructures of electrode structure 110 and / or counter electrode structure 112 at one or more ends 117, 119 of the electrode assembly 106. As an example, according to one embodiment, the alternating sequence of electrode structure 110 and counter electrode structure 112 may terminate at one or more substructures of electrode 110 and counter electrode structure 112, wherein the substructures include electrode trunk 134, counter electrode trunk 141, electrode current collector 136, counter electrode current collector 140, electrode active material layer 132, counter electrode active material layer 138, etc., and may also terminate by having structures such as separator 130 and structures at each longitudinal end 117, 119 of the electrode assembly 106 be the same (symmetrical) or different (asymmetrical). The longitudinal terminals 117, 119 of the electrode assembly 106 may include first and second longitudinal end surfaces 116, 118, which contact the first and second primary growth constraints 154, 156 to constrain the overall growth of the electrode assembly 106.

[0103] According to yet another embodiment, the electrode assembly 106 has first and second lateral ends 145, 147 (see example...). Figure 1B and 2A The first and second lateral ends 145, 147 can be connected to one or more electrode and / or counter electrode tabs 190, 192 (see example). Figure 10 These contact tabs can be used to electrically connect electrode and / or counter electrode structures 110, 112 to a load and / or voltage source (not shown). For example, electrode assembly 106 may include electrode bus 194 (see example...). Figure 2A Each electrode structure 110 can be connected to the electrode bus 194, and the electrode bus 194 collects current from each component of the electrode structure group 110. Similarly, the electrode assembly 106 may include a counter electrode bus 196, each counter electrode structure 112 can be connected to the counter electrode bus 196, and the counter electrode bus 196 collects current from each component of the counter electrode structure group 112. The electrodes and / or counter electrode buses 194, 196 each have a length measured in direction D, and this length extends substantially over the entire length of the series of staggered electrode structures 110, 112. Figure 10In the illustrated embodiment, electrode connector 190 and / or counter electrode connector 192 include electrode connector extensions 191, 193 that are electrically connected to electrode and / or counter electrode buses 194, 196 and extend substantially along the entire length of the electrode and / or counter electrode buses 194, 196. Alternatively, electrode and / or counter electrode connectors 190, 192 may be directly connected to the electrode and / or counter electrode buses 194, 196 along their length, for example, at their ends or midpoints, without the need for connector extensions 191, 193. Thus, in one embodiment, electrode and / or counter electrode buses 194, 196 may form at least a portion of the terminals 145, 147 of the electrode assembly 106 in the lateral direction and connect the electrode assembly to connectors 190, 192 for electrical connection to a load and / or voltage source (not shown). Furthermore, in yet another embodiment, the electrode assembly 106 includes first and second terminals 149, 153 disposed along a vertical (Z) axis. For example, according to one embodiment, each electrode structure 110 and / or counter electrode structure 112 is provided with top and bottom coatings made of a separator material, such as... Figure 2A As shown, the coating forms the terminals 149, 153 of the electrode assembly 106 in the vertical direction. The terminals 149, 153, which may be formed by the coating of the separator material, may include first and second surface regions 148, 150 of the transverse surface 142 along the vertical axis, which may be configured to contact the first and second secondary growth constraints 158, 160 to constrain growth in the vertical direction.

[0104] Typically, electrode assembly 106 may include planar, coplanar, or nonplanar longitudinal end surfaces 116, 118. For example, in one embodiment, opposing longitudinal end surfaces 116, 118 may be convex. As another example, in one embodiment, opposing longitudinal end surfaces 116, 118 may be concave. As another example, in one embodiment, opposing longitudinal end surfaces 116, 118 are substantially planar. In some embodiments, electrode assembly 106 may include opposing longitudinal end surfaces 116, 118 that, when projected onto a plane, have any range of two-dimensional shapes. For example, longitudinal end surfaces 116, 118 may independently have smooth, curved shapes (e.g., circular, elliptical, hyperbolic, or parabolic), they may independently include a series of lines and vertices (e.g., polygons), or they may independently include smooth, curved shapes and include one or more lines and vertices. Similarly, the transverse surface 142 of the electrode assembly 106 may be a smooth, curved shape (e.g., the electrode assembly 106 may have a circular, elliptical, hyperbolic, or parabolic cross-sectional shape) or the transverse surface 142 may include two or more lines connecting at the vertices (e.g., the electrode assembly 106 may have a polygonal cross-section). For example, in one embodiment, the electrode assembly 106 has a cylindrical, elliptical, parabolic, or hyperbolic cylindrical shape. As another example, in one such embodiment, the electrode assembly 106 may have a prism shape, with opposing longitudinal end surfaces 116, 118 of the same size and shape and a transverse surface 142 that is a parallelogram (i.e., a face extending between opposing longitudinal end surfaces 116 and 118). As another example, in one such embodiment, the electrode assembly 106 has a shape corresponding to a triangular prism, with two opposing triangular longitudinal end surfaces 116 and 118 and a transverse surface 142 consisting of three parallelograms (e.g., rectangles) extending between the two longitudinal ends. As another example, in one such embodiment, the electrode assembly 106 has a shape corresponding to a rectangular prism, having two opposing rectangular longitudinal end surfaces 116 and 118 and a transverse surface 142 comprising four parallelogram (e.g., rectangular) faces. As another example, in one such embodiment, the electrode assembly 106 has a shape corresponding to a pentagonal prism, hexagonal prism, etc., wherein the electrode assembly 106 has two opposing longitudinal end surfaces 116 and 118, respectively pentagonal, hexagonal, etc., and a transverse surface comprising five, six, etc., parallelogram (e.g., rectangular) faces.

[0105] Now refer to Figures 3A to 3H The diagram schematically illustrates several exemplary geometries of the electrode assembly 106. More specifically, in Figure 3AIn the middle, the electrode assembly 106 has a triangular prism shape, which has a longitudinal axis A EA Separated opposing first and second longitudinal end surfaces 116, 118, and including connecting longitudinal end surfaces 116, 118 and surrounding longitudinal axis A EA The transverse surface 142 of the three rectangular faces. Figure 3B In the middle, the electrode assembly 106 has a parallelepiped shape, which has a longitudinal axis A EA Separated opposing first and second parallelogram longitudinal end surfaces 116, 118, and including the connection between the two longitudinal end surfaces 116, 118 and surrounding the longitudinal axis A EA The transverse surface 142 of the four parallelogram faces. Figure 3C In the middle, the electrode assembly 106 has a rectangular prism shape, which has a longitudinal axis A EA Separated opposing first and second rectangular longitudinal end surfaces 116, 118, and including the connection between the two longitudinal end surfaces 116, 118 and surrounding the longitudinal axis A EA The transverse surface 142 of the four rectangular faces. Figure 3D In the middle, the electrode assembly 106 has a pentagonal prism shape, which has a longitudinal axis A EA Separated opposing first and second pentagonal longitudinal end surfaces 116, 118, and including the connection between the two longitudinal end surfaces 116, 118 and surrounding the longitudinal axis A EA The transverse surface 142 of the five rectangular faces. Figure 3E In the middle, the electrode assembly 106 has a hexagonal prism shape, which has a longitudinal axis A EA Separated opposing first and second hexagonal longitudinal end surfaces 116, 118, and including the connection between the two longitudinal end surfaces 116, 118 and surrounding the longitudinal axis A EA The transverse surface 142 of the six rectangular faces. Figure 3E In the middle, the electrode assembly has a square truncated cone shape, which has a longitudinal axis A EA Separated opposing first and second square end surfaces 116, 118, and including connecting the two longitudinal end surfaces 116, 118 and surrounding the longitudinal axis A EA The four trapezoidal surfaces have a transverse surface 142, wherein the trapezoidal surfaces gradually taper in size along the longitudinal axis, changing from a larger size at the first surface 116 to a smaller size at the second surface 118, and the size of the second surface is smaller than the size of the first surface. Figure 3F In the middle, the electrode assembly has a pentagonal truncated cone shape, which has a longitudinal axis A EA Separated opposing first and second square end surfaces 116, 118, and including connecting the two longitudinal end surfaces 116, 118 and surrounding the longitudinal axis A EAThe five trapezoidal surfaces have a transverse surface 142, wherein the trapezoidal surfaces gradually taper in size along the longitudinal axis, changing from a larger size at the first surface 116 to a smaller size at the second surface 118, and the size of the second surface is smaller than the size of the first surface. Figure 3H In the process, by means of electrode and counter electrode structures 110, 112, electrode assembly 106 has a pyramid shape in the longitudinal direction, and the length of the electrode and counter electrode structures decreases along the longitudinal axis from a first length toward the middle of electrode assembly 106 to a second length at the longitudinal ends 117, 119 of electrode assembly 106.

[0106] Electrode / counter electrode separation distance

[0107] In one embodiment, the electrode assembly 106 has an electrode structure 110 and a counter electrode structure 112, wherein the offset in height (vertical direction) and / or length (lateral direction) between adjacent electrode structures and counter electrode structures 110, 112 is selected within a predetermined range for the electrode active material layer 132 and the counter electrode material layer 138. By way of illustration, Figure 14A An embodiment depicting a cross-section of an electrode assembly 106 includes an electrode active material layer 132 of an electrode structure 110 adjacent to a counter electrode active material layer 138 of a counter electrode structure 112, with a microporous separator 130 therebetween. In the cross-sectional view shown, the height of the electrode active material layer 132 in the z-direction is approximately equal to the height of the counter electrode active material layer 138 in the z-direction. A structure with electrode active material layers 132 and 138 of equal height can be beneficial in terms of matching the capacity of carrier ions between layers, thereby increasing the storage capacity of a secondary battery 102 with layers of equal height. However, such equal-height layers also present problems. Specifically, for a counter electrode active material layer 138 with a height excessively close to that of the electrode active material layer 132, carrier ions may be attracted to the vertical end surface 500 of the electrode active material layer 132 and / or the exposed portion of the electrode current collector 136 forming part of the electrode structure 110. The result could be the precipitation of carrier ions and / or the formation of dendrites, which could ultimately lead to performance degradation and / or battery failure. Although the height of the cathode active material layer 138 could be reduced relative to the electrode active material layer 34 to mitigate this problem, excessive dimensional inequality affects the storage capacity and functionality of the secondary battery. Furthermore, even when offset or separation distances are provided between layers 138, 132, it is possible that, for example, during the use or transport of the secondary battery 106, mechanical shocks or impacts to the secondary battery with these layers could move and alter the alignment of layers 138, 132, making any original offset and / or separation distance between the layers negligible or even eliminated.

[0108] Accordingly, aspects of this disclosure relate to the following findings: by providing a set of constraints 108 (e.g., a set of constraints corresponding to any embodiment described herein), alignment between layers 138, 132 in the electrode structure 110 and the counter electrode structure 112 can be maintained even under physical and mechanical stresses encountered during normal use or transportation of the secondary battery. Therefore, a sufficiently small predetermined offset and / or separation distance can be selected to provide good storage capacity for the secondary battery 106 while also reducing the risk of battery short circuits or failures, wherein the predetermined offset is as small as 5 μm and typically does not exceed 500 μm.

[0109] refer to Figures 14A-14H Other aspects according to this disclosure are described. Specifically, it should be noted that the electrode assembly 106 includes a group of electrode structures 110, a group of electrode current collectors 136, a group of spacers 130, a group of counter electrode structures 112, a group of counter electrode current collectors 140, and a group of unit cells 504. (See reference...) Figure 1B and 2A As shown, the components of the electrode and counter electrode structure group are arranged in an alternating order in the longitudinal direction. Each component of the electrode structure group 110 includes an electrode current collector 136 and an electrode active material layer 132, the length of which is L. E Corresponding to the Ferrette diameter measured in the lateral direction between the first and second opposing lateral end surfaces 502a, b of the electrode active material layer (see, for example, see...). Figure 15A Height H E Corresponding to the Ferrette diameter of the electrode active material layer 132 measured in the vertical direction between the first and second opposing vertical end surfaces 500a, b of the electrode active material layer 132, this height is measured in the vertical direction between the opposing first and second vertical end surfaces 500a, b of the electrode active material layer (e.g., see...). Figure 17 Each component of the electrode structure 110 also has an electrode active material layer 132, the width of which is W. E Corresponding to the Ferrette diameter of the electrode active material layer 132 measured in the longitudinal direction between the first and second opposing surfaces of the electrode active material layer (e.g., see...). Figure 14A Each component in the counter electrode structure group also includes a counter electrode current collector 140 and a counter electrode active material layer 138, the length of which is L. C Corresponding to the Freette diameter of the counter electrode active material measured in the lateral direction between the first and second opposing lateral end surfaces 503a, b of the counter electrode active material layer 138 (e.g., see...). Figure 15A ), and height H CCorresponding to the Ferrette diameter measured in the vertical direction between the first and second opposing vertical end surfaces 501a, 501b of the counter electrode active material layer 138 (see, for example, [reference]). Figure 17 Each component of the counter electrode structure group 112 also has a counter electrode active material layer 138, the width of which is W. C Corresponding to the Freette diameter of the counter electrode active material layer 138 measured in the longitudinal direction between the first and second opposing surfaces of the electrode active material layer (e.g., see...). Figure 14A ).

[0110] As defined above, the Ferrette diameter of the electrode active material layer 132 in the lateral direction is the distance measured in the lateral direction between two parallel planes that restrict the electrode active material layer in a direction perpendicular to the lateral direction. The Ferrette diameter of the electrode active material layer 132 in the vertical direction is the distance measured in the vertical direction between two parallel planes that restrict the electrode active material layer in a direction perpendicular to the vertical direction. The Ferrette diameter of the counter electrode active material layer 138 in the lateral direction is the distance measured in the lateral direction between two parallel planes that restrict the counter electrode active material layer in a direction perpendicular to the lateral direction. The Ferrette diameter of the counter electrode active material layer 138 in the vertical direction is the distance measured in the vertical direction between two parallel planes that restrict the counter electrode active material layer in a direction perpendicular to the vertical direction. For illustrative purposes, Figure 13A and 13B The Freette diameters of the electrode active material layer 132 and / or the counter electrode active material layer 138, defined in a single 2D plane, are depicted. Specifically, Figure 13A 2D slices of electrode active material layer 132 and / or the electrode active material layer, taken along the ZY plane, are depicted. The distance between the two parallel XY planes (505a, 505b) confining the layer in the z-direction (vertical direction) corresponds to the height of layer H in that plane (i.e., H). E or H C That is, the Ferret diameter in the vertical direction can be understood as a measure corresponding to the maximum height of that layer. Although Figure 13A The description in the text refers only to 2D slices. For illustrative purposes, it can be understood that in 3D space, the Fretter diameter in the vertical direction is not limited to a single slice, but rather the distance between XY planes 505a and 505b, which are vertically separated and constrain the three-dimensional layers within them. Similarly, Figure 13B 2D slices of electrode active material layer 132 and / or counter electrode active material layer 138, taken along the XZ plane, are depicted. The distance between the two parallel ZY planes (505c, 505d) confining the layers in the x-direction (lateral direction) corresponds to layer L in the plane (i.e., L...). E or LC The length of the layer. That is, the Ferrette diameter in the lateral direction can be understood as a measure corresponding to the maximum length of that layer. Although Figure 13B The description herein refers only to 2D slices. For illustrative purposes, it is understood that in 3D space, the Freette diameter in the lateral direction is not limited to a single slice, but rather to the distance between the ZY planes 505c and 505d, which are separated from each other in the lateral direction and constrain the three-dimensional layers therein. The Freette diameters of the electrode active material layer and / or the counter-electrode active material in the longitudinal direction can be obtained similarly to obtain the width W of the electrode active material layer 132. E and / or the width W of the electrode active material layer 138 C .

[0111] In one embodiment, as described elsewhere herein, electrode assembly 106 can be understood as having a transverse axis, a longitudinal axis, and a vertical axis that are perpendicular to each other and correspond to the x, y, and z axes of a hypothetical three-dimensional Cartesian coordinate system, a first longitudinal end surface and a second longitudinal end surface that are separated from each other in the longitudinal direction, and a longitudinal axis A around the electrode assembly. EA The electrode assembly connects the first longitudinal end surface and the second longitudinal end surface to a transverse surface, the transverse surface having opposing first and second regions located on opposite sides of the longitudinal axis and separated in a first direction orthogonal to the longitudinal axis, and having a maximum width W measured in the longitudinal direction. EA The maximum length L defined by the transverse surface and measured in the transverse direction EA and the maximum height H defined by the transverse surface and measured in the vertical direction. EA .

[0112] Reference again Figures 14A to 14H As can be seen, each unit cell 504 includes a unit cell portion of the first electrode current collector 136 of the electrode current collector group, a separator 130 that is ion-permeable to the carrier ions (e.g., a separator comprising a porous material), a first electrode active material layer 132 of a component in the electrode group, a unit cell portion of the first pair electrode current collector 140 of the electrode current collector group, and a first pair electrode active material layer 138 of a component in the electrode group. In one embodiment, in the case of consecutive and / or adjacent components 504a, 504b, 504c in the unit cell group (e.g., as... Figure 18A As shown), at least a portion of electrode current collector 136 and / or the electrode current collector can be shared between units (504a and 504b, and 504b and 504c). For example, see reference... Figure 18AAs can be seen, unit cells 504a and 504b share the counter electrode current collector 140, while unit cells 504b and 504c share the electrode current collector 136. In one embodiment, each unit cell includes half of the shared current collector, although other structural arrangements may also be provided. According to yet another embodiment, for the current collector forming part of the terminal unit cell at the longitudinal end of the electrode assembly 106, unit cell 504 may include a non-shared current collector, and thus include the entire current collector as part of the unit.

[0113] In addition, refer to again Figures 14A to 14H as well as Figure 18A As can be seen from the unit cells 504, within each unit cell 504, the first electrode active material layer 132a is close to the first side 506a of the separator 130, and the first pair of electrode material layers 138a is close to the opposite second side 506b of the separator 130. Figure 18A As shown in the embodiments, electrode structure 110 includes both a first electrode active material layer 132a forming a portion of unit cell 504a in the longitudinal direction and a second electrode active material layer 132b forming a portion of the next adjacent unit cell 504a. Similarly, counter electrode structure 112 includes a first counter electrode active material layer 138a forming a portion of unit cell 504a in the longitudinal direction and a second counter electrode active material layer 138b forming a portion of the next adjacent unit cell 504b. A separator 130 electrically isolates the first electrode active material layer 132a from the first counter electrode active material layer 138a, and during battery cycling between charge and discharge states, carrier ions are exchanged between the first electrode active material layer 132a and the first counter electrode active material layer 138a via the separator 130 of each such unit cell 504.

[0114] To further clarify the offset and / or separation distance between the first electrode active material layer 132a and the first pair of electrode active material layers 138a in each unit cell 504, please refer to... Figure 11A -C and 12A-C. For details, see reference [link / reference]. Figure 11A -C describes the offset and / or separation distance in the vertical direction. As in this embodiment... Figure 11A As shown, the first vertical end surfaces 500a and 501a of the electrode and counter electrode active material layers 132 and 138 are on the same side of the electrode assembly 106. Furthermore, the median vertical position of the first opposing vertical end surfaces 500a of the electrode active material 132 extends along the length L of the electrode active material layer in the XZ plane. E The 2D drawing depicts the surface of the first vertical end, E. VP1 In other words, as referenced... Figure 11CAs shown, for each ZY plane along the lateral direction (X), the median vertical position (z position) of the vertical end surface 500a of the electrode active material layer 132 can be determined as follows: that is, the median z position of the surface as a function of y is obtained at a specific lateral position (e.g., X1, X2, X3, etc.) of the ZY plane. Figure 11C The overall description illustrates an example of a line, showing the median vertical position (z-position) of the vertical end surface 500a of a specific ZY plane at a selected x-slice (e.g., the slice at X1). (Note that...) Figure 11C The determination of the median vertical position of the vertical end surfaces (dashed lines at the top and bottom of the figure) is generally described, namely, the determination of the median vertical position of the first vertical end surface 500a and the second vertical end surface 500b of the electrode active material layer 132, and / or the determination of the median vertical position of the first vertical end surface 501a and the second vertical end surface 501b of the electrode active material layer 138. Figure 11B An embodiment is depicted, wherein along the length L of the electrode active material E (that is, along length L) E The 2D plot of the median vertical position (determined at each x-position X1, X2, X3) shows the first vertical end surface plot E. VP1 First vertical end surface diagram E VP1 This corresponds to the median vertical position (z-position) plotted as a function of x (e.g., at X1, X2, X3, etc.). For example, for X corresponding to the first lateral end of the electrode active material layer... 0E X at the second lateral end of the electrode active material layer LE The x-position can be plotted as a function of x (lateral position) of the median vertical position of the vertical end surface 500a of the electrode active material layer 132, where X... LE -X L0 Equivalent to the Freette diameter of the electrode active material layer 132 in the transverse direction (the length L of the electrode active material layer 132) E ).

[0115] Similarly, in the case of the first opposing end surface 501a of the counter electrode active material layer 138, the median vertical position of the first opposing vertical end surface 501a of the counter electrode active material layer 138 along the length L of the counter electrode active material layer 138 in the XZ plane. C The 2D drawing depicts the surface of the first vertical end, CE. VP1 See again Figure 11CIt can be understood that for each ZY plane along the lateral direction, the median vertical position (z position) of the vertical end surface 501a of the electrode active material layer 138 can be determined as follows: by obtaining the median z position of the surface as a function of y at a specific lateral position (e.g., X1, X2, X3, etc.) in the ZY plane. Figure 11C An example of a line is generally depicted, showing the median vertical position (z position) of the vertical end surface 501a of a specific YZ plane at a selected x-slice (e.g., the slice at X1). Figure 11B One embodiment is depicted, wherein along the length L of the counter electrode active material C (that is, along length L) C The 2D diagram of the median vertical position (determined at each x-position X1, X2, X3) depicts the first vertical end surface map CE. VP1 First vertical end surface diagram CE VP1 This corresponds to the median vertical position (z-position) plotted as a function of x (e.g., at X1, X2, X3, etc.). For example, for X corresponding to the first lateral end of the active material layer of the counter electrode. 0c X at the second lateral end of the active material layer of the counter electrode Lc The x-position can be plotted as a function of x (lateral position) of the median vertical position of the vertical end surface 501a of the counter electrode active material layer 138, where X Lc -X L0 Equivalent to the Freette diameter of the counter electrode active material layer 138 in the transverse direction (the length L of the counter electrode active material layer 138). C ).

[0116] Furthermore, the offset and / or separation distance requirements for the vertical spacing between the first vertical surfaces 500a and 501a of the electrode active material layer 132 and the counter electrode active material layer 138 are as follows: for the length L of the first pair of electrode active material layers C At least 60% of: (i) curve E measured in the vertical direction VP1 and CE VP1 The separation distance S between them Z1 The absolute value is 1000μm≥|S Z1 |≥5μm. Additionally, in one embodiment, it is required that the length L of the first pair of electrode active material layers… C At least 60% of: (ii) for the first vertical end surfaces 500a, 500b of the electrode and counter electrode active material layers 132, 138, the first vertical end surface of the counter electrode active material layer is disposed inward (e.g., inward along 508) relative to the first vertical end surface of the electrode active material layer. That is, by reference Figure 11BIt can be seen that for the length L of the first pair of electrode active material layers 138 C At least 60%, that is, for X 0C to X LC At least 60% of the position x (60% of the Freret diameter of the electrode active material layer in the lateral direction), separation distance S Z1 The absolute value of the separation distance S must be no greater than 1000 μm and no less than 5 μm. Z1 The absolute value corresponds to the curve E at any given point along x. VP1 and CE VP1 The distance between them. Furthermore, it can be seen that for the length L of the first pair of electrode active material layers 138... C At least 60%, that is, for X 0C to X LC At least 60% of position x (60% of the Ferrette diameter of the counter electrode active material layer in the transverse direction), the first vertical end surface of the counter electrode active material layer is disposed inward relative to the first vertical end surface of the counter electrode active material layer.

[0117] In one embodiment, S Z1 The absolute value can be ≥5μm, for example ≥10μm, ≥15μm, ≥20μm, ≥35μm, ≥45μm, ≥50μm, ≥75μm, ≥100μm, ≥150μm, and ≥200μm. In another embodiment, S Z1 The absolute value can be ≤1000 micrometers, for example ≤500μm, for example ≤475μm, ≤425μm, ≤400μm, ≤375μm, ≤350μm, ≤325μm, ≤300μm, and ≤250μm. In one embodiment, S Z1 The absolute value can follow the relationship: 1000μm≥|S Z1 |≥5μm, and / or 500μm≥|S Z1 |≥10μm, and / or 250μm≥|S Z1 |≥20μm. In another embodiment, for the width W of the counter electrode active material layer 132 in the unit cell... E The Ferret diameter, S Z1 The absolute value can be 5×W E ≥|S Z1 |≥0.05×W E Within the range. Furthermore, in one embodiment, |S Z1 Any of the above values ​​and / or relationships can be applied to the length L of the first pair of electrode active material layers. C More than 60%, for example, the length L of the first pair of electrode active material layers. CAt least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or even at least 95%.

[0118] Furthermore, for X 0C To X LC At least 60% of position x (60% of the Ferrette diameter of the counter electrode active material layer in the transverse direction), the first vertical end surface of the counter electrode active material layer is disposed inward relative to the first vertical end surface of the counter electrode active material layer. That is, the electrode active material layer 132 can be understood as, for the length L of the counter electrode active material layer... C At least 60% of it has a median vertical position closer to the lateral surface than the counter electrode active material layer 130 (e.g., Figure 11C As shown, for a given X slice, the position on the z-axis in the YZ plane). In other words, the electrode active material layer 138 can be understood as having a median vertical position (e.g., a position further than the median vertical position of the electrode active material layer 132) along the inward direction 508 of the electrode assembly 106. Figure 11C As shown, for a given X slice, the position on the z-axis in the YZ plane. This vertical offset of the electrode active material layer 132 relative to the counter electrode active material layer 138 can also be related to... Figure 11A As seen in the embodiments, Figure 11A This shows that the height of the electrode material layer 132 exceeds the height of the counter electrode active material layer 138, and Figure 11B The curve shows the median vertical position E of the electrode active material layer 132. VP1 The vertical position CE, extending beyond the median of the active material layer of the counter electrode in the lateral direction. VP1 In one embodiment, for the length L of the first pair of electrode active material layers C More than 60%, for example, the length L of the first pair of electrode active material layers. C At least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or even at least 95%, of the first vertical end surface of the electrode active material layer is disposed inward relative to the first vertical end surface of the electrode active material layer.

[0119] In one embodiment, the separation distance S relative to the first vertical end surfaces 500a, 501a of the electrode and counter electrode active material layers 132, 138 z1 The above relationship can also determine the separation distance between the second vertical surfaces 500b and 501b of the electrode and the counter electrode active material layers 132 and 138 (e.g., as shown in the figure). Figure 18A(As shown). That is, the second vertical end surfaces 500b and 501b are on the same side of the electrode assembly 106 and are opposite to the first vertical end surfaces 500a and 501a of the electrode and counter electrode active material layers 132 and 138, respectively. Furthermore, similar to the separation distance and / or offset S given above... z1 The description states that the median vertical position of the second relatively vertical end surface 500b of the electrode active material 132 is along the length L of the electrode active material layer in the XZ plane. E The 2D diagram of the orientation depicts the second vertical end surface diagram E. VP2 In other words, as referenced... Figure 11A As shown in -C, for each YZ plane along the lateral direction, the median vertical position (z position) of the second vertical end surface 500b of the electrode active material layer 132 can be determined as follows: by obtaining the median z position of the surface as a function of y at a specific lateral position (e.g., X1, X2, X3, etc.) in the YZ plane. Figure 11C An example of a line is generally depicted, showing the median vertical position (z position) of the second vertical end surface 500b of a specific YZ plane at a selected x-slice (e.g., the slice at X1). Figure 11B An embodiment is depicted, wherein along the length L of the electrode active material E (that is, along length L) E The 2D plot of the median vertical position (determined at each x-position X1, X2, X3) shows the second vertical end surface plot E. VP2 Second vertical end surface diagram E VP2 This corresponds to the median vertical position (z-position) plotted as a function of x (e.g., at X1, X2, X3, etc.). For example, for X corresponding to the first lateral end of the electrode active material layer... 0E X at the second lateral end of the electrode active material layer LE The x-position can be plotted as a function of x (lateral position) of the median vertical position of the second vertical end surface 500b of the electrode active material layer 132, where X... LE -X L0 Equivalent to the Freette diameter of the electrode active material layer 132 in the transverse direction (the length L of the electrode active material layer 132) E ).

[0120] Similarly, in the case of the second opposite end surface 501b of the counter electrode active material layer 138, the median vertical position of the second opposite vertical end surface 501b of the counter electrode active material layer 138 along the length L of the counter electrode active material layer 138 in the XZ plane. C The 2D drawing depicts the second vertical end surface CE. VP2 See again Figures 11A to 11C It can be understood that for each YZ plane along the lateral direction, the median vertical position (z position) of the second vertical end surface 501b of the electrode active material layer 138 can be determined as follows: that is, the median z position of the surface as a function of y at a specific lateral position (e.g., X1, X2, X3, etc.) in the YZ plane is obtained. Figure 11C An example of a line is generally depicted, showing the median vertical position (z position) of the second vertical end surface 501b of a specific YZ plane at a selected x-slice (e.g., the slice at X1). Figure 11B One embodiment is depicted, wherein along the length L of the counter electrode active material C (that is, along length L) C The 2D diagram of the median vertical position (determined at each x-position X1, X2, X3) depicts the second vertical end surface map CE. VP2 , second vertical end surface diagram CE VP2 This corresponds to the median vertical position (z-position) plotted as a function of x (e.g., at X1, X2, X3, etc.). For example, for X corresponding to the first lateral end of the active material layer of the counter electrode. 0c X at the second lateral end of the active material layer of the counter electrode Lc The x-position can be plotted as a function of x (lateral position) of the median vertical position of the second vertical end surface 501b of the counter electrode active material layer 138, where X Lc -X L0 Equivalent to the Freette diameter of the counter electrode active material layer 138 in the transverse direction (the length L of the counter electrode active material layer 138). C ).

[0121] Furthermore, the offset and / or separation distance requirements between the vertical spacing of the electrode active material layer 132 and the second vertical surfaces 500b, 501b of the counter electrode active material layer 138, for the length L of the first pair of electrode active material layers, are as follows: C At least 60% of: (i) Figure E measured in the vertical direction VP2 and CE VP2 The separation distance S between them Z2 The absolute value is 1000μm≥|S Z2 |≥5μm. Additionally, in one embodiment, it is required that the length L of the first pair of electrode active material layers… C At least 60% of: (ii) for the second vertical end surfaces 500b, 501b of the electrode and counter electrode active material layers 132, 138, the second vertical end surface of the counter electrode active material layer is disposed inward relative to the second vertical end surface of the electrode active material layer. That is, by referring to Figure 11B It can be seen that the separation distance SZ2 The absolute value requirement is no greater than 1000 μm and no less than 5 μm, which applies to the length L of the first pair of electrode active material layers 138. C At least 60%, that is, for position x from X 0C To X LC At least 60% (60% of the Ferrette diameter of the electrode active material layer in the lateral direction), this separation distance S Z2 The absolute value corresponds to graph E at any given point along x. VP2 and CE VP2 The distance between them. Furthermore, it can be seen that for the length L of the first pair of electrode active material layers 138... C At least 60%, that is, position x from X 0C To X LC At least 60% (60% of the Feret diameter of the counter electrode active material layer in the transverse direction) of the second vertical end surface of the counter electrode active material layer is disposed inward relative to the second vertical end surface of the counter electrode active material layer.

[0122] In one embodiment, S Z2 The absolute value can be ≥5μm, for example ≥10μm, ≥15μm, ≥20μm, ≥35μm, ≥45μm, ≥50μm, ≥75μm, ≥100μm, ≥150μm, and ≥200μm. In another embodiment, S Z2 The absolute value can be ≤1000 micrometers, for example ≤500μm, for example ≤475μm, ≤425μm, ≤400μm, ≤375μm, ≤350μm, ≤325μm, ≤300μm, and ≤250μm. In one embodiment, S Z2 The absolute value can follow the relationship: 1000μm≥|S Z2 |≥5μm, and / or 500μm≥|S Z2 |≥10μm, and / or 250μm≥|S Z2 |≥20μm. In another embodiment, for the width W of the counter electrode active material layer 132 in the unit cell... E The Ferret diameter, S Z2 The absolute value can be 5×W E ≥|S Z2 |≥0.05×W E Within the range. Furthermore, in one embodiment, |S Z2 Any of the above values ​​and / or relationships can be applied to the length L of the first pair of electrode active material layers. C More than 60%, for example, the length L of the first pair of electrode active material layers. CAt least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or even at least 95%. Furthermore, the above applies to S. Z2 The described values ​​and / or relationships can be related to S Z1 Those that are the same and / or different, and / or may apply to those targeting S Z1 Different lengths L C The percentage.

[0123] Furthermore, for position x from X 0C To X LC At least 60% (60% of the Ferrette diameter of the electrode active material layer in the transverse direction) of the second vertical end surface of the electrode active material layer is disposed inward relative to the second vertical end surface of the electrode active material layer. That is, the electrode active material layer 132 can be understood as being disposed with respect to the length L of the electrode active material layer. C At least 60% of it has a median vertical position closer to the lateral surface than the counter electrode active material layer 130 (e.g., Figure 11C As shown, for a given X slice, the position on the z-axis in the YZ plane). In other words, the electrode active material layer 138 can be understood as having a median vertical position (e.g., a position further than the median vertical position of the electrode active material layer 132) along the inward direction 508 of the electrode assembly 106. Figure 11C As shown, for a given X slice, the position on the z-axis in the YZ plane. This vertical offset of the electrode active material layer 132 relative to the counter electrode active material layer 138 can also be related to... Figure 11A As seen in the embodiments, Figure 11A This shows that the height of the electrode material layer 132 exceeds the height of the counter electrode active material layer 138, and Figure 11B The curve shows the median vertical position E of the electrode active material layer 132. VP2 The vertical position CE below the median of the active material layer of the counter electrode in the lateral direction. VP2 In one embodiment, for the length L of the first pair of electrode active material layers C More than 60%, for example, the length L of the first pair of electrode active material layers. C At least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or even at least 95%, of the second vertical end surface of the electrode active material layer is disposed inward relative to the first vertical end surface of the electrode active material layer.

[0124] Furthermore, in one embodiment, the electrode assembly 106 also includes a lateral offset and / or separation distance between the lateral ends of the electrode and counter electrode active material layers 132, 138 in each unit cell. (See reference...) Figures 12A to 12CThis describes the offset and / or separation distance in the lateral direction. As in this embodiment... Figure 12A As shown, the first lateral end surfaces 502a and 503a of the electrode and counter electrode active material layers 132 and 138 are on the same side of the electrode assembly 106 (see also...). Figure 15A-15F Furthermore, the median lateral position of the first opposing lateral end surface 502a of the electrode active material 132 along the height H of the electrode active material layer in the XZ plane. E The 2D drawing depicts the first transverse end surface diagram E. TP1 In other words, as referenced... Figure 12A As shown, for each YX plane along the vertical direction, the median lateral position (x position) of the lateral end surface 502a of the electrode active material layer 132 can be determined as follows: by obtaining the median x position of the surface as a function of y at a specific vertical position (e.g., Z1, Z2, Z3, etc.) of the YX plane. Figure 12C The overall description illustrates an example of a line, showing the median lateral position (x-position) of the first lateral end surface 502a of a specific YX plane at a selected z-slice (e.g., the slice at Z1). (Note that...) Figure 12C The determination of the median lateral position of the lateral end surfaces (dashed lines at the top and bottom of the figure) is generally described, namely, the determination of the median lateral position of the first lateral end surface 5002a and the second lateral end surface 5002b of the electrode active material layer 132, and / or the determination of the median lateral position of the first lateral end surface 503a and the second lateral end surface 503b of the electrode active material layer 138. Figure 12B One embodiment is depicted, wherein along the height H of the electrode active material E (i.e., along height H) E The 2D plot of the median lateral position determined at each z-position (Z1, Z2, Z3) shows the first lateral end surface map E. TP1 First transverse end surface diagram E TP1 This corresponds to the median lateral position (x-position) plotted as a function of z (e.g., at Z1, Z2, Z3, etc.). For example, for Z corresponding to the first vertical end of the electrode active material layer... 0E At the second vertical end of the electrode active material layer, Z HE The z-position can be used to plot the median lateral position of the lateral end surface 502a of the electrode active material layer 132 as a function of z (vertical position), where Z HE -Z 0E Equal to the Freette diameter of the electrode active material layer 132 in the vertical direction (the height H of the electrode active material layer 132) E ).

[0125] Similarly, in the case of the first lateral end surface 503a of the counter electrode active material layer 138, the median lateral position of the first relative lateral end surface 503a of the counter electrode active material layer 138 along the height H of the counter electrode active material layer 138 in the XZ plane. C The 2D drawing depicts the first transverse end surface CE. TP1 Refer again Figure 12A -C, it can be understood that for each YX plane along the vertical direction, the median lateral position (x position) of the lateral end surface 503a of the counter electrode active material layer 138 can be determined as follows: by obtaining the median x position of the surface as a function of y at a specific vertical position (e.g., Z1, Z2, Z3, etc.) of the YX plane. Figure 12C The overall description depicts an example of a line that shows the median lateral position (x position) of the lateral end surface 503a of a specific YX plane at a selected z-slice (e.g., the slice at Z1). Figure 12B One embodiment is depicted, wherein along the height H of the active material of the counter electrode C (i.e., along height H) C The 2D map of the median lateral position determined at each z-position (Z1, Z2, Z3) depicts the first lateral end surface map CE. TP1 First transverse end surface diagram CE TP1 This corresponds to the median lateral position (x-position) plotted as a function of z (e.g., at Z1, Z2, Z3, etc.). For example, for Z corresponding to the first vertical end of the active material layer of the counter electrode... 0c At the second vertical end of the active material layer of the counter electrode, Z Hc The z-position can be used to plot the median lateral position of the lateral end surface 503a of the counter electrode active material layer 138 as a function of z (vertical position), where Z Hc -Z 0c Equivalent to the Freette diameter of the counter electrode active material layer 138 in the vertical direction (the height H of the counter electrode active material layer 138). C ).

[0126] Furthermore, the offset and / or separation distance of the lateral spacing between the first lateral surfaces 502a, 502b of the electrode active material layer 132 and the counter electrode active material layer 138 is required to be relative to the height H of the first pair of electrode active material layers. C At least 60% of: (i) Figure E measured in the vertical direction TP1 and CE TP1 The separation distance S between them X1 The absolute value is 1000μm≥|S X1 |≥5μm. Additionally, in one embodiment, it is required that the height H of the first pair of electrode active material layers...C At least 60% of: (ii) for the first lateral end surfaces 502a, 502b of the electrode and counter electrode active material layers 132, 138, the first lateral end surface of the counter electrode active material layer is disposed inward relative to the first lateral end surface of the electrode active material layer. That is, by referring to Figure 12B It can be seen that for the height H of the first pair of electrode active material layers 138 C At least 60%, that is, for those from Z 0C To Z HC At least 60% of the position z (60% of the Freret diameter of the electrode active material layer in the vertical direction), separation distance S X1 The absolute value of the separation distance S must be no greater than 1000 μm and no less than 5 μm. X1 The absolute value corresponds to the curve E at any given point along z. TP1 and CE TP1 The distance between them. Furthermore, it can be seen that for the height H of the first pair of electrode active material layers 138... C At least 60%, that is, from Z 0C To Z HC The position z is at least 60% (60% of the Ferete diameter of the counter electrode active material layer in the vertical direction), and the first lateral end surface of the counter electrode active material layer is disposed inward relative to the first lateral end surface of the counter electrode active material layer.

[0127] In one embodiment, S X1 The absolute value can be ≥5μm, for example ≥10μm, ≥15μm, ≥20μm, ≥35μm, ≥45μm, ≥50μm, ≥75μm, ≥100μm, ≥150μm, and ≥200μm. In another embodiment, S X1 The absolute value can be ≤1000 micrometers, for example ≤500μm, for example ≤475μm, ≤425μm, ≤400μm, ≤375μm, ≤350μm, ≤325μm, ≤300μm, and ≤250μm. In one embodiment, S X1 The absolute value can follow the relationship: 1000μm≥|S X1 |≥5μm, and / or 500μm≥|S X1 |≥10μm, and / or 250μm≥|S X1 |≥20μm. In another embodiment, for the width W of the counter electrode active material layer 132 in the unit cell... E The Ferret diameter, S X1 The absolute value can be 5×W E ≥|S X1 |≥0.05×W EWithin the range. Furthermore, in one embodiment, |S X1 Any of the above values ​​and / or relationships can be applied to the height H of the electrode active material layer. C More than 60%, for example, the height H of the electrode active material layer. C At least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or even at least 95%. Furthermore, the above applies to S. X1 The described values ​​and / or relationships can be related to S Z1 and / or S Z2 Those that are the same and / or different.

[0128] Furthermore, for Z 0C to Z HC At least 60% of the position z (60% of the Freret diameter of the counter electrode active material layer in the vertical direction), the first lateral end surface of the counter electrode active material layer is disposed inward relative to the first lateral end surface of the counter electrode active material layer. That is, the electrode active material layer 132 can be understood as being disposed with respect to the height H of the counter electrode active material layer. C At least 60% of it has a median lateral position closer to the lateral surface than the counter electrode active material layer 138 (e.g., Figure 12C As shown, for a given Z-slice, the position on the x-axis in the XY plane). In other words, the electrode active material layer 138 can be understood as having a median lateral position (e.g., a position further along the inward direction 510 of the electrode assembly 106 than the median lateral position of the electrode active material layer 132) than the median lateral position of the electrode active material layer 132. Figure 12C As shown, for a given X slice, the position on the x-axis in the XY plane. This lateral offset of the electrode active material layer 132 relative to the counter electrode active material layer 138 can also be relative to... Figure 12A As seen in the embodiments, Figure 12A This shows that the length of the electrode material layer 132 exceeds the length of the counter electrode active material layer 138, and Figure 12B The figure shows the median lateral position E of the electrode active material layer 132. TP1 The lateral position CE, extending vertically beyond the median of the active material layer of the counter electrode, is... TP1 In one embodiment, for the height H of the first pair of electrode active material layers C More than 60%, for example, the height H of the first pair of electrode active material layers. C At least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, and even at least 95%, of the first lateral end surface of the electrode active material layer is disposed inward relative to the first lateral end surface of the electrode active material layer. Furthermore, along a height H in which the electrode active material is disposed further inward than the electrode active material... CThe percentage at the first lateral end surface may differ from that at the second lateral end surface.

[0129] In one embodiment, the relationship between the separation distances of the second lateral surfaces 502b and 503b of the electrode and counter electrode active material layers 132 and 138 (e.g., ...) Figures 15A to 15F As shown), the separation distance S of the first lateral end surfaces 502a and 503a of the active material layers 132 and 138 of the electrode and counter electrode can also be determined. X1 The described relationship is as follows: The second lateral end surfaces 502b and 503b are on the same side of the electrode assembly 106 and are opposite to the first lateral end surfaces 502a and 503a of the electrode and counter electrode active material layers 132 and 138, respectively. Furthermore, similar to the relationship given above regarding the separation distance and / or offset S... X1 The description states that the median lateral position of the second opposing lateral end surface 502b of the electrode active material 132 is along the height H of the electrode active material layer in the XZ plane. E The 2D drawing depicts the second transverse end surface diagram E. TP2 In other words, as referenced... Figure 12A As shown in -C, for each YX plane along the vertical direction, the median lateral position (x position) of the second lateral end surface 502b of the electrode active material layer 132 can be determined as follows: by obtaining the median x position of the surface as a function of y at a specific vertical position (e.g., Z1, Z2, Z3, etc.) in the YX plane. Figure 12C The overall depiction is an example of a line that shows the median lateral position (x position) of the second lateral end surface 502b of a specific YX plane at a selected slice (e.g., the slice at Z1). Figure 12B One embodiment is depicted, wherein along the height H of the electrode active material E (i.e., along height H) E The 2D plot of the median lateral position determined at each z-position (Z1, Z2, Z3) shows the second lateral end surface map E. TP2 Second transverse end surface diagram E TP2 This corresponds to the median lateral position (x-position) plotted as a function of z (e.g., at Z1, Z2, Z3, etc.). For example, for Z corresponding to the first vertical end of the electrode active material layer... 0E At the second vertical end of the electrode active material layer, Z HE The z-position can be used to plot the median lateral position of the second lateral end surface 502b of the electrode active material layer 132 as a function of z (vertical position), where Z HE -Z 0EEquivalent to the Fretter diameter of the electrode active material layer 132 in the vertical direction (the height H of the electrode active material layer 132) E ).

[0130] Similarly, in the case of the second opposite lateral end surface 503b of the counter electrode active material layer 138, the median lateral position of the second opposite lateral end surface 503b of the counter electrode active material layer 138 along the height H of the counter electrode active material layer 138 in the XZ plane. C The 2D drawing depicts the second transverse end surface CE. TP2 See again Figures 12A to 12C It can be understood that for each YX plane along the vertical direction, the median lateral position (x position) of the second lateral end surface 503b of the electrode active material layer 138 can be determined by obtaining the median z position of the surface as a function of y at a specific vertical position (e.g., Z1, Z2, Z3, etc.) in the YX plane. Figure 12C The overall depiction is an example of a line that shows the median lateral position (x position) of the second lateral end surface 503b of a specific YX plane at a selected z-slice (e.g., the slice at Z1). Figure 12B One embodiment is depicted, wherein along the height H of the active material of the counter electrode C (i.e., along height H) C The 2D map of the median lateral position determined at each z-position (Z1, Z2, Z3) depicts the second lateral end surface map CE. TP2 , second transverse end surface diagram CE TP2 This corresponds to the median lateral position (x-position) plotted as a function of z (e.g., at Z1, Z2, Z3, etc.). For example, for Z corresponding to the first lateral end of the counter electrode active material layer... 0c At the second lateral end of the active material layer of the counter electrode, Z Hc The z-position can be plotted as a function of z (vertical position) of the median lateral position of the second lateral end surface 503b of the counter electrode active material layer 138, where Z Hc -X 0c Equivalent to the Freette diameter of the counter electrode active material layer 138 in the vertical direction (the height H of the counter electrode active material layer 138). C ).

[0131] Furthermore, the offset and / or separation distance requirements between the second lateral surfaces 502b and 503b of the electrode active material layer 132 and the counter electrode active material layer 138, are related to the height H of the first pair of electrode active material layers. C At least 60% of: (i) curve E measured in the vertical direction TP2 and CETP2 The separation distance S between them X2 The absolute value is 1000μm≥|S X2 |≥5μm. Additionally, in one embodiment, it is required that the height H of the first pair of electrode active material layers… C At least 60% of: (ii) for the second lateral end surfaces 502b, 503b of the electrode and counter electrode active material layers 132, 138, the second lateral end surface of the counter electrode active material layer is disposed inward relative to the second lateral end surface of the electrode active material layer. That is, by referring to Figure 12B It can be seen that for the height H of the first pair of electrode active material layers 138 C At least 60%, that is, from Z 0C to Z HC At least 60% of the position z (60% of the Freret diameter of the electrode active material layer in the vertical direction), separation distance S X2 The absolute value of the separation distance S must be no greater than 1000 μm and no less than 5 μm. X2 The absolute value corresponds to the graph E at any given point along z. TP2 and CE TP2 The distance between them. Furthermore, it can be seen that for the height H of the first pair of electrode active material layers 138... C At least 60%, that is, from Z 0C to Z HC The position z is at least 60% (60% of the Ferete diameter of the counter electrode active material layer in the vertical direction), and the second lateral end surface of the counter electrode active material layer is disposed inward relative to the second lateral end surface of the counter electrode active material layer.

[0132] In one embodiment, S X2 The absolute value can be ≥5μm, for example ≥10μm, ≥15μm, ≥20μm, ≥35μm, ≥45μm, ≥50μm, ≥75μm, ≥100μm, ≥150μm, and ≥200μm. In another embodiment, S X2 The absolute value can be ≤1000 micrometers, for example ≤500μm, for example ≤475μm, ≤425μm, ≤400μm, ≤375μm, ≤350μm, ≤325μm, ≤300μm, and ≤250μm. In one embodiment, S X2 The absolute value can follow the relationship: 1000μm≥|S X2 |≥5μm, and / or 500μm≥|S X2 |≥10μm, and / or 250μm≥|S X2 |≥20μm. In another embodiment, for the width W of the counter electrode active material layer 132 in the unit cell... EThe Ferret diameter, S X2 The absolute value can be 5×W E ≥|S X2 |≥0.05×W E Within the range. Furthermore, in one embodiment, |S X2 Any of the above values ​​and / or relationships can be applied to the height H of the electrode active material layer. C More than 60%, for example, the height H of the electrode active material layer. C At least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or even at least 95%. Furthermore, the above applies to S. X2 The described values ​​and / or relationships can be related to S X1 S Z1 and / or S Z2 Those that are the same and / or different.

[0133] Furthermore, for Z 0C to Z HC At least 60% of the position z (60% of the Freret diameter of the counter electrode active material layer in the vertical direction), the second lateral end surface of the counter electrode active material layer is disposed inward relative to the second lateral end surface of the counter electrode active material layer. That is, the electrode active material layer 132 can be understood as being disposed with respect to the height H of the counter electrode active material layer. C At least 60% of it has a median lateral position closer to the lateral surface than the counter electrode active material layer 130 (e.g., Figure 12C As shown, for a given Z-slice, the position on the x-axis in the XY plane). In other words, the electrode active material layer 138 can be understood as having a median lateral position (e.g., a position further along the inward direction 510 of the electrode assembly 106 than the median lateral position of the electrode active material layer 132) than the median lateral position of the electrode active material layer 132. Figure 12C As shown, for a given X slice, the position on the x-axis in the XY plane. This lateral offset of the electrode active material layer 132 relative to the counter electrode active material layer 138 can also be related to... Figure 12A As seen in the embodiments, Figure 12A This shows that the length of the electrode material layer 132 exceeds the length of the counter electrode active material layer 138, and Figure 12B The figure shows the median lateral position E of the electrode active material layer 132. TP2 The lateral position CE below the median of the active material layer of the counter electrode in the vertical direction. TP2 In one embodiment, for the height H of the first pair of electrode active material layers C More than 60%, for example, the height H of the first pair of electrode active material layers. CAt least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, and even at least 95%, of the second lateral end surface of the electrode active material layer is disposed inward relative to the second lateral end surface of the electrode active material layer. Furthermore, along a height H in which the electrode active material is disposed further inward than the electrode active material... C The percentage at the first lateral end surface may differ from that at the second lateral end surface.

[0134] According to one embodiment, offset and / or separation distances in the vertical and / or lateral directions can be maintained by providing a set of electrode constraints 108 capable of maintaining and stabilizing the alignment of the electrode active material layer 132 and the counter electrode active material layer 138 in each unit cell, and even stabilizing the position of the electrode structure 110 and the counter electrode structure 112 relative to each other in the electrode assembly 106. In one embodiment, the set of electrode constraints 108 includes any of those described herein, including any combination or portion thereof. For example, in one embodiment, the set of electrode constraints 108 includes a primary constraint system 151 comprising first and second primary growth constraints 154, 156 and at least one primary connecting member 162, the first and second primary growth constraints 154, 156 being separated from each other in the longitudinal direction, and the at least one primary connecting member 162 connecting the first and second primary growth constraints 154, 156, wherein the primary constraint system 151 restricts the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction during 20 consecutive cycles of the secondary battery is less than 20%. In yet another embodiment, the set of electrode constraints 108 further includes a secondary constraint system 152 comprising first and second secondary growth constraints 158, 160 separated in a second direction and connected by at least one secondary connecting member 166, wherein the secondary constraint system 152 at least partially restricts the growth of the electrode assembly 106 in a second direction orthogonal to the longitudinal direction during cycling of the secondary battery 106. Other embodiments of the set of electrode constraints 108 are described below.

[0135] return Figures 14A to 14H This describes various different configurations of the cell element 504 regarding vertical separation distance and / or offset. In the illustrated embodiment, a portion of a set of constraints 108 is located at at least one vertical end of layer 132 and can be connected to one or more structures of cell element 504. For example, this set of electrode constraints 108 includes first and second secondary growth constraints 158, 160, and these growth constraints can be connected to the vertical ends of structures in the cell element. In such cases... Figure 14AIn the illustrated embodiment, the first and second growth constraints 158, 160 are attached to the adhesive layer 516 of the constraints 158, 160 by bonding the structure of the unit cell to the structure of the unit cell. Figure 1A The sectional view shows the upper constraint member 158. Figure 14A In this configuration, the vertical end of the electrode current collector 136, the separator layer 130, and the counter electrode current collector 140 are bonded to the first and second growth constraint members 158 and 160 via an adhesive layer 516. Therefore, as described in further detail below, one or more of the electrode current collector 136, the separator layer 130, and the counter electrode current collector 140 can individually or collectively serve as a secondary connecting member 166 connecting the first and second growth constraint members to constrain the growth of the electrode assembly 106. Figure 14B Another embodiment is shown, in which all electrode current collectors 136, separator layers 130, and counter electrode current collectors 140 of unit cell 504 are bonded to first and second secondary growth constraints 158, 160. Optionally, some of the structure may be bonded to the first secondary growth constraint 158, while others may be bonded to the second secondary growth constraint. Figure 14C In the illustrated embodiment, the vertical ends of both the electrode current collector 136 and the separator layer 130 are joined to the first and second secondary growth constraints 158, 160, while the electrode current collector 140 terminates before contacting the first and second growth constraints in the vertical direction. (As shown in the example...) Figures 14D to 14E In the illustrated embodiment, the vertical ends of the electrode current collector 136 and the counter electrode current collector 140 are coupled to the first and second secondary growth constraints 158, 160, while the separator 130 terminates before contacting the first and second growth constraints in the vertical direction. In the example shown... Figure 14F In the illustrated embodiment, the vertical end of the electrode current collector 136 engages with the first and second secondary growth constraints 158, 160, while the separator 130 and the counter electrode current collector 140 terminate before contacting the first and second growth constraints in the vertical direction. (As shown in the example...) Figures 14G to 14H In the illustrated embodiment, the vertical end of the electrode current collector 140 is engaged with the first and second secondary growth constraints 158, 160, while the separator 130 and the electrode current collector 136 terminate before contacting the first and second growth constraints in the vertical direction.

[0136] Furthermore, in one embodiment, the cell element 504 may include one or more insulating members 514 disposed between one or more of the first and second vertical surfaces of the electrode active material layer 132 and / or the counter electrode active material layer. The insulating member 514 may be electrically insulating to suppress short circuits between structures in the cell element 504. The insulating member may also be non-ion-permeable, or at least less ion-permeable than the separator 130, to prevent the passage of carrier ions. That is, the insulating member 514 may be provided to insulate the vertical surfaces of the electrode and counter electrode active material layers 132, 138 from plating out, dendrite formation, and / or other electrochemical reactions that could otherwise affect exposed surfaces, thereby extending the lifespan of the secondary battery 102 having the cell element 504 with the insulating member 514. For example, the ion permeability and / or ion conductivity of the insulating member 514 may be less than the ion permeability and / or ion conductivity of the separator 130 disposed in the same cell element 504. For example, insulating member 514 may have the same and / or similar permeability and / or conductivity to carrier ions as the carrier ion insulating material layer 674 described further below. Insulating member 514 may be made of a variety of different materials, including ceramics, polymers, glass, combinations thereof, and / or composites thereof.

[0137] exist Figure 14A In the illustrated embodiment, the cell element 504 does not have an insulating member 514 because the vertical dimension z of the first vertical end surfaces 500a and 501a of the electrode and counter electrode active material layers 132 and 138 is close to, or even substantially flush with, the first secondary growth constraint 158. The second vertical end surfaces 500b and 501b can similarly reach the second secondary growth constraint 160 in the opposite vertical direction (not shown). In some embodiments, even if an insulating member 514 is not provided on the vertical surfaces of one or more of the electrode and counter electrode active material layers 132 and 138, the cell element may still include a predetermined vertical offset S. z1 and S z2 As stated above. Therefore, on one hand, such as Figure 14A The illustrated embodiment can have an offset S even without the insulating member 514. z1 and / or S z2 (Not explicitly shown).

[0138] Figure 14B The illustrated embodiment shows a unit cell 504 with a significant offset S between the first vertical end surfaces 500a and 501a of the electrode and counter electrode active material layers. z1 And / or have a significant offset S between the second vertical end surfaces 500a, 501a of the electrode and counter electrode active material layers.z2 (Not shown). In this embodiment, the insulating member 514 is disposed between the first vertical end surface 501a of the counter electrode active material layer 138 and the inner surface of the first secondary growth constraint 158, and / or between the second vertical end surface 501b of the counter electrode active material layer 138 and the inner surface of the second secondary growth constraint 160 (not shown). Although in Figure 14B Not shown in the 2D ZY plane, the insulating member 514 may extend substantially and even entirely on the vertical surface of the counter electrode active material layer 138, for example in the longitudinal direction (y direction) and the transverse direction (x direction – into). Figure 14B The page extends to cover one or more vertical surfaces 501a, b. Furthermore, in Figure 14B In the illustrated embodiment, the insulating member 514 is disposed between a separator 130 at one longitudinal end of the counter electrode active material layer 138 and a counter electrode current collector 140 at the other longitudinal end, and / or is defined by the separator 130 at one longitudinal end of the counter electrode active material layer 138 and the counter electrode current collector 140 at the other longitudinal end.

[0139] Figure 14C The illustrated embodiment also shows a unit cell 504, which has a significant offset S between the first vertical end surfaces 500a and 501a of the electrode and counter electrode active material layers. z1 And / or have a significant offset S between the second vertical end surfaces 500b, 501b of the electrode and counter electrode active material layers. z2 (Not shown). Also in this embodiment, the insulating member 514 is disposed between the first vertical end surface 500a of the counter electrode active material layer 138 and the inner surface of the first secondary growth constraint 158, and / or between the second vertical end surface 501b of the counter electrode active material layer 138 and the inner surface of the second secondary growth constraint 160 (not shown). Although in Figure 14C Not shown in the 2D ZY plane, the insulating member 514 may extend substantially and even entirely on the vertical surface of the counter electrode active material layer 138, for example in the longitudinal direction (y direction) and the transverse direction (x direction – into). Figure 14C The page extends to cover one or more vertical surfaces 501a, b. Furthermore, in Figure 14CIn the illustrated embodiment, the insulating member 514 is defined by a separator 130 at one longitudinal end of the counter electrode active material layer, but extends on the vertical surface 516a of the counter electrode current collector 140 at the other longitudinal end. That is, the insulating member may extend longitudinally toward and abut against an adjacent unit cell structure (e.g., an adjacent counter electrode active material layer 138 of an adjacent unit cell structure). In one embodiment, the insulating member 514 may extend across one or more vertical surfaces 501a, b of an adjacent counter electrode active material layer 138 by passing over the counter electrode current collector 140 that separates layers 138 in adjacent unit cells 504a, 504b, and across the vertical surface of an adjacent counter electrode active material layer 138 in an adjacent cell. That is, the insulating member 514 can extend across one or more vertical surfaces 501a, b of the counter electrode active material layer 138 in the first unit cell 504a by crossing the vertical surface of the counter electrode current collector 140 that separates the unit cells 504a, b from each other in the longitudinal direction, and can extend across one or more vertical surfaces 501a, b of the counter electrode active material layer 138 in the second unit cell 504b adjacent to the first unit cell 504a.

[0140] Figure 14D The illustrated embodiment shows a unit cell 504, in which an insulating member 514 is disposed between the first vertical end surface 500a of the counter electrode active material layer 138 and the inner surface of the first secondary growth constraint 158 ​​and / or between the second vertical end surface 500b of the counter electrode active material layer 138 and the inner surface of the second secondary growth constraint 160 (not shown), and the insulating member 514 also extends on one or more vertical surfaces 518a, b of the separator 130 to similarly cover one or more vertical end surfaces 500a, 500b of the electrode active material layer 138. That is, the insulating member 514 is also disposed between the first vertical end surface 500a of the electrode active material layer 132 and the inner surface of the first secondary growth constraint 158, and / or between the second vertical end surface 500b of the electrode active material layer 132 and the inner surface of the second secondary growth constraint 160 (not shown) (and in the space between the first and second secondary growth constraints 158, 160 and the vertical surfaces 518a, b of the separator 130). Although in Figure 14D Not shown in the 2D ZY plane, the insulating member 514 may extend substantially and even entirely on the vertical surfaces of the electrode and counter electrode active material layers 132, 138, for example, in the longitudinal direction (y direction) and the transverse direction (x direction – into). Figure 14D (The pages in the document) to cover one or more vertical surfaces 500a, b, 501a, b. Furthermore, in Figure 14DIn the illustrated embodiment, the insulator member 514 is disposed between the electrode current collector 136 at one longitudinal end of the unit element 504 and the counter electrode current collector 140 at the other longitudinal end, and / or is defined by the electrode current collector 136 at one longitudinal end of the unit element 504 and the counter electrode current collector 140 at the other longitudinal end.

[0141] Figure 14D The embodiment shown does not clearly illustrate the offset S between the first vertical end surfaces 500a, 501a of the electrode and the counter electrode active material layer. V1 The offset S between the second vertical end surfaces 500a and 501a of the active material layers of the electrode and the counter electrode V2 However, it can also be achieved by including a vertical offset S as described in this article. z1 and / or S z2 To modify one or more of them Figure 14D The embodiments described herein. For example, Figure 14E The illustrated embodiments may include with Figure 14D The same and / or similar structure exists because the insulating member 514 covers not only one or more vertical end surfaces 501a, b of the counter electrode active material layer 138, but also one or more vertical end surfaces 500a, b of the electrode active material layer 132. However, Figure 14E A significant vertical offset and / or separation distance Sz1 between the vertical end surfaces 500a, b of the electrode active material layer 132 and the vertical end surfaces 501a, b of the counter electrode active material layer 138 is shown. Therefore, as shown in the embodiment, the insulating member 514 includes: a first thickness T1 measured between the inner and outer vertical surfaces of the insulating member 514 on the first and second vertical end surfaces 500a, b of the electrode active material layer 132, and a second thickness T2 measured between the inner and outer vertical surfaces of the insulating member 514 on the first and second vertical end surfaces 501a, b of the counter electrode active material layer 138, wherein the first thickness T1 is less than the second thickness T2. Furthermore, although only a single insulating member 514 is shown, multiple insulating members 514 may also be provided, such as a first member having a first thickness T1 on the electrode active material layer and a second insulating member 514 having a second thickness T2 on the counter electrode active material layer 138. Figure 14F The illustrated embodiments are similar to Figure 14E In the illustrated embodiment, one or more insulating members 514 have thicknesses T1 and T2, respectively, relating to their arrangement on the vertical end surfaces of the electrode active material layer and the counter electrode active material layer. However, in this embodiment, the insulating members 514 extend on one or more vertical surfaces 516 of the counter electrode current collector 140, and may even extend to cover surfaces in adjacent cell units, as referenced above. Figure 14CAs stated above.

[0142] Figure 14G The illustrated embodiment shows a unit cell 504, in which an insulating member 514 is disposed between the first vertical end surface 500a of the counter electrode active material layer 138 and the inner surface of the first secondary growth constraint 158, and / or between the second vertical end surface 500b of the counter electrode active material layer 138 and the inner surface of the second secondary growth constraint 160 (not shown), and also extends on one or more vertical surfaces 518a, b of the separator 130 to similarly cover one or more vertical end surfaces 500a, 500b of the electrode active material layer 138. That is, the insulating member 514 is also disposed between the first vertical end surface 500a of the electrode active material layer 132 and the inner surface of the first secondary growth constraint 158, and / or between the second vertical end surface 500b of the electrode active material layer 132 and the inner surface of the second secondary growth constraint 160 (not shown) (and in the space between the first and second secondary growth constraints 158, 160 and the vertical surfaces 518a, b of the separator 130). Although in Figure 14D Not shown in the 2D ZY plane, the insulating member 514 may extend substantially and even entirely on the vertical surfaces of the electrode and counter electrode active material layers 132, 138, for example, in the longitudinal direction (y direction) and the transverse direction (x direction – into). Figure 14D (The pages in the document) to cover one or more vertical surfaces 500a, b, 501a, b. Furthermore, in Figure 14G In the illustrated embodiment, the insulator member 514 is defined by a counter electrode current collector 140 at one longitudinal end of the unit cell 504, but extends in another longitudinal direction on one or more vertical end surfaces 520 of the electrode current collector 136. For example, similar to the description above. Figure 14C The insulating member 514 may extend longitudinally toward and abut against a neighboring unit cell structure (e.g., an adjacent electrode active material layer 132 of a neighboring unit cell structure). In one embodiment, the insulating member 514 may extend across one or more vertical surfaces 500a, b of an adjacent electrode active material layer 132 by passing over the electrode current collector 136 that separates layers 138 in adjacent unit cells 504a, 504b and over the vertical surface of an adjacent electrode active material layer 132 in an adjacent unit. That is, the insulating member 514 may extend across one or more vertical surfaces 500a, b of an electrode active material layer 132 in a first unit cell 504a by traversing the vertical end surfaces 520a, b of an electrode current collector 140 that separates unit cells 504a, b from each other in the longitudinal direction, and may extend across the vertical surfaces 500a, b of an electrode active material layer 132 in a second unit cell 504b adjacent to the first unit cell 504a.

[0143] Figure 14G The embodiment shown does not clearly illustrate the offset S between the first vertical end surfaces 500a, 501a of the electrode and the counter electrode active material layer. Z1 The offset S between the second vertical end surfaces 500a and 501a of the active material layers of the electrode and the counter electrode Z2 However, it can also be achieved by including a vertical offset S as described in this article. z1 and / or S z2 To modify one or more of them Figure 14G The embodiments described herein. For example, Figure 14H The illustrated embodiments may include with Figure 14G The same and / or similar structure exists because the insulating member 514 covers not only one or more vertical end surfaces 501a, b of the counter electrode active material layer 138, but also one or more vertical end surfaces 500a, b of the electrode active material layer 132. However, Figure 14H The diagram shows a clear vertical offset and / or separation distance S between the vertical end surfaces 500a, b of the electrode active material layer 132 and the vertical end surfaces 501a, b of the counter electrode active material layer 138. V1 Accordingly, in the illustrated embodiment, the insulating member 514 includes: a first thickness T1 measured between the inner and outer vertical surfaces of the insulating member 514 on the first and second vertical end surfaces 500a, b of the electrode active material layer 132, and a second thickness T2 measured between the inner and outer vertical surfaces of the insulating member 514 on the first and second vertical end surfaces 501a, b of the counter electrode active material layer 138, wherein the first thickness T1 is less than the second thickness T2. Furthermore, although only a single insulating member 514 is shown, multiple insulating members 514 may also be provided, such as a first member having a first thickness T1 on the electrode active material layer and a second insulating member 514 having a second thickness T2 on the counter electrode active material layer 138.

[0144] refer to Figures 15A to 15F It describes the presence or absence of insulating member 514 and / or lateral offset S. X1 and S X2 Other embodiments of the unit primitive 504. Figure 15A In the illustrated embodiment, electrode active material layers 132 and 138 are shown as having no discernible (lateral offset S) X1 and / or S X2 Although the aforementioned offset and / or separation distance can be set along the x-axis, for example, as in Figure 15B As shown in the embodiment. As illustrated via 2D slicing in the YX plane, as... Figure 15AThe unit cell 504 shown includes an electrode current collector 136, an electrode active material layer 132, a separator 130, a counter electrode active material layer 138, and a counter electrode current collector 140. Although Figure 15A The embodiments described do not include the insulating member 514, but it can be seen that the electrode current collector 136 extends beyond the second lateral ends 502b, 503b of the electrode and counter electrode active material layers 132, 138, and can be connected to the electrode busbar 600, for example, as shown in the example. Figure 16A As shown in -16F. Similarly, the counter electrode current collector 140 extends beyond the first lateral ends 502a, 503a of the electrode and counter electrode active material layers 132, 138, and can be connected to the counter electrode busbar 602, for example, as shown in... Figure 16A As shown in -16F.

[0145] refer to Figure 15B The illustrated embodiment shows a unit cell structure having an insulating member 514 extending on at least one of the lateral surfaces 503a, b of the counter electrode active material layer 138. In the illustrated embodiment, the insulating member 514 is disposed at either lateral end of the counter electrode active material layer 138 and is located between a counter electrode current collector 140 at one longitudinal end of the unit cell 504 and a separator 130 at the other longitudinal end of the unit cell, and is defined by the counter electrode current collector 140 located at one longitudinal end of the unit cell 504 and the separator 130 at the other longitudinal end of the unit cell. In the illustrated embodiment, the insulating member has a length L of the counter electrode active material layer 132. E The lateral extent of the insulating member 514 is matched and separated from the electrode active material layer 132 by a separator having the same length as the electrode active material layer in the lateral direction. In one embodiment, the lateral extent of the insulating member 514 in the x-direction may be separated from the lateral separation distance and / or offset by S. X1 S X2 Same, such as Figure 15B As shown. Additionally, although in Figure 15B Not shown in the 2D YX plane, the insulating member can also be in the z direction (e.g., along the height H of the counter electrode active material layer 138). E And it extends between the opposite vertical end surfaces 501a and b.

[0146] Figure 15CThe illustrated embodiment also shows a unit cell structure having an insulating member 514 extending on at least one of the lateral surfaces 503a, b of the counter electrode active material layer 138. In the illustrated embodiment, the insulating member 514 is disposed at either lateral end of the counter electrode active material layer 138 and has a separator layer 130 at at least one longitudinal end of the unit cell 504. At the other longitudinal end, at least one insulating member is further defined by a counter electrode current collector 140. However, at least one insulating member 514 may also extend on the lateral surfaces 522a, b of the counter electrode current collector 140 at the other longitudinal end of the unit cell 504. That is, the insulating member 514 may extend in the longitudinal direction beyond the lateral end surface of the counter electrode active material layer 138 to cover the counter electrode current collector 140, and may even extend to cover the lateral surface of the counter electrode active layer of an adjacent unit cell. In the embodiment shown in FIG15B1, the insulating member 514 has a length L of the counter electrode active material layer 132. E The lateral extent of the insulating member 514 is matched and separated from the electrode active material layer 132 by a separator having the same length as the electrode active material layer 132 in the lateral direction. In one embodiment, the lateral extent of the insulating member 514 in the x direction may be separated from the lateral separation distance and / or offset by S. X1 S X2 Same, such as Figure 15C As shown. Additionally, although in Figure 15C Not shown in the 2D YX plane, the insulating member can also extend in the z direction, for example, along the height H of the counter electrode active material layer 138. E And extending between the opposing vertical end surfaces 501a and b. In addition to the length of the current collector 140 extending across the transverse surface of the insulating member 514, the length of the current collector 136 also extends across the transverse end surface of the electrode active material layer. Figure 15E The structure and Figure 15C similar.

[0147] Figure 15D The illustrated embodiment shows a unit cell structure having an insulating member 514 extending on at least one of the lateral surfaces 502a, b, 503a, b of both the electrode active material layer 132 and the counter electrode active material layer 138. In the illustrated embodiment, the insulating member 514 is disposed at either lateral end of the electrode and counter electrode active material layers 132, 138. The insulating member is disposed between and defined by the electrode current collector 136 at one longitudinal end and the counter electrode current collector 140 at the other longitudinal end. The insulating member 514 may extend on the lateral end surfaces 524a, b of the separator 130 to cross the lateral surfaces of the electrode and counter electrode layers 132, 138. Figure 15D In the illustrated embodiment, the insulating member 514 has a lateral range matching the length of the electrode current collector 136 at one lateral end and the length of the counter electrode current collector 140 at the other lateral end. In the illustrated embodiment, the electrode and counter electrode active material layers 132, 138 are not shown to have lateral offset and / or separation distances, although separation distances and / or offsets may also be provided. Additionally, although in Figure 15D Not shown in the 2D YX plane, the insulating member may also extend in the z-direction, for example, along the height H of the counter electrode active material layer 138. E And it extends between the opposite vertical end surfaces 501a and b.

[0148] Figure 15F The illustrated embodiment also shows a unit cell structure having an insulating member 514 extending on at least one of the lateral surfaces 503a, b of the counter electrode active material layer 138. In the illustrated embodiment, the insulating member 514 is disposed at either lateral end of the counter electrode active material layer 138. The insulating member 514 covers the lateral surfaces of both the electrode and counter electrode active material layers and is disposed between an electrode current collector 136 at one longitudinal end and a counter electrode current collector 140 at at least one lateral end at the other end, defined by the electrode current collector 136 at one longitudinal end and the counter electrode current collector 140 at at least one lateral end at the other end. In the illustrated embodiment, the insulating member further extends on the lateral surfaces 524a, b of the separator 130, between the electrode and counter electrode active material layers 132, 138, to extend on these surfaces. In the illustrated embodiment, the insulating member 514 has a first lateral thickness T1 extending from the vertical end surface of the electrode active material layer 132 and a second lateral thickness T2 extending from the vertical end surface of the counter electrode active material layer 138, wherein the second lateral thickness is greater than the first lateral thickness. In one embodiment, the difference between the lateral extent of the second thickness T2 and the first thickness T1 can be equivalent to the lateral offset and / or separation distance S. X1 and / or S X2Furthermore, in the illustrated embodiment, at least one insulating member 514 may also extend on one of the transverse surfaces 522a, b of the counter electrode current collector 138 at one of the longitudinal ends of the unit cell 504. That is, the insulating member 514 may extend longitudinally beyond the transverse end surface of the counter electrode active material layer 138 to cover the counter electrode current collector 140, and may even extend to cover the transverse surface of the counter electrode active material layer of an adjacent unit cell. On the other hand, the insulating member 514 at the opposite transverse ends of the counter electrode active material layer may be defined by the counter electrode current collector such that the length of the counter electrode current collector in the transverse direction exceeds the transverse thickness of the insulating member 514. At the other longitudinal end, the insulating member 514 is defined by the electrode current collector 136, wherein the transverse thickness of the insulating member at one transverse end satisfies the transverse length of the electrode current collector 136, and the electrode current collector 136 exceeds the transverse thickness of the insulating member at the other transverse end. In addition, although in Figure 15C Not shown in the 2D YX plane, the insulating member may also extend in the z-direction, for example, along the height H of the counter electrode active material layer 138. E And it extends between the opposite vertical end surfaces 501a and b.

[0149] Furthermore, it should be noted that, in order to determine the first and second vertical and / or lateral end surfaces of the electrode active material layers and / or counter electrode active material layers 132 and 138, only those portions of these layers containing electrode and / or counter electrode active materials that can participate in the electrochemical reactions in each unit cell 504 are considered part of the active material layers 132, 138. That is, if the electrode or counter electrode active material is modified to no longer function as an electrode or counter electrode active material, for example by covering the active material with an ion-insulating material, the portion of that material that has been effectively removed as a participant in the electrochemical unit cell is not considered part of the electrode active and / or counter electrode active material layers 132, 138.

[0150] Electrode and counter electrode busbar

[0151] In one embodiment, the secondary battery 102 includes an electrode busbar 600 and a counter electrode busbar 602 (e.g., as shown in the figure). Figure 17 One or more of the following (shown) are used to collect current from the electrode current collector 136 and the counter electrode current collector, respectively. As similarly described with respect to embodiments having the above offset and / or separation distance, the electrode assembly 106 may include an electrode structure group, an electrode current collector group, a separator group, a counter electrode structure group, a counter electrode current collector group, and a unit cell group, wherein the components of the electrode and counter electrode structure groups are arranged in an alternating order in the longitudinal direction. Furthermore, each component of the electrode structure group includes an electrode current collector and an electrode active material layer, the electrode active material layer having a length L. E Height HE and width W E The length L E The Freette diameter of the electrode active material layer, measured in the lateral direction between the first and second opposing lateral end surfaces of the electrode active material layer, and the height H. E The Freette diameter of the electrode active material layer, measured in the vertical direction between the first and second opposing vertical end surfaces of the electrode active material layer, and the width W. E This corresponds to the Freret diameter of the electrode active material layer measured in the longitudinal direction between the first and second opposing surfaces of the electrode active material layer. Furthermore, each component of the counter electrode structure group includes a counter electrode current collector and a counter electrode active material layer having a length L. C Height H C and width W C The length L C The Freret diameter of the counter electrode active material layer, measured in the lateral direction between the first and second opposing lateral end surfaces of the counter electrode active material layer, and the height H. C Corresponding to the Freette diameter of the counter electrode active material layer measured in the vertical direction between the first and second opposing vertical end surfaces of the counter electrode active material layer, and the width W C This corresponds to the Freette diameter of the counter electrode active material layer measured in the longitudinal direction between the first and second opposing surfaces of the counter electrode active material layer.

[0152] Furthermore, as described elsewhere herein, in one embodiment, the electrode assembly has mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y, and z axes of a hypothetical three-dimensional Cartesian coordinate system, respectively; a first longitudinal end surface and a second longitudinal end surface separated from each other in the longitudinal direction; and a region surrounding the longitudinal axis A of the electrode assembly. EA A transverse surface connects the first longitudinal end surface and the second longitudinal end surface. This transverse surface has opposing first and second regions located on opposite sides of the longitudinal axis and separated in a first direction orthogonal to the longitudinal axis. The electrode assembly has a maximum width W measured in the longitudinal direction. EA The maximum length L defined by the transverse surface and measured in the transverse direction EA and the maximum height H defined by the transverse surface and measured in the vertical direction. EA .

[0153] refer to Figure 17 Each component of the electrode structure group 110 includes an electrode current collector 136 for collecting current from the electrode active material layer 132, the electrode current collector being at least partially along the length L of the electrode active material layer 132. EExtending in the lateral direction, the electrode current collector includes an electrode current collector end 604 extending beyond a first lateral end surface 503a of the counter electrode active material layer 138. Furthermore, each component in the counter electrode structure group 112 includes a counter electrode current collector 140 to collect current from the counter electrode active material layer 138, the counter electrode current collector 140 being at least partially along the length L of the counter electrode active material layer 132. C Extending in the lateral direction, and including a counter electrode current collector end 606 extending in the lateral direction beyond the second lateral end surface 502b of the electrode active material layer (e.g., also as Figure 15A (As shown). In Figure 17 In the illustrated embodiment, the electrode and counter electrode current collectors 136, 140 are sandwiched between adjacent electrode active material layers (in the case of electrode structure 110) or adjacent counter electrode active material layers (in the case of counter electrode structure 112). However, the current collector can also be a surface current collector, present on at least a portion of the surface of the separator 130 between the electrode and / or counter electrode active material layers facing the electrode and counter electrode structures 110, 112. Furthermore, in... Figure 17 In the illustrated embodiment, electrode bus 600 and counter electrode bus 602 are disposed on opposite lateral sides of electrode assembly 106, wherein electrode current collector 604 is electrically connected and / or physically connected to electrode bus 600 at one lateral end, and counter electrode current collector 606 is electrically connected and / or physically connected to counter electrode bus 602 at the opposite lateral end.

[0154] Similarly, as described above, each unit cell 504 of the electrode assembly includes a unit cell portion of a first electrode current collector of an electrode current collector group, a first electrode active material layer of a component of the electrode group, a separator that is ion-permeable to carrier ions, a first pair of electrode active material layers of a component of the electrode group, and a unit cell portion of a first pair of electrode current collectors of the electrode current collector group, wherein (aa) the first electrode active material layer is adjacent to a first side of the separator, and the first pair of electrode material layers is adjacent to an opposite second side of the separator, and (bb) the separator electrically isolates the first electrode active material layer from the first pair of electrode active material layers, and during the cycling between the charging and discharging states of the battery, carrier ions are exchanged primarily between the first electrode active material layer and the first pair of electrode active material layers via the separator of each such unit cell.

[0155] refer to Figure 16A It illustrates an embodiment of a busbar, which can be an electrode busbar 600 or a counter electrode busbar 602 (depending on whether an electrode current collector or a counter electrode current collector is attached to it). That is, Figure 16AThis can be understood as depicting a structure suitable for either the electrode busbar 600 or the counter electrode busbar 602. The electrode busbar 600 is shown... Figure 16A However, it should be understood that the same structure described herein also applies to the counter electrode busbar 602, as described herein, even if not specifically shown. A secondary battery may include a single electrode busbar 600 and a single counter electrode busbar 602 to be connected to all electrode current collectors and counter electrode current collectors of the electrode assembly 106, respectively, and / or multiple busbars and / or counter electrode busbars may be provided. For example, in Figure 16A As understood to illustrate an embodiment of the electrode busbar 600, it can be seen that the electrode busbar 600 includes at least one conductive segment 608 configured to be electrically connected to the electrode current collector group 136 and extending in the longitudinal direction (Y direction) between the first and second longitudinal end surfaces 116, 118 of the electrode assembly 106. The conductive segment 608 includes a first side surface 610 and an opposing second side surface 614, the first side surface 610 having an inner surface 612 facing a first lateral end surface 503a of the counter electrode active material layer 136, and the opposing second side surface 614 having an outer surface 616. Furthermore, the conductive segment 608 optionally includes a plurality of holes 618 spaced apart in the longitudinal direction. The conductive segment 608 of the electrode busbar 600 is arranged relative to the electrode current collector end 604 such that the electrode current collector end 604 extends at least partially across the thickness of the conductive segment 608 for electrical connection thereto. The total thickness t of the conductive segment 608 can be measured between the inner surface 612 and the outer surface 616, and the electrode current collector end 608 can extend at least a distance into the thickness of the conductive segment, for example through the hole 618, and can even extend completely beyond the thickness of the conductive segment (i.e., beyond the thickness t measured in the lateral direction). Although in Figure 16A The image depicts an electrode busbar 600 having a single conductive segment 608, but some embodiments may also include multiple conductive segments.

[0156] In addition, Figure 16AIn the case of an embodiment illustrating the counter electrode busbar 602, it can be seen that the counter electrode busbar 602 includes at least one conductive segment 608 configured to be electrically connected to the counter electrode current collector group 140 and extending in the longitudinal direction (y-direction) between the first and second longitudinal end surfaces 116, 118 of the electrode assembly 106. The conductive segment 608 includes a first side surface 610 and an opposing second side surface 614, the first side surface 610 having an inner surface 612 facing the second lateral end surface 502b of the electrode active material layer 136, and the opposing second side surface 614 having an outer surface 616. Furthermore, the conductive segment 608 optionally includes a plurality of holes 618 spaced apart in the longitudinal direction. The conductive segment 608 of the electrode busbar 600 is arranged relative to the counter electrode current collector end 606 such that the counter electrode current collector end 606 extends at least partially across the thickness of the conductive segment 608 for electrical connection thereto. The total thickness t of the conductive segment 608 can be measured between the inner surface 612 and the outer surface 616, and the electrode current collector end 606 can extend at least a distance into the thickness of the conductive segment, for example through the hole 618, and can even extend completely beyond the thickness of the conductive segment (i.e., beyond the thickness t measured in the lateral direction). Although in Figure 16A The image depicts a counter electrode busbar 602 having a single conductive segment 608, but some embodiments may also include multiple conductive segments.

[0157] Furthermore, according to one embodiment, the secondary battery 102 having busbars and counter electrode busbars 600, 602 also includes a set of electrode constraints, such as any constraints described herein. For example, in one embodiment, the set of electrode constraints 108 includes a primary constraint system 151, which includes first and second primary growth constraints 154, 156 and at least one primary connecting member 162, the first and second primary growth constraints 154, 156 being separated from each other in the longitudinal direction, and the at least one primary connecting member 162 connecting the first and second primary growth constraints 154, 156, wherein the primary constraint system 151 restricts the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction during 20 consecutive cycles of the secondary battery is less than 20%. In yet another embodiment, the set of electrode constraints 108 further includes a secondary constraint system 152, which includes first and second secondary growth constraints 158, 160 separated in a second direction and connected by at least one secondary connecting member 166, wherein during cycling of the secondary battery 106, the secondary constraint system 155 at least partially restricts the growth of the electrode assembly 106 in a second direction orthogonal to the longitudinal direction. Other embodiments of the set of electrode constraints 108 are described below.

[0158] refer to Figure 16A Other embodiments of electrode busbar 600 and / or counter electrode busbar 602 are described. In one embodiment, such as Figure 16A As shown, the electrode busbar 600 includes a conductive segment 608 having a plurality of longitudinally spaced holes 618, each of which is configured to allow one or more electrode current collector ends 604 to extend at least partially through it for electrically connecting one or more electrode current collector ends 604 to the electrode busbar 600. Similarly, the counter electrode busbar 602 may include a conductive segment 608 including a plurality of longitudinally spaced holes 618, each of which is configured to allow one or more counter electrode current collector ends 606 to extend at least partially through it for electrically connecting one or more counter electrode current collector ends 606 to the counter electrode busbar 602. Reference Figure 16A As can be seen from the cross-section, on one side of the electrode busbar, the current collector 136 of the electrode structure 110 extends across the first lateral surface 502a of the electrode active material layer 132 and through the hole 618 formed in the conductive segment. The electrode current collector end 604 is connected to the outer surface 616 of the electrode busbar 600. Similarly, although not specifically shown, on the other lateral end where the counter electrode busbar 602 is located, the electrode current collector 140 of the counter electrode structure 112 extends across the second lateral surface 503b of the counter electrode active material layer 138 and through the hole 618 formed in the conductive segment. The counter electrode current collector end 606 is connected to the outer surface 616 of the counter electrode busbar 600.

[0159] Furthermore, although in one embodiment both the electrode busbars and the counter electrode busbars 600 and 602 may include multiple holes 618, in another embodiment only the electrode busbar 600 includes holes 618, and in yet another embodiment only the counter electrode busbar 602 includes holes 618. In yet another embodiment, the secondary battery may include both electrode busbars and counter electrode busbars, while in other embodiments, the secondary battery may include only electrode busbars or counter electrode busbars and collect current from the remaining current collector through other mechanisms. Figure 16A and 16A In the illustrated embodiment, orifice 618 is shown as being sized to allow either electrode current collector or counter electrode current collector to pass through it. While in one embodiment, the orifices are sized and configured to allow only a single current collector through each orifice, in another embodiment, the orifices may be sized to allow more than one electrode current collector 136 and / or counter electrode current collector 140 to pass through them. Furthermore, in... Figure 16A and 16AIn the illustrated embodiment, the electrode current collector end and / or the counter electrode current collector end extend completely through one or more holes 618, and the ends 604, 606 are bent toward the outer surface 616 of the electrode busbar and / or the counter electrode busbar to attach to the portion 622 of the outer surface electrode busbar and / or the counter electrode busbar between the holes 618. The ends 604, 608 may also and / or optionally connect to other portions of the conductive segment 608, such as portions of the conductive segment located above or below the hole in the vertical direction, and / or connect to the inner surface 624 of the hole 618 itself.

[0160] In such Figure 16B and Figure 16B In the illustrated embodiment, the electrode current collector ends and / or counter electrode current collector ends 604, 606 extend completely through one or more holes 618, and the ends are bent toward the outer surface 616 of the electrode busbar and / or counter electrode busbar. However, in this embodiment, at least one or more of the current collector ends extend at least partially into or across adjacent holes 618 in the longitudinal direction (e.g., as shown in the figure). Figure 16B (As shown, extending beyond adjacent holes) to attach to individual electrode current collector ends and / or counter electrode current collector ends. That is, the ends of the electrode and / or counter electrode current collectors can be attached to each other. In yet another embodiment, also as... Figure 16B As shown, the electrode current collector end and / or the counter electrode current collector end are attached at a first end region 624 to a portion 622 of the outer surface 616 of the electrode busbar and / or the counter electrode busbar between holes 618, and are attached at a second end region 626 to another separate electrode current collector end and / or the counter electrode current collector end.

[0161] In one embodiment, electrode current collector end 604 and / or counter electrode current collector end 606 are attached to one or more of the following by means of adhesive, welding, crimping, brazing, rivets, mechanical pressure / friction, clamping, and soldering: a portion 622 of the outer surface of the electrode busbar and / or counter electrode busbar, and / or individual electrode current collector ends and / or counter electrode current collector ends (such as adjacent current collectors extending through adjacent holes). Ends 604, 604 may also be connected via such attachment to other portions of the electrode busbar and / or counter electrode busbar, such as the inner surface 624 of hole 618 or other portions of the busbar. Furthermore, according to a preferred embodiment, the number of current collector ends attached to each other rather than only to the busbars can be selected. For example, in one embodiment, in a given group, each of the electrode current collector ends and the counter electrode current collector ends is respectively attached to a portion 622 of the outer surface 616 of the electrode and / or counter electrode busbars 600, 602. In yet another embodiment, at least some of the electrode current collector ends and / or counter electrode current collector ends are attached to each other (e.g., by extending through a hole and then longitudinally toward or across an adjacent hole to connect to an adjacent current collector extending through the adjacent hole), while at least one of the electrode current collector ends and / or counter electrode current collector ends is attached to a portion of the outer surface of the electrode busbar and / or counter electrode busbar (e.g., to provide an electrical connection between the busbar and current collector ends that are attached to each other). In yet another embodiment, all current collectors in the group may be individually connected to the busbar without necessarily being connected to other current collector ends.

[0162] In another embodiment, the electrode current collector end and / or the counter electrode current collector end have a surface region (e.g., a first region 624) that attaches to the surface of the busbar and / or the counter electrode busbar (e.g., an outer surface). For example, the electrode current collector end and / or the counter electrode current collector end have a surface region that attaches to at least one of the outer surface of the electrode busbar and / or the counter electrode busbar and the inner surface 624 of the hole 618 of the busbar and / or the counter electrode busbar. In one embodiment, one or more ends of the electrode busbar and / or the counter electrode busbar may include a surface region that attaches to the inner surface 612 of the busbar and / or the counter electrode busbar. The size of the connection surface region can be selected according to the attachment type to which the end is to be attached to the electrode and / or the counter electrode busbar. In one embodiment, for example, as Figure 16A 'and Figure 16BAs shown, the electrode busbar and / or counter electrode busbar includes: an insulating material layer 628 on an inner surface 612 near the lateral ends of the electrode and / or counter electrode, and a conductive material layer (e.g., a conductive segment 608) on an outer surface 616 opposite the inner surface. The insulating material layer 628 may include insulating members 514 disposed between the lateral surfaces of the active material layers 132, 138 of the electrode and / or counter electrode and the busbar, as described elsewhere herein, and / or may include a separate insulating material layer 632 along the inner surface of the busbar to insulate the electrode assembly from the conductive segment of the busbar.

[0163] In one embodiment, the material and / or physical properties of the electrode and / or counter electrode current collectors 136, 140 can be selected to provide good electrical contact with the busbar while also imparting good structural stability to the electrode assembly. For example, in one embodiment, the electrode current collector end 604 and / or the counter electrode current collector end 606 (and optionally, at least a portion and even all of the electrode and / or counter electrode current collectors) comprise the same material as the material used to make the electrode busbar and / or counter electrode busbar. For example, if the busbar and / or counter electrode busbar comprises aluminum, the electrode and / or counter electrode current collectors may also comprise aluminum. In one embodiment, the electrode current collector end and / or counter electrode current collector end comprises any one selected from aluminum, copper, stainless steel, nickel, nickel alloys, carbon, and combinations / alloys thereof. Furthermore, in one embodiment, the electrode current collector end and / or counter electrode current collector end comprises a material with a conductivity relatively close to that of the material of the electrode busbar and / or counter electrode busbar, and / or the electrode and / or counter electrode current collectors may comprise the same material as the electrode and / or counter electrode busbar.

[0164] In yet another embodiment, the end of the electrode current collector and / or the counter electrode current collector extends through the hole 618 of the electrode busbar and / or the counter electrode busbar and bends rearward toward the outer surface 616 of the electrode busbar and / or the counter electrode busbar to attach thereto, and wherein the end region 624 that bends to attach to the outer surface is substantially flat, for example as... Figure 16A and 16A As shown.

[0165] In one embodiment, the electrode current collector and / or the counter-electrode current collectors 136 and 140 are respectively along the length L of the electrode material layer in the lateral direction. E and / or the length L of the electrode material layer C Extend by at least 50%, of which L E and L C As defined above. For example, in one embodiment, the electrode current collector and / or the counter-electrode current collector are respectively along the length L of the electrode material layer in the lateral direction. E and / or the length L of the electrode material layer CThe extension is at least 60%. In another embodiment, the electrode current collector and / or the counter-electrode current collector extend in the lateral direction along the length L of the electrode material layer, respectively. E and / or the length L of the electrode material layer C The extension is at least 70%. In yet another embodiment, the electrode current collector and / or the counter-electrode current collector extend in the lateral direction along the length L of the electrode material layer, respectively. E and / or the length L of the electrode material layer C The extension is at least 80%. In another embodiment, the electrode current collector and / or the counter-electrode current collector extend in the lateral direction along the length L of the electrode material layer, respectively. E and / or the length L of the electrode material layer C Extend by at least 90%.

[0166] Furthermore, in one embodiment, the electrode current collector and / or the counter-electrode current collector are respectively positioned along the height H of the electrode material layer in the vertical direction. E and / or the height H of the electrode material layer C Extend at least 50%, of which H E and H C As defined above. For example, in one embodiment, the electrode current collector and / or the counter-electrode current collector are respectively positioned along the height H of the electrode material layer in the vertical direction. E and / or the height H of the electrode material layer C The extension is at least 60%. In another embodiment, the electrode current collector and / or the counter-electrode current collector extend vertically along the height H of the electrode material layer, respectively. E and / or the height H of the electrode material layer C Extending by at least 70%. In yet another embodiment, the electrode current collector and / or the counter-electrode current collector extend vertically along the height H of the electrode material layer, respectively. E and / or the height H of the electrode material layer C The extension is at least 80%. In another embodiment, the electrode current collector and / or the counter-electrode current collector extend vertically along the height H of the electrode material layer, respectively. E and / or the height H of the electrode material layer C Extend by at least 90%.

[0167] According to yet another embodiment, reference is made to Figure 18A and Figure 18BThe electrode assembly 106 includes at least one of a vertical electrode current collector end 640 and a vertical counter electrode current collector end 642, which extend across one or more of the first and second vertical surfaces 500a, b, 501a, b of the adjacent electrode active material layer 132 and / or counter electrode active material layer 138. In one embodiment, the vertical current collector ends 640, 642 may also be at least partially coated with a carrier ion insulating material, as described in further detail below, to reduce the possibility of short circuits and / or deposition of carrier ions on the exposed vertical current collector ends.

[0168] According to one embodiment, for at least one of the components of the electrode group and the components of the counter-electrode group, (I) each component of the electrode structure group 110 includes an electrode current collector 136 to collect current from the electrode active material layer 132, the electrode current collector 136 extending at least partially along the height H of the electrode active material layer 132 in the vertical direction. E The structure extends and includes at least one of the following: (a) a first vertical electrode current collector end 640a extending beyond the first vertical end surface 500a of the electrode active material layer 132; and (b) a second vertical electrode current collector end 640b extending beyond the second vertical end surface 500b of the electrode active material layer 132; and / or (ii) each component of the counter electrode structure group 112 includes a counter electrode current collector 140 to collect current from the counter electrode active material layer 138, the counter electrode current collector 140 being at least partially along the height H of the counter electrode active material layer 138 in the vertical direction. C The extension includes at least one of the following: (a) a first vertical counter electrode current collector end 642a extending vertically over the first vertical end surface 501a of the counter electrode active material layer 138; and (b) a second vertical electrode current collector end 640b extending over the second vertical end surface 501b of the electrode active material layer 138. Reference Figure 18A As can be seen from the embodiment shown, the vertical ends 640a, b, 642a, b of the electrode current collector 136 and the counter electrode current collector 140 extend over the first and second vertical end surfaces of the electrode active and counter electrode active material layers 132, 138.

[0169] Electrode constraint

[0170] In one embodiment, a set of electrode constraints 108 is provided that constrain the overall macroscopic growth of the electrode assembly 106, such as, for example... Figure 1AAs shown. The set of electrode restraints 108 can restrain the growth of the electrode assembly 106 along one or more dimensions, for example, to reduce the enlargement and deformation of the electrode assembly 106, thereby improving the reliability and cycle life of the energy storage device 100 having the set of electrode restraints 108. As mentioned above, without being limited to any particular theory, it can be considered that carrier ions traveling between the electrode structure 110 and the counter electrode structure 112 during the charging and / or discharging of the secondary battery 102 can insert into the electrode active material, thereby causing the electrode active material and / or electrode structure 110 to expand. Such expansion of the electrode structure 110 can cause the electrode and / or electrode assembly 106 to deform and enlarge, thereby impairing the structural integrity of the electrode assembly 106 and / or increasing the likelihood of electrical short circuits or other failures. In one example, excessive enlargement and / or expansion and contraction of the electrode active material layer 132 during the cycling of the energy storage device 100 can cause fragments of the electrode active material to detach from and / or delaminate from the electrode active material layer 132, thereby impairing the efficiency and cycle life of the energy storage device 100. In another example, excessive growth and / or expansion and contraction of the electrode active material layer 132 can cause the electrode active material to damage the electrically insulating microporous separator 130, resulting in an electrical short circuit and other malfunctions in the electrode assembly 106. Therefore, the set of electrode restraints 108 suppresses this growth or increase that might otherwise occur during cycling between charging and discharging states, thereby improving the reliability, efficiency, and / or cycle life of the energy storage device 100.

[0171] According to one embodiment, the electrode constraint 108 includes a primary growth constraint system 151 to constrain the electrode assembly 106 along a longitudinal axis (e.g., Figure 1A The growth and / or increase (along the Y-axis). In another embodiment, the set of electrode constraints 108 may include a secondary growth constraint system 152 that constrains growth along the vertical axis (e.g., the Y-axis). Figure 1A The growth along the Z-axis (in the context of growth). In another embodiment, the set of electrode constraints 108 may include a three-level growth constraint system 155, which constrains growth along the transverse axis (e.g., the Z-axis). Figure 4CThe growth along the X-axis (in the context of the electrode assembly 106). In one embodiment, the set of electrode constraints 108 includes primary and secondary growth constraint systems 151, 152, and even a tertiary growth constraint system 155, which cooperate to simultaneously constrain growth in one or more directions, such as along longitudinal and vertical axes (e.g., Y-axis and Z-axis), or even simultaneously along all longitudinal, vertical, and lateral axes (e.g., Y, Z, and X-axis). For example, the primary growth constraint system 151 may constrain growth that would otherwise occur along the stacking direction D of the electrode assembly 106 during cycling between a charge state and a discharge state, while the secondary growth constraint system 152 may constrain enlargement and growth that would occur along the vertical axis to prevent bending or other deformation of the electrode assembly 106 in the vertical direction. As another example, in one embodiment, the secondary growth constraint system 152 may reduce enlargement and / or expansion along the vertical axis that would otherwise be exacerbated by the restriction on growth imposed by the primary growth constraint system 151. The tertiary growth constraint system 155 may also optionally reduce enlargement and / or expansion along the lateral axis that may occur during cycling. That is, according to one embodiment, the primary growth constraint system 151, the secondary growth constraint system 152, and the optional tertiary growth constraint system 155 can operate together to cooperatively constrain the multidimensional growth of the electrode assembly 106.

[0172] See Figures 4A to 4B An embodiment of a set of electrode constraints 108 is shown, which has a primary growth constraint system 151 and a secondary growth constraint system 152 for the electrode assembly 106. Figure 4A This shows a cut along the longitudinal axis (Y-axis). Figure 1A The cross-section of the electrode assembly 106 is shown such that the resulting 2-D cross-section is shown through the vertical axis (Z-axis) and the longitudinal axis (Y-axis). Figure 4B This shows a cutoff along the horizontal axis (X-axis). Figure 1A The cross-section of the electrode assembly 106 is shown such that the resulting 2-D cross-section is displayed along the vertical axis (Z-axis) and the horizontal axis (X-axis). For example... Figure 4AAs shown, the primary growth constraint system 151 may typically include first and second primary growth constraint members 154 and 156, which are separated from each other along the longitudinal direction (Y-axis). For example, in one embodiment, the first and second primary growth constraint members 154 and 156 each include a first primary growth constraint member 154 that at least partially or even completely covers a first longitudinal end surface 116 of the electrode assembly 106, and a second primary growth constraint member 156 that at least partially or even completely covers a second longitudinal end surface 118 of the electrode assembly 106. In another version, one or more of the first and second primary growth constraint members 154 and 156 may be located inside the longitudinal ends 117 and 119 of the electrode assembly 106, for example, when one or more of the primary growth constraint members include the internal structure of the electrode assembly 106. The primary growth constraint system 151 may further include at least one primary connecting member 162 that connects the first and second primary growth constraint members 154 and 156 and may have a main axis parallel to the longitudinal direction. For example, the primary growth constraint system 151 may include first and second primary connecting members 162 and 164, which are separated from each other along an axis orthogonal to the longitudinal axis, such as along a vertical axis (Z-axis) as shown in this embodiment. The first and second primary connecting members 162 and 164 can be used to connect the first and second primary growth constraints 154 and 156 to each other and to keep the first and second primary growth constraints 154 and 156 tensioned to constrain growth along the longitudinal axis of the electrode assembly 106.

[0173] According to one embodiment, the set of electrode constraints 108, including the primary growth constraint system 151, is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction (i.e., the electrode stacking direction D) such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 20% during 20 consecutive cycles of the secondary battery between a state of charge and a state of discharge. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 20% during 30 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 20% during 50 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 20% during 80 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 20% during 100 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 20% during 200 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 20% during 300 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 20% during 500 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 20% during 800 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 20% during 1000 consecutive cycles of the secondary battery.As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 20% during 2000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 20% during 3000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 20% during 5000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 20% during 8000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is able to constrain the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freette diameter of the electrode assembly in the longitudinal direction is less than 20% during 10,000 consecutive cycles of the secondary battery.

[0174] In yet another embodiment, the set of electrode constraints 108, including the primary growth constraint system 151, is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 10 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 20 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 30 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 50 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 80 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 100 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 200 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 300 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 500 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 800 consecutive cycles of the secondary battery between a state of charge and a state of discharge.As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 1000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 2000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 3000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 5000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 8000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 10% during 10000 consecutive cycles of the secondary battery.

[0175] In yet another embodiment, the set of electrode constraints 108, including the primary growth constraint system 151, is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 5 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 10 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 20 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 30 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 50 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 80 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 100 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 200 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 300 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 500 consecutive cycles of the secondary battery between a state of charge and a state of discharge.As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 800 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 1000 consecutive cycles of the secondary battery between a state of charge and a state of discharge. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 2000 consecutive cycles of the secondary battery between a state of charge and a state of discharge. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 3000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 5000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 8000 consecutive cycles of the secondary battery. In one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 5% during 10000 consecutive cycles of the secondary battery.

[0176] In yet another embodiment, the set of electrode constraints 108, including the primary growth constraint system 151, is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during each cycle of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 5 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 10 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 20 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 30 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 50 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 80 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 100 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 200 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 300 consecutive cycles of the secondary battery.As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 500 consecutive cycles of the secondary battery between a state of charge and a state of discharge. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 800 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 1000 consecutive cycles of the secondary battery between a state of charge and a state of discharge. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 2000 consecutive cycles of the secondary battery between a state of charge and a state of discharge. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 3000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 5000 consecutive cycles of the secondary battery between a state of charge and a state of discharge. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 8000 consecutive cycles of the secondary battery. In one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Freret diameter of the electrode assembly in the longitudinal direction is less than 1% during 10000 consecutive cycles of the secondary battery.

[0177] The state of charge means that the secondary battery 102 is charged to at least 75% of its rated capacity, for example, at least 80% of its rated capacity, or even at least 90% of its rated capacity, for example, at least 95% of its rated capacity, or even 100% of its rated capacity. The state of discharge means that the secondary battery is discharged to below 25% of its rated capacity, for example, below 20% of its rated capacity, or even below 10%, for example, below 5%, or even 0% of its rated capacity. Furthermore, it should be noted that the actual capacity of the secondary battery 102 can vary with time and the number of cycles the battery undergoes. That is, although the secondary battery 102 may initially exhibit an actual measured capacity close to its rated capacity, the actual capacity of the battery will decrease over time, wherein the secondary battery 102 is considered to be at the end of its life when the actual capacity measured during the transition from the state of charge to the state of discharge drops to below 80% of its rated capacity.

[0178] exist Figure 4A and 4B The diagram further illustrates that the set of electrode constraints 108 may further include a secondary growth constraint system 152, which typically includes first and second secondary growth constraints 158, 160, separated from each other along a second direction orthogonal to the longitudinal direction (e.g., along the vertical axis (Z-axis) in the illustrated embodiment). For example, in one embodiment, the first secondary growth constraint 158 ​​extends at least partially across a first region 148 of the transverse surface 142 of the electrode assembly 106, and the second secondary growth constraint 160 extends at least partially across a second region 150 of the transverse surface 142 of the electrode assembly 106 opposite to the first region 148. In yet another version, one or more of the first and second secondary growth constraints 154, 156 may be internal to the transverse surface 142 of the electrode assembly 106, for example, when one or more of the secondary growth constraints include the internal structure of the electrode assembly 106. In one embodiment, the first and second secondary growth constraints 158 and 160 are each connected by at least one secondary connecting member 166, which may have a principal axis parallel to a second direction, such as a vertical axis. The secondary connecting member 166 can be used to connect and hold the first and second secondary growth constraints 158 and 160 at tension to suppress the growth of the electrode assembly 106 in a direction orthogonal to the longitudinal direction, such as suppressing growth in the vertical direction (e.g., along the Z-axis). Figure 4A In the illustrated embodiment, at least one secondary connecting member 166 may correspond to at least one of the first and second primary growth constraints 154, 156. However, the secondary connecting member 166 is not limited thereto and may alternatively and / or additionally include other structures and / or configurations.

[0179] According to one embodiment, the set of constraints including the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in a second direction orthogonal to the longitudinal direction (e.g., a vertical direction (Z-axis)), such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 20% during 20 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction, such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 20% during 30 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction, such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 20% during 50 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction, such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 20% during 80 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 20% during 100 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 20% during 200 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 20% during 300 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 20% during 500 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 20% during 800 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 20% during 1000 consecutive cycles of the secondary battery.As another example, in one embodiment, the secondary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 20% during 2000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 20% during 3000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 20% during 5000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 20% during 8000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is able to constrain the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrite diameter of the electrode assembly in the second direction is less than 20% during 10,000 consecutive cycles between the secondary battery's state of charge and state of discharge.

[0180] In one embodiment, the set of constraints including the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 10 consecutive cycles of the secondary battery between the charging and discharging states. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 20 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 30 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 50 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 80 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 100 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 200 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 300 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 500 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 800 consecutive cycles of the secondary battery.As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 1000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 2000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 3000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 5000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 8000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 10% during 10000 consecutive cycles of the secondary battery.

[0181] In one embodiment, the set of constraints including the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during five consecutive cycles of the secondary battery between the charging and discharging states. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 10 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 20 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 30 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 50 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 80 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 100 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 200 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 300 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 500 consecutive cycles of the secondary battery.As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 800 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 1000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 2000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 3000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 5000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 8000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 5% during 10000 consecutive cycles of the secondary battery.

[0182] In one embodiment, the set of constraints including the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during each cycle of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 5 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 10 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 20 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 30 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 50 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 80 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 100 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 200 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 300 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 500 consecutive cycles of the secondary battery.As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 800 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 1000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 2000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 3000 consecutive cycles of the secondary battery between the state of charge and the state of discharge. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 5000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 8000 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the second direction such that any increase in the Ferrette diameter of the electrode assembly in the second direction is less than 1% during 10000 consecutive cycles of the secondary battery.

[0183] Figure 4C An embodiment of a set of electrode constraints 108 is shown, which further includes a tertiary growth constraint system 155 to constrain the growth of the electrode assembly in a third direction (e.g., the lateral (X) direction) perpendicular to the longitudinal and second directions. The tertiary growth constraint system 155 can be provided in addition to the primary and secondary growth constraint systems 151, 152 to constrain the overall growth of the electrode assembly 106 in three dimensions, and / or the tertiary growth constraint system 155 can be provided in combination with one of the primary or secondary growth constraint systems 151, 152 to constrain the overall growth of the electrode assembly 106 in two dimensions. Figure 4C This shows a cutoff along the horizontal axis (X-axis). Figure 1A The cross-section of the electrode assembly 106 is shown such that the resulting 2D cross-section is displayed along the vertical axis (Z-axis) and the horizontal axis (X-axis). For example... Figure 4C As shown, the tertiary growth constraint system 155 typically includes first and second tertiary growth constraint members 157, 159, which are separated from each other along a third direction (e.g., the lateral direction (X-axis)). For example, in one embodiment, the first tertiary growth constraint member 157 extends at least partially across a first region 144 of the lateral surface 142 of the electrode assembly 106, and the second tertiary growth constraint member 159 extends at least partially across a second region 146 of the lateral surface 142 of the electrode assembly 106, which is opposite to the first region 144 in the lateral direction. In another version, one or more of the first and second tertiary growth constraint members 157, 159 may be inside the lateral surface 142 of the electrode assembly 106, for example, when one or more of the tertiary growth constraint members include the internal structure of the electrode assembly 106. In one embodiment, the first and second tertiary growth constraint members 157, 159 are each connected by at least one tertiary connecting member 165, which may have a main axis parallel to the third direction. The tertiary connecting member 165 can be used to connect the first and second tertiary growth restraints 157 and 159 respectively and keep them tensioned together to suppress the growth of the electrode assembly 106 in a direction orthogonal to the longitudinal direction, for example, suppressing growth in the transverse direction (e.g., along the X-axis). Figure 4C In the illustrated embodiment, the at least one tertiary connecting member 165 may correspond to at least one of the first and second secondary growth constraints 158, 160. However, the tertiary connecting member 165 is not limited thereto and may alternatively and / or additionally include other structures and / or configurations. For example, in one embodiment, the at least one tertiary connecting member 165 may correspond to at least one of the first and second primary growth constraints 154, 156 (not shown).

[0184] According to one embodiment, the set of constraints of the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in a third direction orthogonal to the longitudinal direction (e.g., the lateral direction (X-axis)) such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 20% during 20 consecutive cycles of the secondary battery. As another example, in one embodiment, the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 20% during 30 consecutive cycles of the secondary battery. As another example, in one embodiment, the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 20% during 50 consecutive cycles of the secondary battery. As another example, in one embodiment, the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 20% during 80 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 20% during 100 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 20% during 200 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 20% during 300 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 20% during 500 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 20% during 800 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 20% during 1000 consecutive cycles of the secondary battery.As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 20% during 2000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 20% during 3000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 20% during 5000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 20% during 8000 consecutive cycles of the secondary battery. As another example, in one embodiment, the three-level growth constraint system 155 is able to constrain the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrite diameter of the electrode assembly in the third direction is less than 20% during 10,000 consecutive cycles of the secondary battery.

[0185] In one embodiment, the set of constraints of the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 10 consecutive cycles of the secondary battery. As another example, in one embodiment, the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 20 consecutive cycles of the secondary battery. As another example, in one embodiment, the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 30 consecutive cycles of the secondary battery. As another example, in one embodiment, the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 50 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 80 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 100 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 200 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 300 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 500 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 800 consecutive cycles of the secondary battery.As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 1000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 2000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 3000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 5000 consecutive cycles of the secondary battery between the state of charge and the state of discharge. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in a third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 8000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in a third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 10% during 10000 consecutive cycles of the secondary battery.

[0186] In one embodiment, the set of constraints of the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 5 consecutive cycles of the secondary battery. As another example, in one embodiment, the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 10 consecutive cycles of the secondary battery. As another example, in one embodiment, the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 20 consecutive cycles of the secondary battery. As another example, in one embodiment, the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 30 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 50 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 80 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 100 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 200 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in a third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 300 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in a third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 500 consecutive cycles of the secondary battery.As another example, in one embodiment, the tertiary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 800 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 1000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 2000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 3000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 5000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 8000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 10000 consecutive cycles of the secondary battery.

[0187] In one embodiment, the set of constraints of the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during each cycle of the secondary battery. As another example, in one embodiment, the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 5 consecutive cycles of the secondary battery. As another example, in one embodiment, the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 10 consecutive cycles of the secondary battery. As another example, in one embodiment, the three-level growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 20 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 30 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 5% during 50 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 80 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 100 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in a third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 200 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in a third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 300 consecutive cycles of the secondary battery.As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in a third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 500 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in a third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 800 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in a third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 1000 consecutive cycles of the secondary battery between a state of charge and a state of discharge. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in a third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 2000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 3000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 5000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 8000 consecutive cycles of the secondary battery. As another example, in one embodiment, the tertiary growth constraint system 155 is capable of constraining the growth of the electrode assembly 106 in the third direction such that any increase in the Ferrette diameter of the electrode assembly in the third direction is less than 1% during 10000 consecutive cycles of the secondary battery.

[0188] According to one embodiment, primary and secondary growth constraint systems 151, 152 and an optional tertiary growth constraint system 155 are configured to operate cooperatively, such that multiple portions of the primary growth constraint system 151 cooperatively act as part of the secondary growth constraint system 152, and / or multiple portions of the secondary growth constraint system 152 cooperatively act as part of the primary growth constraint system 151, and multiple portions of either the primary and / or secondary constraint systems 151, 152 can also cooperatively act as part of the tertiary growth constraint system, and vice versa. For example, in Figure 4A and 4BIn the illustrated embodiment, the first and second primary connecting members 162 and 164 of the primary growth constraint system 151 can be used as at least a portion or even the entire structure of the first and second secondary growth constraint members 158 and 160, respectively, which constrain growth in a second direction orthogonal to the longitudinal direction. In another embodiment, as described above, one or more of the first and second primary growth constraint members 154 and 156 can be used as one or more secondary connecting members 166 to connect the first and second secondary growth constraint members 158 and 160, respectively. Conversely, at least a portion of the first and second secondary growth constraint members 158 and 160 can serve as the first and second primary connecting members 162 and 164 of the primary growth constraint system 151, and in one embodiment, at least one secondary connecting member 166 of the secondary growth constraint system 152 can serve as one or more of the first and second primary growth constraint members 154 and 156, respectively. In another embodiment, at least a portion of the first and second primary connecting members 162, 164 of the primary growth constraint system 151 and / or at least one secondary connecting member 166 of the secondary growth constraint system 152 can be used as at least a portion or even the entire structure of the first and second tertiary growth constraint members 157, 159, which constrain growth in the transverse direction orthogonal to the longitudinal direction. In yet another embodiment, one or more of the first and second primary growth constraint members 154, 156 and / or the first and second secondary growth constraint members 158, 160 can be used as one or more tertiary connecting members 165 to connect the first and second tertiary growth constraint members 157, 159, respectively. Conversely, at least a portion of the first and second tertiary growth constraint members 157, 159 may respectively serve as the first and second primary connecting members 162, 164 of the primary growth constraint system 151, and / or in one embodiment, at least one secondary connecting member 166 of the secondary growth constraint system 152 and at least one tertiary connecting member 165 of the tertiary growth constraint system 155 may respectively serve as one or more of the first and second primary growth constraint members 154, 156, and / or one or more of the first and second secondary growth constraint members 158, 160. Alternatively and / or additionally, the primary and / or secondary and / or tertiary growth constraint members may include other structures that cooperatively constrain the growth of the electrode assembly 106. Thus, the primary and secondary growth constraint systems 151, 152 and the optional tertiary growth constraint system 155 may share components and / or structures that constrain the growth of the electrode assembly 106.

[0189] In one embodiment, the set of electrode constraints 108 may include structures such as primary and secondary growth constraints, and primary and secondary connection members, which are structures located outside and / or inside the battery housing 104, or may be part of the battery housing 104 itself. For example, the set of electrode constraints 108 may include a combination of structures including the battery housing 104 and other structural components. In one such embodiment, the battery housing 104 may be a component of the primary growth constraint system 151 and / or the secondary growth constraint system 152; in other words, in one embodiment, the battery housing 104, alone or in combination with one or more other structures (inside and / or outside the battery housing 104, such as the primary growth constraint system 151 and / or the secondary growth constraint system 152), constrains the growth of the electrode assembly 106 in the electrode stacking direction D and / or in a second direction orthogonal to the stacking direction D. For example, one or more of the primary growth constraints 154, 156 and the secondary growth constraints 158, 160 may include structures located inside the electrode assembly. In another embodiment, the primary growth constraint system 151 and / or the secondary growth constraint system 152 do not include the battery housing 104. Instead, one or more discrete structures other than the battery housing 104 (located inside and / or outside the battery housing 104) constrain the growth of the electrode assembly 106 in the electrode stacking direction D and / or in a second direction orthogonal to the stacking direction D. In another embodiment, the primary and secondary growth constraint systems, and optionally a tertiary growth constraint system, are housed within the battery housing, which may be a sealed battery housing, such as a hermetically sealed battery housing. During repeated cycles of the energy storage device 100 or secondary battery having the electrode assembly 106, the set of electrode constraints 108 can constrain the electrode assembly 106 at a pressure greater than the pressure applied by the growth and / or increase of the electrode assembly 106.

[0190] In one exemplary embodiment, the primary growth constraint system 151 includes one or more discrete structures located within the battery housing 104 that constrain the growth of the electrode structure 110 in the stacking direction D by applying a pressure exceeding the pressure generated by the electrode structure 110 in the stacking direction D during repeated cycling of the secondary battery 102 having an electrode structure 110 as part of the electrode assembly 106. In another exemplary embodiment, the primary growth constraint system 151 includes one or more discrete structures located within the battery housing 104 that constrain the growth of the counter electrode structure 112 in the stacking direction D by applying a pressure exceeding the pressure generated by the counter electrode structure 112 in the stacking direction D during repeated cycling of the secondary battery 102 having a counter electrode structure 112 as part of the electrode assembly 106. The secondary growth constraint system 152 may similarly include one or more discrete structures located within the battery casing 104, which constrain the growth of at least one of the electrode structures 110 and counter electrode structures 112 in a second direction (e.g., along the vertical axis (Z-axis)) orthogonal to the stacking direction D during repeated cycling of the secondary battery 102 having electrode or counter electrode structures 110, 112 by applying pressure in a second direction exceeding the pressure generated by the electrode or counter electrode structures 110, 112 in the second direction.

[0191] In another embodiment, the first and second primary growth constraint members 154, 156 of the primary growth constraint system 151 constrain the growth of the electrode assembly 106 by applying pressure to the first and second longitudinal end surfaces 116, 118 of the electrode assembly 106 (i.e., in the longitudinal direction), which exceeds the pressure applied by the first and second primary growth constraint members 154, 156 to other surfaces of the electrode assembly 106 (e.g., the first and second regions of the transverse surface 142 of the electrode assembly 106 opposite each other along the transverse axis and / or vertical axis) in a direction orthogonal to the longitudinal direction. That is, the first and second primary growth constraint members 154, 156 can apply pressure in the longitudinal direction (Y-axis) that exceeds the pressure generated thereby in directions orthogonal to them (e.g., the transverse (X-axis) direction and the vertical (Z-axis) direction). For example, in one such embodiment, the primary growth constraint system 151 constrains the growth of the electrode assembly 106 by pressure on the first and second longitudinal end surfaces 116, 118 (i.e., in the stacking direction D), which exceeds at least twice the pressure held by the primary growth constraint system 151 on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the stacking direction D. As another example, in one such embodiment, the primary growth constraint system 151 constrains the growth of the electrode assembly 106 by pressure on the first and second longitudinal end surfaces 116, 118 (i.e., in the stacking direction D), which exceeds at least three times the pressure held by the primary growth constraint system 151 on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the stacking direction D. As another example, in one such embodiment, the primary growth constraint system 151 constrains the growth of the electrode assembly 106 by pressure on the first and second longitudinal end surfaces 116, 118 (i.e., in the stacking direction D), which exceeds at least four times the pressure held on the electrode assembly 106 in at least one or even both directions perpendicular to the stacking direction D.

[0192] Similarly, in one embodiment, the first and second secondary growth constraint members 158, 160 of the primary growth constraint system 151 constrain the growth of the electrode assembly 106 by applying pressure in a second direction orthogonal to the longitudinal direction on the first and second opposing regions of the transverse surface 142 of the electrode assembly 106 (e.g., the first and second opposing surface regions along the vertical axes 148, 150 (i.e., in the vertical direction)). This pressure exceeds the pressure that the first and second secondary growth constraint members 158, 160 would apply to other surfaces of the electrode assembly 106 in the direction orthogonal to the second direction. That is, the first and second secondary growth constraint members 158, 160 can apply pressure in the vertical direction (Z-axis) that exceeds the pressure generated therein in the directions orthogonal to them (e.g., the transverse (X-axis) direction and the longitudinal (Y-axis) direction). For example, in one such embodiment, the secondary growth constraint system 152 constrains the growth of the electrode assembly 106 by pressure on the first and second opposing surface regions 148, 150 (i.e., in the vertical direction), which exceeds at least twice the pressure held on the electrode assembly 106 by the secondary growth constraint system 152 in at least one or even all two directions perpendicular to the vertical direction. As another example, in one such embodiment, the secondary growth constraint system 152 constrains the growth of the electrode assembly 106 by pressure on the first and second opposing surface regions 148, 150 (i.e., in the vertical direction), which exceeds at least three times the pressure held on the electrode assembly 106 by the secondary growth constraint system 152 in at least one or even all two directions perpendicular to the vertical direction. As yet another example, in one such embodiment, the secondary growth constraint system 152 constrains the growth of the electrode assembly 106 by pressure on the first and second opposing surface regions 148, 150 (i.e., in the vertical direction), which exceeds at least four times the pressure held on the electrode assembly 106 in at least one or even all two directions perpendicular to the vertical direction.

[0193] In another embodiment, the first and second tertiary growth constraint members 157 and 159 of the tertiary growth constraint system 155 constrain the growth of the electrode assembly 106 by applying pressure to the first and second opposing regions (e.g., the first and second opposing surface regions along the tertiary axes 161 and 163, respectively, in a direction orthogonal to the longitudinal and second directions) of the lateral surface 142 of the electrode assembly 106. This pressure exceeds the pressure that the tertiary growth constraint system 155 would apply to other surfaces of the electrode assembly 106 in a direction orthogonal to the lateral direction. That is, the first and second tertiary growth constraint members 157 and 159 can apply pressure in the lateral direction (X-axis), which exceeds the pressure generated therein in directions orthogonal to them (e.g., the perpendicular (Z-axis) direction and the longitudinal (Y-axis) direction). For example, in one such embodiment, the tertiary growth constraint system 155 constrains the growth of the electrode assembly 106 by pressure on the first and second opposing surface regions 144, 146 (i.e., in the lateral direction), which exceeds at least twice the pressure held on the electrode assembly 106 by the tertiary growth constraint system 155 in at least one or even both of the two directions perpendicular to the lateral direction. As another example, in one such embodiment, the tertiary growth constraint system 155 constrains the growth of the electrode assembly 106 by pressure on the first and second opposing surface regions 144, 146 (i.e., in the lateral direction), which exceeds at least three times the pressure held on the electrode assembly 106 by the tertiary growth constraint system 155 in at least one or even both of the two directions perpendicular to the lateral direction. As another example, in one such embodiment, the three-level growth constraint system 155 constrains the growth of the electrode assembly 106 by pressure on the first and second opposing surface regions 144, 146 (i.e., in the lateral direction), which exceeds the pressure held on the electrode assembly 106 in at least one or even both directions perpendicular to the lateral direction by at least four times.

[0194] In one embodiment, the set of electrode constraints 108 (which may include a primary growth constraint system 151, a secondary growth constraint system 152, and an optional tertiary growth constraint system 155) is configured to apply pressure to the electrode assembly 106 along two or three dimensions (e.g., along the longitudinal and vertical directions, and optionally along the transverse direction), wherein the pressure applied by the set of electrode constraints 108 along the longitudinal direction is greater than any pressure applied by the set of electrode constraints 108 in any of the directions orthogonal to the longitudinal direction (e.g., the Z and X directions). That is, when the pressures applied by the primary, secondary, and optional tertiary growth constraint systems 151, 152, 155 constituting the set of electrode constraints 108 are added together, the pressure applied to the electrode assembly 106 along the longitudinal axis exceeds the pressure applied to the electrode assembly 106 in the directions orthogonal to the longitudinal axis. For example, in one such embodiment, the set of electrode restraints 108 applies pressure to the first and second longitudinal end surfaces 116, 118 (i.e., in the stacking direction D), the pressure exceeding at least twice the pressure exerted by the set of electrode restraints 108 on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the stacking direction D. As another example, in one such embodiment, the set of electrode restraints 108 applies pressure to the first and second longitudinal end surfaces 116, 118 (i.e., in the stacking direction D), the pressure exceeding at least three times the pressure exerted by the set of electrode restraints 108 on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the stacking direction D. As yet another example, in one such embodiment, the set of electrode restraints 108 applies pressure to the first and second longitudinal end surfaces 116, 118 (i.e., in the stacking direction D), the pressure exceeding at least four times the pressure exerted by the set of electrode restraints 108 on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the stacking direction D.

[0195] According to one embodiment, the first and second longitudinal end surfaces 116, 118 each have a combined surface area smaller than the total surface area of ​​the entire electrode assembly 106 by a predetermined amount. For example, in one embodiment, the geometry of the electrode assembly 106 may correspond to the geometry of a rectangular prism having the first and second longitudinal end surfaces 116, 118 and a transverse surface 142 extending between the end surfaces 116, 118, the transverse surface 142 constituting the remaining surface of the electrode assembly 106 and having opposing surface regions 144, 146 in the X direction (i.e., the sides of the rectangular prism) and opposing surface regions 148, 150 in the Z direction (i.e., the top and bottom surfaces of the rectangular prism, where X, Y, and Z are dimensions measured in directions corresponding to the X, Y, and Z axes, respectively). Therefore, the total surface area is the sum of the surface area covered by the transverse surface 142 (i.e., the surface areas of the opposing surfaces 144, 146, 148, and 150 in the X and Z directions) and the surface areas of the first and second longitudinal end surfaces 116, 118. According to one aspect of the invention, the sum of the surface areas of the first and second longitudinal end surfaces 116, 118 is less than 33% of the total surface area of ​​the electrode assembly 106. For example, in one such embodiment, the sum of the surface areas of the first and second longitudinal end surfaces 116, 118 is less than 25% of the total surface area of ​​the electrode assembly 106. As another example, in one embodiment, the sum of the surface areas of the first and second longitudinal end surfaces 116, 118 is less than 20% of the total surface area of ​​the electrode assembly 106. As another example, in one embodiment, the sum of the surface areas of the first and second longitudinal end surfaces 116, 118 is less than 15% of the total surface area of ​​the electrode assembly 106. As another example, in one embodiment, the sum of the surface areas of the first and second longitudinal end surfaces 116, 118 is less than 10% of the total surface area of ​​the electrode assembly 106.

[0196] In another embodiment, the electrode assembly 106 is configured such that the surface area of ​​the projection of the electrode assembly 106 in a plane orthogonal to the stacking direction (i.e., the longitudinal direction) is smaller than the surface area of ​​the projection of the electrode assembly 106 in other orthogonal planes. For example, refer to Figure 2A As can be seen from the embodiment of electrode assembly 106 shown (e.g., a rectangular prism), the surface area of ​​the projection of electrode assembly 106 onto a plane orthogonal to the stacking direction (i.e., the XZ plane) corresponds to L. EA ×H EA Similarly, the projection of electrode assembly 106 into the ZY plane corresponds to W. EA ×H EA And the projection of electrode assembly 106 in the XY plane corresponds to L EA ×W EATherefore, the electrode assembly 106 is configured such that the stacking direction intersects the plane containing the projection with the smallest surface area. Therefore, in Figure 2A In one embodiment, the electrode assembly 106 is positioned such that the ...

Claims

1. A secondary battery for cycling between a charged state and a discharged state, the secondary battery comprising a battery housing, an electrode assembly and a group of lithium ions and electrode restraints within the battery housing, wherein (a) the electrode assembly having a mutually perpendicular transverse axis, a longitudinal axis and a vertical axis respectively corresponding to the x-axis, the y-axis and the z-axis of an imaginary three-dimensional Cartesian coordinate system, a first longitudinal end surface and a second longitudinal end surface separated from each other in the longitudinal direction, and a longitudinal axis A around the electrode assembly EA and a transverse surface connecting the first longitudinal end surface and the second longitudinal end surface, the transverse surface having opposing first and second regions located on opposite sides of the longitudinal axis and separated in a first direction orthogonal to the longitudinal axis, the electrode assembly having a maximum width W measured in the longitudinal direction EA , the maximum length L defined by the transverse surface and measured in the transverse direction EA , and a maximum height H defined by said lateral surface and measured in the vertical direction EA ,in, The maximum length L EA and the maximum width W EA With the maximum height H EA The ratio is at least 2:1, (b) the electrode assembly comprises a series of layers stacked in a stacking direction parallel to the longitudinal axis within the electrode assembly, wherein the stacked series of layers comprises a negative electrode active material layer group, a negative electrode current collector layer group, a separator material layer group, a positive electrode active material layer group, and a positive electrode current collector material layer group, wherein (i) Each member in the negative electrode active material layer group has a length L E , height H E , and width W E , the length L E corresponds to a Feret diameter of the negative electrode active material layer measured in the lateral direction between the first and second opposite lateral end surfaces of the negative electrode active material layer, and the height H E corresponds to the Feret diameter of the negative electrode active material layer measured in the vertical direction between the first and second opposite vertical end surfaces of the negative electrode active material layer, and the width W E corresponds to a Feret diameter of the negative electrode active material layer measured in the longitudinal direction between the first and second opposing surfaces of the negative electrode active material layer, wherein L E With H E and W E The ratio is at least 5:1; (ii) Each member in the positive electrode active material layer group has a length L C , height H C , and width W C , the length L C corresponds to a Feret diameter of the positive electrode active material layer measured in the lateral direction between the first and second opposite lateral end surfaces of the positive electrode active material layer, and the height H C corresponds to the Feret diameter of the positive electrode active material layer measured in the vertical direction between the first and second opposite vertical end surfaces of the positive electrode active material layer, and the width W C corresponds to a Feret diameter of the positive electrode active material layer measured in the longitudinal direction between the first and second opposing surfaces of the positive electrode active material layer, wherein L C With H C and W C The ratio is at least 5:

1. (iii) the negative electrode active material layer group comprises a particulate material having at least 60 wt % of a negative electrode active material, less than 20 wt % of a conductive aid and a binder material, and wherein the negative electrode active material comprises a silicon-containing material, (c) The set of electrode restraints includes a primary restraint system and a secondary restraint system, wherein (i) the primary restraint system comprises first and second growth restraints and at least one primary connecting member, the first and second primary growth restraints being separated from each other in the longitudinal direction, and the at least one primary connecting member connecting the first and second primary growth restraints to at least partially restrict the growth of the electrode assembly in the longitudinal direction, and (ii) the secondary restraint system comprises first and second secondary growth restraints separated in a second direction and connected by members of the stacked series of layers, wherein the secondary restraint system at least partially restricts growth of the electrode assembly in the second direction when the secondary battery is cycled, the second direction being orthogonal to the longitudinal direction, and (iii) the primary restraint system maintains a pressure on the electrode assembly in the stacking direction that exceeds the pressure maintained on the electrode assembly in each of two directions that are mutually perpendicular and perpendicular to the stacking direction, and (d) the electrode assembly comprises a group of unit cells, wherein each unit cell comprises a unit cell portion of a first member of an electrode current collector layer group, a member of a separator group ionically permeable to carrier ions, a first member of an electrode active material layer group, a unit cell portion of a first member of a counter electrode current collector group, and a first member of a counter electrode active material layer group, wherein (aa) the first member of the electrode active material layer group is adjacent to a first side of the separator and the first member of the counter electrode active material layer group is adjacent to an opposite second side of the separator, (bb) the separator electrically isolates the first member of the electrode active material layer group from the first member of the counter electrode active material layer group, and carrier ions are exchanged primarily between the first member of the electrode active material layer group and the first member of the counter electrode active material layer group via the separator of each such unit cell during cycling between the charge state and the discharge state of the battery, and (cc) within each unit cell, a. The first vertical end surface of the electrode and the first relative vertical end surface of the electrode active material layer are located on the same side of the electrode assembly, and the median vertical position of the first relative vertical end surface of the electrode active material is along the length L of the electrode active material layer in the XZ plane E The 2D diagram plots the first vertical end surface E VP1 , the median vertical position of the first relatively vertical end surface of the counter electrode active material layer in the XZ plane along the length L of the counter electrode active material layer C The 2D diagram plots the first vertical end surface CE VP1 , wherein, for the length L of the electrode active material layer C At least 60% of: (i) the image E measured in the vertical direction VP1 and CE VP1 The separation distance S Z1 The absolute value is 1000μm≥|S Z1 |≥5 μm, (ii) between the electrode and the first vertical end surface of the counter electrode active material layer, the first vertical end surface of the counter electrode active material layer is arranged inwardly relative to the first vertical end surface of the electrode active material layer, b. The second vertical end surfaces of the electrode and the counter electrode active material layer are located on the same side of the electrode assembly and are opposite to the first vertical end surfaces of the electrode and the counter electrode active material layer, respectively, and the median vertical position of the second relative vertical end surfaces of the electrode active material layer is along the length L of the electrode active material layer in the XZ plane. E The 2D diagram depicts the second vertical end surface diagram E VP2 The median vertical position of the second relatively vertical end surface of the counter electrode active material layer is in the XZ plane along the length L of the counter electrode active material layer. C The 2D diagram plots the second vertical end surface CE VP2 , wherein, for the length L of the electrode active material layer C At least 60% of: (i) the image E measured in the vertical direction VP2 and CE VP2 The separation distance S Z2 The absolute value is 1000μm≥|S Z2 |≥5μm, and (ii) between the electrode and the second vertical end surface of the counter electrode active material layer, the second vertical end surface of the counter electrode active material layer is arranged inwardly relative to the second vertical end surface of the electrode active material layer.

2. The secondary battery according to claim 1, wherein The stacked series of layers includes layers having relative end surfaces spaced apart from each other in the transverse direction, wherein, due to elongation and contraction of the layers at the relative end surfaces, multiple relative end surfaces of the layers exhibit plastic deformation and fracture directed in the transverse direction.

3. The secondary battery according to any one of claims 1 to 2, wherein: In each unit cell, c. The first lateral end surfaces of the electrode and the counter electrode active material layer are on the same side of the electrode assembly, and the median lateral position of the first opposite lateral end surface of the electrode active material layer is along the height H of the electrode active material layer in the XZ plane. E The 2D diagram depicts the first transverse end surface E TP1 , the median lateral position of the first relative lateral end surface of the counter electrode in the XZ plane along the height H of the counter electrode active material layer C The 2D diagram depicts the first transverse end surface CE TP1 , wherein, for the height H of the electrode active material layer C At least 60% of: (i) the image E measured in the transverse direction TP1 and CE TP1 The separation distance S X1 The absolute value is 1000μm≥|S X1 | ≥ 5 μm, and (ii) between the electrode and the first lateral end surface of the counter electrode active material layer, the first lateral end surface of the counter electrode active material layer is arranged inwardly relative to the first lateral end surface of the electrode active material layer, and d. The second lateral end surfaces of the electrode and the counter electrode active material layer are on the same side of the electrode assembly and are opposite to the first lateral end surfaces of the electrode and the counter electrode active material layer, respectively, and the median lateral position of the second opposite lateral end surfaces of the electrode active material layer is along the height H of the electrode active material layer in the XZ plane. E The 2D diagram depicts the second lateral end surface E TP2 , the median lateral position of the second relative lateral end surface of the counter electrode in the XZ plane along the height H of the counter electrode active material layer C The 2D diagram depicts the second transverse end surface CE TP2 , wherein the height H of the electrode active material layer C At least 60% of: (i) the image E measured in the transverse direction TP2 and CE TP2 The separation distance S X2 The absolute value is 1000μm≥|S X2 |≥5μm, and (ii) between the electrode and the second lateral end surface of the counter electrode active material layer, the second lateral end surface of the counter electrode active material layer is arranged inwardly relative to the second lateral end surface of the electrode active material layer.

4. A secondary battery for cycling between a charged state and a discharged state, the secondary battery comprising a battery housing, an electrode assembly and a group of carrier ions and electrode restraints within the battery housing, wherein (a) the electrode assembly having a mutually perpendicular transverse axis, a longitudinal axis and a vertical axis respectively corresponding to the x-axis, the y-axis and the z-axis of an imaginary three-dimensional Cartesian coordinate system, a first longitudinal end surface and a second longitudinal end surface separated from each other in the longitudinal direction, and a longitudinal axis A around the electrode assembly EA and a transverse surface connecting the first longitudinal end surface and the second longitudinal end surface, the transverse surface having opposing first and second regions located on opposite sides of the longitudinal axis and separated in a first direction orthogonal to the longitudinal axis, the electrode assembly having a maximum width W measured in the longitudinal direction EA , the maximum length L defined by the transverse surface and measured in the transverse direction EA , and a maximum height H defined by said lateral surface and measured in the vertical direction EA ,in, The maximum length L EA and / or the maximum width W EA Greater than the maximum height H EA , (b) the electrode assembly comprises a series of layers stacked in a stacking direction parallel to the longitudinal axis within the electrode assembly, wherein the stacked series of layers comprises a negative electrode active material layer group, a negative electrode current collector layer group, a separator material layer group, a positive electrode active material layer group, and a positive electrode current collector material layer group, wherein (i) Each member in the negative electrode active material layer group has a length L E , height H E , and width W E , the length L E corresponds to a Feret diameter of the negative electrode active material layer measured in the lateral direction between the first and second opposite lateral end surfaces of the negative electrode active material layer, and the height H E corresponds to the Feret diameter of the negative electrode active material layer measured in the vertical direction between the first and second opposite vertical end surfaces of the negative electrode active material layer, and the width W E corresponds to a Feret diameter of the negative electrode active material layer measured in the longitudinal direction between the first and second opposing surfaces of the negative electrode active material layer, wherein L E With the H E and the W E The ratio is at least 5:1; (ii) Each member in the positive electrode active material layer group has a length L C , height H C , and width W C , the length L C corresponds to a Feret diameter of the positive electrode active material layer measured in the lateral direction between the first and second opposite lateral end surfaces of the positive electrode active material layer, and the height H C corresponds to the Feret diameter of the positive electrode active material layer measured in the vertical direction between the first and second opposite vertical end surfaces of the positive electrode active material layer, and the width W C corresponds to a Feret diameter of the positive electrode active material layer measured in the longitudinal direction between the first and second opposing surfaces of the positive electrode active material layer, wherein L C With H C and W C The ratio is at least 5:

1. (iii) the negative electrode active material layer group comprises a particulate material having at least 60 wt % of a negative electrode active material, less than 20 wt % of a conductive aid and a binder material, (c) The set of electrode restraints includes a primary restraint system and a secondary restraint system, wherein (i) the primary restraint system comprises first and second growth restraints and at least one primary connecting member, the first and second primary growth restraints being separated from each other in the longitudinal direction, and the at least one primary connecting member connecting the first and second primary growth restraints to at least partially restrict the growth of the electrode assembly in the longitudinal direction, and (ii) the secondary restraint system comprises first and second secondary growth restraints separated in a second direction and connected by members of the stacked series of layers, wherein the secondary restraint system at least partially restricts growth of the electrode assembly in the second direction when the secondary battery is cycled, the second direction being orthogonal to the longitudinal direction, and (iii) the primary restraint system maintains a pressure on the electrode assembly in the stacking direction that exceeds the pressure maintained on the electrode assembly in each of two directions that are mutually perpendicular and perpendicular to the stacking direction, and (d) the stacked series of layers comprises layers having opposite end surfaces spaced apart from each other in the transverse direction, wherein a plurality of the opposite end surfaces of the layers exhibit plastic deformation and fracture directed in the transverse direction due to elongation and contraction of the layers at the opposite end surfaces, wherein the electrode assembly comprises a group of unit cells, wherein each unit cell comprises a unit cell portion of a first member of an electrode current collector layer group, a member of a separator group that is ion-permeable to carrier ions, a first member of an electrode active material layer group, a unit cell portion of a first member of a counter electrode current collector group, and a first member of a counter electrode active material layer group, wherein (aa) the first member of the electrode active material layer group is adjacent to a first side of the separator, and the first member of the counter electrode active material layer group is adjacent to an opposite second side of the separator, (bb) the separator electrically isolates the first member of the electrode active material layer group from the first member of the counter electrode active material layer group, and carrier ions are exchanged primarily between the first member of the electrode active material layer group and the first member of the counter electrode active material layer group via the separator of each such unit cell during cycling between the charge state and the discharge state of the battery, and (cc) within each unit cell, a. The first vertical end surface of the electrode and the first relative vertical end surface of the electrode active material layer are located on the same side of the electrode assembly, and the median vertical position of the first relative vertical end surface of the electrode active material is along the length L of the electrode active material layer in the XZ plane E The 2D diagram plots the first vertical end surface E VP1 , the median vertical position of the first relatively vertical end surface of the counter electrode active material layer in the XZ plane along the length L of the counter electrode active material layer C The 2D diagram plots the first vertical end surface CE VP1 , wherein, for the length L of the electrode active material layer C At least 60% of: (i) the image E measured in the vertical direction VP1 and CE VP1 The separation distance S Z1 The absolute value is 1000μm≥|S Z1 |≥5 μm, (ii) for the distance between the electrode and the first vertical end surface of the counter electrode active material layer, the first vertical end surface of the counter electrode active material layer is arranged inwardly relative to the first vertical end surface of the electrode active material layer, b. The second vertical end surfaces of the electrode and the counter electrode active material layer are located on the same side of the electrode assembly and are opposite to the first vertical end surfaces of the electrode and the counter electrode active material layer, respectively, and the median vertical position of the second relative vertical end surfaces of the electrode active material layer is along the length L of the electrode active material layer in the XZ plane. E The 2D diagram depicts the second vertical end surface diagram E VP2 The median vertical position of the second relatively vertical end surface of the counter electrode active material layer is in the XZ plane along the length L of the counter electrode active material layer. C The 2D diagram plots the second vertical end surface CE VP2 , wherein the length L of the electrode active material layer is C At least 60% of: (i) the image E measured in the vertical direction VP2 and CE VP2 The separation distance S Z2 The absolute value is 1000μm≥|S Z2 |≥5μm, and (ii) between the electrode and the second vertical end surface of the counter electrode active material layer, the second vertical end surface of the counter electrode active material layer is arranged inwardly relative to the second vertical end surface of the electrode active material layer.

5. The secondary battery according to claim 4, wherein The electrode assembly comprises a group of unit cells, wherein each unit cell comprises a unit cell portion of a first member of an electrode current collector layer group, a member of a separator group that is ion-permeable to carrier ions, a first member of an electrode active material layer group, a unit cell portion of a first member of a counter electrode current collector group, and a first member of a counter electrode active material layer group, wherein (aa) the first member of the electrode active material layer group is adjacent to a first side of the separator and the first member of the counter electrode active material layer group is adjacent to an opposite second side of the separator, (bb) the separator electrically isolates the first member of the electrode active material layer group from the first member of the counter electrode active material layer group, and carrier ions are exchanged primarily between the first member of the electrode active material layer group and the first member of the counter electrode active material layer group via the separator of each such unit cell during cycling between the charge state and the discharge state of the battery, and (cc) within each unit cell, c. The first lateral end surfaces of the electrode and the counter electrode active material layer are on the same side of the electrode assembly, and the median lateral position of the first opposing lateral end surfaces of the electrode active material layer is in the XZ plane along the height H of the electrode active material layer. E The 2D diagram depicts the first transverse end surface E TP1 , the median lateral position of the first relative lateral end surface of the counter electrode in the XZ plane along the height H of the counter electrode active material layer C The 2D diagram depicts the first transverse end surface CE TP1 , wherein, for the height H of the electrode active material layer C At least 60% of: (i) the image E measured in the transverse direction TP1 and CE TP1 The separation distance S X1 The absolute value is 1000μm≥|S X1 | ≥ 5 μm, and (ii) between the electrode and the first lateral end surface of the counter electrode active material layer, the first lateral end surface of the counter electrode active material layer is arranged inwardly relative to the first lateral end surface of the electrode active material layer, and d. The second lateral end surfaces of the electrode and the counter electrode active material layer are on the same side of the electrode assembly and are opposite to the first lateral end surfaces of the electrode and the counter electrode active material layer, respectively, and the median lateral position of the second opposite lateral end surfaces of the electrode active material layer is along the height H of the electrode active material layer in the XZ plane. E The 2D diagram depicts the second lateral end surface E TP2 , the median lateral position of the second relative lateral end surface of the counter electrode in the XZ plane along the height H of the counter electrode active material layer C The 2D diagram depicts the second transverse end surface CE TP2 , wherein, for the height H of the electrode active material layer C At least 60% of: (i) the image E measured in the transverse direction TP2 and CE TP2 The separation distance S X2 The absolute value is 1000μm≥|S X2 |≥5μm, and (ii) between the electrode and the second lateral end surface of the counter electrode active material layer, the second lateral end surface of the counter electrode active material layer is arranged inwardly relative to the second lateral end surface of the electrode active material layer.

6. A secondary battery for cycling between a charged state and a discharged state, the secondary battery comprising a battery housing, an electrode assembly and a group of lithium ions and electrode restraints within the battery housing, wherein (a) the electrode assembly having a mutually perpendicular transverse axis, a longitudinal axis and a vertical axis respectively corresponding to the x-axis, the y-axis and the z-axis of an imaginary three-dimensional Cartesian coordinate system, a first longitudinal end surface and a second longitudinal end surface separated from each other in the longitudinal direction, and a longitudinal axis A around the electrode assembly EA and a transverse surface connecting the first longitudinal end surface and the second longitudinal end surface, the transverse surface having opposing first and second regions located on opposite sides of the longitudinal axis and separated in a first direction orthogonal to the longitudinal axis, the electrode assembly having a maximum width W measured in the longitudinal direction EA , the maximum length L defined by the transverse surface and measured in the transverse direction EA , and a maximum height H defined by said lateral surface and measured in the vertical direction EA ,in, The maximum length L EA and the maximum width W EA With the maximum height H EA The ratio is at least 2:1, (b) the electrode assembly comprises a series of layers stacked in a stacking direction parallel to the longitudinal axis within the electrode assembly, wherein the stacked series of layers comprises a negative electrode active material layer group, a negative electrode current collector layer group, a separator material layer group, a positive electrode active material layer group, and a positive electrode current collector material layer group, wherein (i) Each member in the negative electrode active material layer group has a length L E , height H E , and width W E , the length L E corresponds to a Feret diameter of the negative electrode active material layer measured in the lateral direction between the first and second opposite lateral end surfaces of the negative electrode active material layer, and the height H E corresponds to a Feret diameter measured in the vertical direction between the first and second relatively vertical end surfaces of the negative electrode active material layer, and the width W E corresponds to a Feret diameter of the negative electrode active material layer measured in the longitudinal direction between the first and second opposing surfaces of the negative electrode active material layer, wherein L E With H E and W E The ratio is at least 5:1; (ii) Each member in the positive electrode active material layer group has a length L C , height H C , and width W C , the length L C corresponds to a Feret diameter of the positive electrode active material layer measured in the lateral direction between the first and second opposite lateral end surfaces of the positive electrode active material layer, and the height H C corresponds to the Feret diameter of the positive electrode active material layer measured in the vertical direction between the first and second opposite vertical end surfaces of the positive electrode active material layer, and the width W C corresponds to a Feret diameter of the positive electrode active material layer measured in the longitudinal direction between the first and second opposing surfaces of the positive electrode active material layer, wherein L C With H C and W C The ratio is at least 5:1; (iii) the negative electrode active material layer group comprises a particulate material having at least 60 wt % of a negative electrode active material, less than 20 wt % of a conductive aid and a binder material, and wherein the negative electrode active material comprises a silicon-containing material, (c) The set of electrode restraints includes a primary restraint system and a secondary restraint system, wherein (i) the primary restraint system comprises first and second growth restraints and at least one primary connecting member, the first and second primary growth restraints being separated from each other in the longitudinal direction, and the at least one primary connecting member connecting the first and second primary growth restraints to at least partially restrict the growth of the electrode assembly in the longitudinal direction, and (ii) the secondary restraint system comprises first and second secondary growth restraints separated in a second direction and connected by members of the stacked series of layers, wherein the secondary restraint system at least partially restricts growth of the electrode assembly in the second direction when the secondary battery is cycled, the second direction being orthogonal to the longitudinal direction, and (iii) the primary restraint system maintains a pressure on the electrode assembly in the stacking direction that exceeds the pressure maintained on the electrode assembly in each of two directions that are mutually perpendicular and perpendicular to the stacking direction, and (d) the electrode assembly comprises a population of unit cells, wherein each unit cell comprises a unit cell portion of a first member of an electrode current collector layer group, a member of a separator group that is ion-permeable to carrier ions, a first member of an electrode active material layer group, a unit cell portion of a first member of a counter electrode current collector group, and a first member of a counter electrode active material layer group, wherein (aa) the first member of the electrode active material layer group is adjacent to a first side of the separator and the first member of the counter electrode active material layer group is adjacent to an opposite second side of the separator, (bb) the separator electrically isolates the first member of the electrode active material layer group from the first member of the counter electrode active material layer group, and carrier ions are exchanged primarily between the first member of the electrode active material layer group and the first member of the counter electrode active material layer group via the separator of each such unit cell during cycling between the charge state and the discharge state of the battery, and (cc) within each unit cell, c. The first lateral end surfaces of the electrode and the counter electrode active material layer are on the same side of the electrode assembly, and the median lateral position of the first opposing lateral end surfaces of the electrode active material layer is in the XZ plane along the height H of the electrode active material layer. E The 2D diagram depicts the first transverse end surface E TP1 , the median lateral position of the first relative lateral end surface of the counter electrode in the XZ plane along the height H of the counter electrode active material layer C The 2D diagram depicts the first transverse end surface CE TP1 , wherein, for the height H of the electrode active material layer C At least 60% of: (i) the image E measured in the transverse direction TP1 and CE TP1 The separation distance S X1 The absolute value is 1000μm≥|S X1 | ≥ 5 μm, and (ii) between the electrode and the first lateral end surface of the counter electrode active material layer, the first lateral end surface of the counter electrode active material layer is arranged inwardly relative to the first lateral end surface of the electrode active material layer, and d. The second lateral end surfaces of the electrode and the counter electrode active material layer are on the same side of the electrode assembly and are opposite to the first lateral end surfaces of the electrode and the counter electrode active material layer, respectively, and the median lateral position of the second opposite lateral end surfaces of the electrode active material layer is along the height H of the electrode active material layer in the XZ plane. E The 2D diagram depicts the second lateral end surface E TP2 , the median lateral position of the second relative lateral end surface of the counter electrode in the XZ plane along the height H of the counter electrode active material layer C The 2D diagram depicts the second transverse end surface CE TP2 , wherein, for the height H of the electrode active material layer C At least 60% of: (i) the image E measured in the transverse direction TP2 and CE TP2 The separation distance S X2 The absolute value is 1000μm≥|S X2 |≥5μm, and (ii) between the electrode and the second lateral end surface of the counter electrode active material layer, the second lateral end surface of the counter electrode active material layer is arranged inwardly relative to the second lateral end surface of the electrode active material layer.

7. The secondary battery according to claim 6, wherein The stacked series of layers includes layers having relative end surfaces spaced apart from each other in the transverse direction, wherein, due to elongation and contraction of the layers at the relative end surfaces, multiple relative end surfaces of the layers exhibit plastic deformation and fracture directed in the transverse direction.

8. The secondary battery according to any one of claims 6 to 7, wherein: In each unit cell, a. The first vertical end surface of the electrode and the counter electrode active material layer are located on the same side of the electrode assembly, and the median vertical position of the first relative vertical end surface of the electrode active material is along the length L of the electrode active material layer in the XZ plane E The 2D diagram plots the first vertical end surface E VP1 , the median vertical position of the first relatively vertical end surface of the counter electrode active material layer in the XZ plane along the length L of the counter electrode active material layer C The 2D diagram plots the first vertical end surface CE VP1 , wherein, for the length L of the electrode active material layer C At least 60% of: (i) the image E measured in the vertical direction VP1 and CE VP1 The separation distance S Z1 The absolute value is 1000μm≥|S Z1 |≥5 μm, (ii) between the electrode and the first vertical end surface of the counter electrode active material layer, the first vertical end surface of the counter electrode active material layer is arranged inwardly relative to the first vertical end surface of the electrode active material layer, b. The second vertical end surfaces of the electrode and the counter electrode active material layer are located on the same side of the electrode assembly and are opposite to the first vertical end surfaces of the electrode and the counter electrode active material layer, respectively, and the median vertical position of the second relative vertical end surfaces of the electrode active material layer is along the length L of the electrode active material layer in the XZ plane. E The 2D diagram depicts the second vertical end surface diagram E VP2 The median vertical position of the second relatively vertical end surface of the counter electrode active material layer is in the XZ plane along the length L of the counter electrode active material layer. C The 2D diagram plots the second vertical end surface CE VP2 , wherein, for the length L of the electrode active material layer C At least 60% of: (i) the image E measured in the vertical direction VP2 and CE VP2 The separation distance S Z2 The absolute value is 1000μm≥|S Z2 |≥5μm, and (ii) between the electrode and the second vertical end surface of the counter electrode active material layer, the second vertical end surface of the counter electrode active material layer is arranged inwardly relative to the second vertical end surface of the electrode active material layer.

9. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The member of the negative electrode active material layer group includes a granular material having at least 80 wt % of a negative electrode active material.

10. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The member of the negative electrode active material layer group includes a granular material having at least 90 wt % of a negative electrode active material.

11. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The member of the negative electrode active material layer group includes a granular material having at least 95 wt % of a negative electrode active material.

12. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The electrode active material including the silicon-containing material includes at least one of silicon, silicon oxide, and a mixture thereof.

13. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The member of the negative electrode active material layer group includes less than 10% of a conductive aid.

14. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The member of the negative electrode active material layer group includes a conductive aid including at least one of copper, nickel, and carbon.

15. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The member of the positive electrode active material layer group includes a transition metal oxide material containing lithium and at least one of cobalt and nickel.

16. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The first and second secondary growth restraints separated in the second direction are connected to each other by members of the stacked series of layers including members of the negative electrode current collector layer group.

17. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The first and second secondary growth restraints separated in the second direction are connected to each other by members of the stacked series of layers including members of the negative current collector layer group, and wherein the negative current collector layer includes a negative backbone layer.

18. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The first and second secondary growth restraints separated in the second direction are connected to each other by components of the stacked series of layers including components of the negative electrode current collector layer group, wherein, for each component of the negative electrode current collector layer group, the negative electrode current collector layer component has a component of the negative electrode active material layer group arranged on its surface.

19. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The first and second secondary growth restraints separated in the second direction are connected to each other by components of the stacked series of layers including components of the negative electrode current collector layer group, and wherein the components of the negative electrode current collector layer group include components of the negative electrode active material layer group arranged on two relative surfaces thereof in the stacked series of layers.

20. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The negative electrode current collector layer group includes one or more of copper and stainless steel.

21. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The member of the negative current collector layer group comprises a thickness measured along the stacking direction of less than 20 microns and at least 2 microns.

22. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The negative current collector layer group member comprises a thickness in the range of 6 to 18 micrometers measured along the stacking direction.

23. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The negative current collector layer group member includes a thickness in the range of 8 to 14 microns measured along the stacking direction.

24. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The first and second secondary growth restraints separated in the second direction are connected to each other by components of the stacked series of layers including components of the positive electrode current collector material layer group.

25. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The components of the positive electrode current collector material layer group include aluminum.

26. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The member of the positive current collector material layer group comprises a thickness measured along the stacking direction of less than 20 microns and at least 2 microns.

27. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The members of the positive current collector material layer group include a thickness in the range of 6 to 18 micrometers measured along the stacking direction.

28. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The members of the positive current collector material layer group include a thickness in the range of 8 to 14 microns measured along the stacking direction.

29. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The first and second secondary growth restraints separated in the second direction are connected to each other by a member including the stacked series of layers of members of the negative electrode active material layer group.

30. The secondary battery according to any one of claims 1, 2, 4, 6 to 7, wherein: The first and second secondary growth restraints separated in the second direction are connected to each other by a member including the stacked series of layers of members of the positive electrode active material layer group.

31. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein: The first and second secondary growth constraints separated in the second direction are connected to each other by means of a series of layers of members comprising the stack of members of the spacer material layer group.

32. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein: The housing is hermetically sealed.

33. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein: The set of restraints is within the battery housing.

34. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein: The primary restraint system is within the battery housing.

35. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein: The secondary restraint system is within the battery housing.

36. The secondary battery according to any one of claims 1, 2, 4, 6-7, further includes a tertiary restraint system, the tertiary restraint system including a first and a second tertiary growth restraint and at least one tertiary connecting member, the first and second tertiary growth restraints are separated from each other in a third direction orthogonal to the longitudinal direction and the second direction, and the at least one tertiary connecting member connects the first and second tertiary growth restraints to at least partially restrict the growth of the electrode assembly in the third direction.

37. The secondary battery according to claim 36, wherein: The three-level restraint system is within the battery housing.

38. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein: The separator material layer includes a polymer electrolyte, or includes a microporous separator material through which a liquid electrolyte passes.

39. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein: The electrode active material includes a compact of the silicon-containing particulate electrode active material.

40. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein The components of the negative current collector layer group include a copper-containing layer, and wherein the stacked series of layers includes components of the negative current collector layer group in a stacked order, wherein components of the negative active material layer group are disposed on opposite sides of the negative current collector layer.

41. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein The negative electrode active material layer group member comprises a compact of a particulate silicon-containing material, and wherein the member is disposed on opposite sides of a copper-containing negative electrode current collector forming a negative electrode backbone.

42. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein The components of the electrode active material layer group include a height dimension H of at least 2.5 mm E .

43. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein The components of the electrode active material layer group include a height dimension H of at least 3 mm. E .

44. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein The negative electrode current collector has longitudinally opposite ends welded to the conductive bus bar.

45. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein The components of the positive electrode current collector material layer group include aluminum-containing materials.

46. ​​The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein The primary restraint system approximately limits the growth of the electrode assembly in the longitudinal direction so that during 20 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20%, wherein the charge state of the secondary battery is at least 75% of the rated capacity of the secondary battery and the discharge state of the secondary battery is less than 25% of the rated capacity of the secondary battery.

47. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein The primary restraint system limits growth of the electrode assembly in the longitudinal direction such that any increase in a Feret diameter of the electrode assembly in the longitudinal direction is less than 20% during 50 consecutive cycles of the secondary battery.

48. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein The primary restraint system limits growth of the electrode assembly in the longitudinal direction to less than 20% during 100 consecutive cycles of the secondary battery.

49. The secondary battery according to any one of claims 1, 2, 4, 6-7, wherein The primary restraint system limits growth of the electrode assembly in the longitudinal direction such that any increase in a Feret diameter of the electrode assembly in the longitudinal direction is less than 20% during 10 consecutive cycles of the secondary battery.

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