Longitudinal restraint for energy storage devices

Abstract

An energy storage device for cycling between a charge state and a discharge state, the energy storage device comprising a housing, an electrode assembly and a non-aqueous liquid electrolyte within the housing, and a constraint that maintains pressure on the electrode assembly as the energy storage device cycles between a charge state and a discharge state.

Description

[0001] This application is a divisional application of a patent application with an application date of May 13, 2016, application number 201680039194.3, and name “Longitudinal Constraint for Energy Storage Devices”. Technical Field

[0002] The present disclosure generally relates to structures for energy storage devices, to energy storage devices incorporating such structures, and to methods for making such structures and energy devices. Background Art

[0003] 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, magnesium ions, or aluminum ions move between a positive electrode and a negative electrode through an electrolyte. A secondary battery may include a single cell or two or more cells that have been electrically coupled to form a battery, wherein each cell includes a positive electrode, a negative electrode, a microporous separator, and an electrolyte.

[0004] In a rocking-chair cell, both the positive and negative electrode structures include materials into which carrier ions are inserted and extracted. When the battery is discharged, 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.

[0005] Figure 1 A cross-sectional view of an electrochemical stack of an existing energy storage device (e.g., non-aqueous, secondary battery) is shown. The electrochemical stack 1 includes a positive electrode current collector 3, a positive electrode active material layer 5, a microporous separator 7, a negative electrode active material layer 9, and a negative electrode current collector 11 in a stacked manner. Each layer has a plurality of electrodes in the stacking direction (i.e., as shown in FIG. 1 ). Figure 1 The height of each layer measured in the direction from the positive electrode collector 3 to the negative electrode collector 11 as shown is significantly smaller (e.g., at least ten times smaller) than the length and width of each layer measured in directions perpendicular to each other and perpendicular to the electrode stacking direction, respectively. Now referring to Figure 2 A roll 13 (sometimes referred to as a "jelly roll") having a top 15 and a bottom 17 is formed by winding the electrochemical stack around a central axis 19; the roll 13 is then loaded into a can (not shown) and filled with a non-aqueous electrolyte to assemble a secondary battery. Figure 2 As shown, the electrode stacking direction of the layers is orthogonal to the central axis 19 .

[0006] Existing energy storage devices such as batteries, fuel cells, and electrochemical capacitors typically have Figure 1 and 2A two-dimensional layered structure (e.g., a planar or spirally wound stack) is shown, wherein the surface area of ​​each stack is roughly equal to its geometric coverage (ignoring porosity and surface roughness). Three-dimensional batteries have been proposed in the literature as a method to increase battery capacity and active material utilization. It has been proposed that three-dimensional structures can be used to provide higher surface area and higher energy compared to two-dimensional layered battery structures. Due to the increased energy that can be obtained from a small geometric area, it is beneficial to manufacture three-dimensional energy storage devices. See, for example, Rust et al., WO2008 / 089110 and Long et al., "Three-Dimensional Battery Architectures", Chemical Reviews, (2004), 104, 4463-4492.

[0007] Conventional wound cells (see, e.g., U.S. Pat. Nos. 6,090,505 and 6,235,427 and Figure 2 ) typically have electrode materials (active materials, binders, conductive aids) coated onto a single foil and compressed prior to battery assembly. The foil on which the electrodes are coated is typically part of the current collection path. In a single jelly roll battery such as an 18650 or square cell, the current collector foil is ultrasonically welded to an electrode bus, tab, tag, etc., which carries the current from the active material through the current collector foil and tab to the outside of the battery. Depending on the design, there may be tabs in multiple locations along a single jelly roll, or at one location along one or both ends of the current collector foil. Conventional stacked cell pouch batteries have multiple plates (or foils) of active material, where the areas on the top of each foil are then gathered and welded together to the tabs; which then carry the current to the outside of the battery pouch (see, e.g., U.S. Patent Publication No. 2005 / 0008939).

[0008] However, one of the challenges associated with secondary batteries is the reliability and cycle life of the battery. For example, the electrode structure of lithium-ion batteries tends to expand (swell) and contract as the battery is repeatedly charged and discharged, which in turn can lead to electrical shorts and failure of the device. Summary of the invention

[0009] In various aspects of the present disclosure, three-dimensional structures for energy storage devices (e.g., batteries, fuel cells, and electrochemical capacitors) are provided. Advantageously, according to one aspect of the present disclosure, the proportion of electrode active materials relative to other components of the energy storage device (i.e., inactive material components of the energy storage device) can be increased. As a result, energy storage devices including three-dimensional structures of the present disclosure can have increased energy density. For a specific amount of energy stored, they can also provide a higher energy retrieval rate than two-dimensional energy storage devices, such as by minimizing or reducing the transport distance of electron and ion transfer between the positive and negative electrodes. These devices may be more suitable for miniaturization and are suitable for applications where the geometric area available for the device is limited and / or the energy density requirements are higher than those achievable using layered devices.

[0010] In short, therefore, according to one aspect of the present disclosure, there is provided an energy storage device for cycling between a charge state and a discharge state. The energy storage device includes a housing, an electrode assembly, and a non-aqueous liquid electrolyte in the housing, and a constraint for maintaining pressure on the electrode assembly when the energy storage device cycles between a charge state and a discharge state. The electrode assembly has a population of electrode structures, a population of counter electrode structures, and an electrically insulating microporous diaphragm material between the electrodes and the components of the counter electrode group. The electrode assembly has a first and second longitudinal end surface separated along a longitudinal axis and a side surface surrounding the longitudinal axis and connecting the first and second longitudinal end surfaces, and the combined surface area of ​​the first and second longitudinal end surfaces is less than 33% of the combined surface area of ​​the side surface and the first and second longitudinal end surfaces. The components of the electrode group and the components of the counter electrode group are arranged in an alternating order in the stacking direction of the parallel longitudinal axis within the electrode assembly. The constraint has first and second compression members connected by at least one tensioning member that pulls the compression members toward each other, and the constraint maintains a pressure on the electrode assembly in the stacking direction that exceeds the pressure maintained on the electrode assembly in each of the two directions perpendicular to each other and perpendicular to the stacking direction.

[0011] According to another aspect of the present disclosure, a secondary battery for cycling between a charged state and a discharged state is provided, the secondary battery having a battery housing, an electrode assembly and a non-aqueous liquid electrolyte in the battery housing, and a constraint that maintains pressure on the electrode assembly as the secondary battery cycles between a charged state and a discharged state. The electrode assembly has a group of electrode structures, a group of counter electrode structures, and an electrically insulating microporous diaphragm material between the components of the electrode and counter electrode groups. The electrode assembly has a first and second longitudinal end surface that are separated along a longitudinal axis, and a side surface that surrounds the longitudinal axis and connects the first and second longitudinal end surfaces, and the surface area of ​​the first and second longitudinal end surfaces is less than 33% of the surface area of ​​the electrode assembly. The components of the electrode group and the components of the counter electrode group are arranged in an alternating order in the stacking direction of the parallel longitudinal axes within the electrode assembly. The projections of the components of the electrode group and the counter electrode group on the first longitudinal surface surround the first projection area, and the projections of the components of the electrode group and the counter electrode group on the second longitudinal surface surround the second projection area. The constraint has first and second compression members respectively covering the first and second projected areas, the compression members being connected by a tensioning member covering the side surfaces of the electrode assembly and pulling the compression members toward each other, and the constraint maintaining 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.

[0012] Other objects and features will be in part apparent and in part pointed out hereinafter. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 A cross section of an electrochemically stacked cell that is a prior art two-dimensional energy storage device such as a lithium-ion battery.

[0014] Figure 2 A cross section of a wound electrochemical stack of cells that is a prior art two-dimensional energy storage device such as a lithium-ion battery.

[0015] Figure 3A is a schematic diagram of one embodiment of an electrode assembly of the present disclosure having a triangular prism shape.

[0016] Figure 3B is a schematic diagram of one embodiment of an electrode assembly of the present disclosure having a parallelepiped shape.

[0017] Figure 3C is a schematic diagram of one embodiment of an electrode assembly of the present disclosure having a rectangular prism shape.

[0018] Figure 3D is a schematic diagram of one embodiment of an electrode assembly of the present disclosure having a pentagonal prism shape.

[0019] Figure 3E is a schematic diagram of one embodiment of an electrode assembly of the present disclosure having a hexagonal prism shape.

[0020] Figure 4 is a schematic exploded view of one embodiment of a secondary battery of the present disclosure.

[0021] Figure 5A yes Figure 4 A schematic end view of one end portion of an electrode assembly of a secondary battery.

[0022] Figure 5B yes Figure 5A Schematic end views of opposite ends of an electrode assembly.

[0023] Figure 5C yes Figure 5A Schematic top view of the side surface of an electrode assembly.

[0024] Figure 5D yes Figure 5A Schematic bottom view of opposite side surfaces of an electrode assembly.

[0025] Fig. 6A yes Figure 4 A schematic perspective view of the constraint of a secondary battery.

[0026] Figure 6B An embodiment of a cross-section of an electrode assembly having a constraint employing an internal compression member is shown.

[0027] Figure 6C An embodiment of a cross-section of an electrode assembly having a constraint employing multiple internal compression members is shown.

[0028] Figure 7 is a schematic exploded view of an alternative embodiment of a secondary battery of the present disclosure.

[0029] Figure 8 is a schematic diagram of an alternative embodiment of a constraint for an electrode assembly of a secondary battery of the present disclosure in an expanded form.

[0030] Fig. 9 After folding Figure 8 Schematic diagram of the constraints.

[0031] Fig. 10A is a schematic diagram of an alternative embodiment of a constraint and electrode assembly of a secondary battery of the present disclosure.

[0032] Fig. 10B yes Fig. 10A A magnified view of the restraint and electrode assembly.

[0033] Fig.11Ais a schematic diagram of an alternative embodiment of a constraint for an electrode assembly of a secondary battery of the present disclosure.

[0034] Fig. 11B yes Fig.11A A magnified view of the constraints.

[0035] Fig. 12A is a perspective view of one embodiment of an electrode assembly of a secondary battery of the present disclosure, in which a portion is cut away to show an internal structure.

[0036] Fig. 12B yes Fig. 12A An end view of one end of an electrode assembly.

[0037] Fig. 12C yes Fig. 12A End views of opposite ends of an electrode assembly.

[0038] Fig.13 is a perspective view of an alternative embodiment of a secondary battery of the present disclosure, with a portion cut away to show the internal structure.

[0039] Fig.14 is a perspective view of an alternative embodiment of a secondary battery of the present disclosure, with a portion cut away to show the internal structure.

[0040] Fig.15 is a perspective view of an alternative embodiment of a secondary battery of the present disclosure, with a portion cut away to show the internal structure.

[0041] Fig.16 is a cross-sectional view of an alternative embodiment of a constraint and electrode assembly of the present disclosure.

[0042] Corresponding reference characters indicate corresponding parts throughout the drawings. DETAILED DESCRIPTION

[0043] Unless the context clearly indicates otherwise, as used herein, "a", "an", and "the" (ie, the singular form) refer to plural referents. For example, in one example, reference to "an electrode" includes a single electrode and multiple similar electrodes.

[0044] As used herein, "about" and "approximately" refer to plus or minus 10%, 5%, or 1% of the value. For example, in one example, about 250 μm will include 225 μm to 275 μm. As a further example, in one example, about 1000 μm will include 900 μm to 1100 μm. Unless otherwise indicated, all numbers used in the specification and claims to indicate quantities (e.g., measured values, etc.) should be understood to be modified by the term "about" in all cases. Therefore, unless otherwise indicated, the numerical parameters set forth in the following specification and the attached claims are approximate values. Each numerical parameter should at least be interpreted according to the number of reported significant figures and by using ordinary rounding techniques.

[0045] As used herein, "charged state" in the context of a secondary battery's state refers to a state in which the secondary battery is charged to at least 75% of its rated capacity. For example, the battery may 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.

[0046] The "discharge state" used herein in the context of the state of a secondary battery refers to a state in which the secondary battery is discharged to less than 25% of its rated capacity. For example, the battery may 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.

[0047] As used herein, "cycling" in the context of cycling of a secondary battery between a charged state and a discharged state refers to charging and / or discharging a battery so that the battery moves from a first state of a charged state or a discharged state back to a second state opposite the first state (i.e., a charged state if the first state is discharged, and a discharged state if the first state is charged) in a cyclic manner, and then moving the battery back to the first state to complete the cycle. For example, a single cycle of a secondary battery between a charged state and a discharged state may include charging the battery from a discharged state to a charged state, and then discharging it back to a discharged state to complete the cycle. A single cycle may also include discharging the battery from a charged state to a discharged state, and then charging it back to a charged state to complete the cycle.

[0048] "Feret's diameter" as referred to herein with respect to an electrode assembly is defined as the distance between two parallel planes of the electrode assembly measured in a direction perpendicular to the two planes.

[0049] As used herein, "longitudinal axis," "transverse axis," and "vertical axis" refer to axes that are perpendicular to one another (i.e., each is orthogonal to one another). For example, "longitudinal axis," "transverse axis," and "vertical axis" as used herein are analogous to a Cartesian coordinate system for defining a three-dimensional aspect or orientation. Thus, the description of an element of the inventive subject matter herein is not limited to a particular axis or axes for describing the three-dimensional orientation of the element. Alternatively, these axes may be interchangeable when referring to the three-dimensional aspect of the inventive subject matter.

[0050] As used herein, "longitudinal direction", "lateral direction" and "vertical direction" refer to directions that are perpendicular to each other (i.e., each is orthogonal to each other). For example, the "longitudinal direction", "lateral direction" and "vertical direction" used herein can be approximately parallel to the longitudinal axis, the transverse axis and the vertical axis, respectively, of a Cartesian coordinate system used to define a three-dimensional aspect or orientation.

[0051] As used herein, "repeated cycling" in the context of cycling between a charged state and a discharged state of a secondary battery refers to cycling more than once from a discharged state to a charged state or from a charged state to a discharged state. For example, repeated cycling between a charged state and a discharged state may include cycling from a discharged state to a charged state at least 2 times, such as charging from a discharged state to a charged state, discharging back to a discharged state, charging again to a charged state, and finally discharging back to a discharged state. As yet another example, repeated cycling between a charged state and a discharged state at least 2 times may include discharging from a charged state to a discharged state, charging back to a charged state, discharging again to a discharged state, and finally charging back to a charged state. As a further example, repeated cycling between a charged state and a discharged state may include cycling at least 5 times, or even cycling at least 10 times from a discharged state to a charged state. As a further example, repeated cycling between a charged state and a discharged state may include cycling from a discharged state to a charged state at least 25, 50, 100, 300, 500, and even 1000 times.

[0052] As used herein, "rated capacity" in the context of a secondary battery refers to the ability of a secondary battery to deliver current over a period of time as measured under standard temperature conditions (25°C). For example, the rated capacity can be measured in ampere-hours, either by determining the current output for a specific time, or by determining the time a specific current can output current, and multiplying the current by the time. For example, for a battery with a rated current of 20 ampere-hours, if the current is specified as a rate of 2 amperes, the battery can be understood as a battery capable of providing a current output for 10 hours, whereas if the time is specified at a rate of 10 hours, the battery can be understood as a battery that will output 2 amperes during 10 hours.

[0053] In general, the secondary battery of the present disclosure includes a battery housing, an electrode assembly, and a non-aqueous liquid electrolyte in the battery housing, and a constraint that maintains the pressure on the electrode assembly when the secondary battery is cycled between a charged state and a discharged state. As previously mentioned, during the formation of the secondary battery and / or the subsequent circulation of the secondary battery between a charged state and a discharged state, the electrode and / or the counter electrode in the electrode assembly can expand along the stacking direction of the electrode and the counter electrode (i.e., the electrode stacking direction). When the electrode assembly includes dozens (or even more) stacked electrodes and counter electrodes, such expansion brings challenges. Advantageously, the constraint of the present disclosure maintains the pressure on the electrode assembly during the formation of the battery and / or during the subsequent circulation of the battery between a charged state and a discharged state, which suppresses the expansion of the electrode assembly (in the stacking direction). In addition, the constraint further suppresses the buckling of the electrode assembly, which may be caused by the difference in pressure applied on different surfaces of the electrode assembly by the constraint.

[0054] The constraints of the present disclosure may be embodied in any one of a series of structures including the following: for example, the battery housing itself, a structure outside the battery housing, a structure inside the battery housing, or even a combination of the battery housing, a structure inside the battery housing, and / or a structure outside the battery housing. In one such embodiment, the battery housing is a constrained component; in other words, in this embodiment, the battery housing alone or in combination with one or more other structures (inside and / or outside the battery housing) applies a pressure on the electrode structure in the electrode stacking direction, which is greater than the pressure applied on the electrode structure in the direction perpendicular to each other and perpendicular to the electrode stacking direction. In another embodiment, the constraint does not include the battery housing and one or more discrete structures (inside and / or outside the battery housing) other than the battery housing, and the pressure applied to the electrode structure in the electrode stacking direction is greater than the pressure applied to the electrode structure in the direction perpendicular to the electrode stacking direction and perpendicular to each other.

[0055] In one exemplary embodiment, the constraint includes one or more discrete structures within the battery housing that exert pressure on the electrode structure in the electrode stacking direction that exceeds the pressure exerted on the electrode structure in two directions perpendicular to the electrode stacking direction and perpendicular to each other.

[0056] In an exemplary embodiment, the electrode structure is constrained within a battery housing and a pressure is applied to the electrode structure in the electrode stacking direction, which pressure exceeds the pressure applied to the electrode structure in two directions perpendicular to the electrode stacking direction and perpendicular to each other.

[0057] In an exemplary embodiment, the constraint includes one or more discrete structures outside the battery housing and one or more discrete structures inside the battery housing, the discrete structures combining to apply pressure on the electrode structure in the electrode stacking direction that exceeds the pressure applied to the electrode structure in two directions perpendicular to the electrode stacking direction and perpendicular to each other.

[0058] Independent of the location of the constraint (e.g., inside or outside the battery housing, and / or contained by the housing), the constraint and the battery housing combined and preferably occupy no more than 75% of the volume limited by the outer surface of the battery housing (i.e., the displacement volume of the battery). For example, in one such embodiment, the constraint and the battery housing combined occupy no more than 60% of the volume limited by the outer surface of the battery housing. As a further example, in one such embodiment, the constraint and the battery housing combined occupy no more than 45% of the volume limited by the outer surface of the battery housing. As a further example, in one such embodiment, the constraint and the battery housing combined occupy no more than 30% of the volume limited by the outer surface of the battery housing. As a further example, in one such embodiment, the constraint and the battery housing combined occupy no more than 20% of the volume limited by the outer surface of the battery housing.

[0059] The electrode assembly of the present disclosure generally includes two opposing longitudinal end surfaces (separated along the longitudinal axis of the electrode assembly) and a side surface extending between the two opposing longitudinal end surfaces (which surrounds the longitudinal axis). Generally, the longitudinal end surfaces can be planar or non-planar. For example, in one embodiment, the opposing longitudinal end surfaces are convex. As a further example, in one embodiment, the opposing longitudinal end surfaces are concave. As a further example, in one embodiment, the opposing longitudinal end surfaces are substantially planar.

[0060] When projected onto a plane, the relative longitudinal end surfaces may also have any range of two-dimensional shapes. For example, the longitudinal end surfaces may independently have a smooth curved shape (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 a smooth curved shape and include one or more lines and vertices. Similarly, the side surface of the electrode assembly may be a smooth curved shape (e.g., the electrode assembly has a circular, elliptical, hyperbolic, or parabolic cross-sectional shape), or the side surface may include two or more faces connected at the vertex (e.g., the electrode assembly may have a polygonal cross-section). For example, in one embodiment, the electrode assembly has a cylindrical, elliptical, parabolic, or hyperbolic shape. As a further example, in one such embodiment, the electrode assembly may have a prismatic shape, relative longitudinal end surfaces of the same size and shape, and a parallelogram-shaped side surface (i.e., a face extending between relative longitudinal end surfaces). As a further example, in one such embodiment, the electrode assembly has a shape corresponding to a triangular prism, the electrode assembly having two opposing triangular longitudinal end surfaces and a side surface including three parallelograms (e.g., rectangles) extending between the two longitudinal end surfaces. As a further example, in one such embodiment, the electrode assembly has a shape corresponding to a rectangular prism, the electrode assembly having two opposing rectangular longitudinal end surfaces and a side surface including four parallelogram (e.g., rectangle) faces. By way of further example, in one such embodiment, the electrode assembly has a shape corresponding to a pentagonal prism, a hexagonal prism, etc., wherein the electrode assembly has two opposing longitudinal end surfaces of a pentagon, a hexagon, etc., respectively, and a side surface including five, six, etc. parallelogram (e.g., rectangle) faces, respectively.

[0061] Reference now Figures 3A-3E , for the electrode assembly 120, several exemplary geometries are schematically shown. Figure 3A In 3B, the electrode assembly 120 has a triangular prism shape, wherein the electrode assembly 120 has a first and second longitudinal end surfaces 122, 124 that are opposite and separated along the longitudinal axis A, and a side surface (not shown) including three rectangular faces connecting the longitudinal end surfaces and surrounding the longitudinal axis A. In 3B, the electrode assembly 120 has a parallelepiped shape, wherein the electrode assembly 120 has a first and second parallelogram-shaped longitudinal end surfaces 122, 124 that are opposite and separated along the longitudinal axis A, and a side surface (not shown) including four parallelogram-shaped faces connecting the two longitudinal end surfaces and surrounding the longitudinal axis A. Figure 3C In the embodiment, the electrode assembly 120 has a rectangular prism shape, wherein the electrode assembly 120 has first and second opposite rectangular longitudinal end surfaces 122, 124 separated along the longitudinal axis A, and a side surface (not shown) including four rectangular faces connecting the two longitudinal end surfaces and surrounding the longitudinal axis A. Figure 3D In the embodiment, the electrode assembly 120 has a pentagonal prism shape, wherein the electrode assembly 120 has opposing first and second pentagonal longitudinal end surfaces 122, 124 separated along the longitudinal axis A, and a side surface (not shown) including five rectangular faces connecting the two longitudinal end surfaces and surrounding the longitudinal axis A. Figure 3E In the figure, the electrode assembly 120 has a hexagonal prism shape, having first and second opposite hexagonal longitudinal end surfaces 122, 124 separated along the longitudinal axis A, and a side surface (not marked) including six rectangular faces connecting the two longitudinal end surfaces and surrounding the longitudinal axis A.

[0062] Independent of the overall geometry of the electrode assembly, the opposing first and second longitudinal end surfaces of the electrode assembly have a combined surface area that is less than 50% of the total surface area of ​​the electrode assembly (i.e., the total surface area is the sum of the surface areas of the first and second longitudinal end surfaces of the electrode assembly and the surface areas of the side surfaces). For example, Figures 3A-3E The first and second opposing longitudinal end surfaces 122, 124 of each of the electrode assemblies 120 have a combined surface area (i.e., the sum of the surface areas of the first and second longitudinal end surfaces) that is smaller than the surface area of ​​the triangular prism ( Figure 3A ), parallelepiped( Figure 3B ), rectangular prism( Figure 3C ), pentagonal prism ( Figure 3D ) or hexagonal prism ( Figure 3E ). For example, in one such embodiment, the relative first and second longitudinal end surfaces of the electrode assembly have a surface area less than 33% of the total surface of the electrode assembly. As a further example, in one such embodiment, the relative first and second longitudinal end surfaces of the electrode assembly have a surface area less than 25% of the total surface of the electrode assembly. As a further example, in one such embodiment, the relative first and second longitudinal end surfaces of the electrode assembly have a surface area less than 20% of the total surface of the electrode assembly. As a further example, in one such embodiment, the relative first and second longitudinal end surfaces of the electrode assembly have a surface area less than 15% of the total surface of the electrode assembly. As a further example, in one such embodiment, the relative first and second longitudinal end surfaces of the electrode assembly have a surface area less than 10% of the total surface of the electrode assembly.

[0063] In some embodiments, the electrode assembly is a rectangular prism, and the first and second opposing longitudinal end surfaces have a combined surface area that is less than the combined surface area of ​​at least two opposing faces of the side surface (i.e., the sum of the surface areas of the two opposing rectangular sides connecting the opposing longitudinal end surfaces). In some embodiments, the electrode assembly is a rectangular prism having first and second opposing longitudinal end surfaces and a side surface including two pairs of opposing surfaces (faces), and the two opposing longitudinal end surfaces have a combined surface area that is less than the combined surface area of ​​at least one pair of the two pairs of opposing faces included by the side surface. In some embodiments, the electrode assembly is a rectangular prism having two opposing first and second longitudinal end surfaces and a side surface including two pairs of opposing surfaces (faces), and the two opposing longitudinal end surfaces have a combined surface area that is less than the combined surface area of ​​each pair of the two pairs of opposing faces included by the side surface.

[0064] Typically, the electrode assembly includes a longitudinal axis (see, e.g., Figures 3A-3E ) coincide with each other (i.e., the electrode stacking direction). In other words, the electrodes and counter electrodes are stacked in a direction extending from a first relative longitudinal end surface to a second relative longitudinal end surface of the electrode assembly. In one embodiment, the components of the electrode group and / or the components of the counter electrode group are layered in nature (see, e.g., Figure 1 and Figure 2 ). In another embodiment, the components of the electrode group and / or the components of the counter electrode group are essentially non-layered; in other words, in one embodiment, the components of the electrode and / or the counter electrode group extend sufficiently from the imaginary back plate (e.g., a plane substantially coinciding with the surface of the electrode assembly) to have a surface area (ignoring porosity) that is twice as high as the geometric dimensions (i.e., projection) of the components in the back plate. In certain embodiments, the ratio of the surface area of ​​the non-layered (i.e., three-dimensional) electrode and / or counter electrode structure to its geometric dimensions in the imaginary back plate can be at least about 5, at least about 10, at least about 50, at least about 100, or even at least about 500. However, typically, the ratio will be between about 2 and about 1000. In one such embodiment, the components of the electrode group are essentially non-layered. As a further example, in one such embodiment, the components of the counter electrode group are essentially non-layered. As a further example, in one such embodiment, the components of the electrode group and the components of the counter electrode group are essentially non-layered.

[0065] During formation of a secondary battery including an electrode assembly and / or during cycling, the electrode assembly is Figures 3A-3EExpansion of the electrode assembly in a direction parallel to the longitudinal axis A in each of the electrodes (i.e., in a direction parallel to the longitudinal axis A in each of the electrodes) can be suppressed by the constraints of the present disclosure. In general, the constraints include a compression member (adapted to cover the first projected area and the second projected area, respectively) connected by a tensioning member (adapted to cover the side surface of the electrode assembly). The tensioning member tends to pull the compression member toward each other, thereby applying a compressive force to the relative first and second longitudinal end surfaces of the electrode assembly, which in turn suppresses expansion of the electrode assembly in the longitudinal direction (which coincides with the electrode stacking direction as further described herein). In addition, after the battery is formed, the constraint applies a pressure on the electrode assembly in the longitudinal direction (i.e., the electrode stacking direction) that exceeds the pressure maintained on the electrode assembly in each of the two directions that are perpendicular to each other and perpendicular to the longitudinal direction.

[0066] Reference now Figure 4 , an exploded view of one embodiment of a secondary battery of the present disclosure can be seen, generally indicated at 100. The secondary battery includes a battery housing 102 and a collection 110 of electrode assemblies 120 within the battery housing 102, each electrode assembly having a first longitudinal end surface 122, an opposite second longitudinal end surface 124 (separated from the first longitudinal end surface 122 along a longitudinal axis (not shown), the longitudinal axis being parallel to the Figure 4 The "Y axis" of the imaginary Cartesian coordinate system), and the side surfaces 123, 125, 126, 127 (see Fig. 12A ). Each electrode assembly includes a group of electrode structures and a group of counter electrode structures, and the electrode structures and counter electrode structures are stacked relative to each other in each electrode assembly in the electrode stacking direction D (see, for example, Fig. 12A ); In other words, the group of electrode and counter-electrode structures is arranged in an alternating series of electrodes and counter-electrodes, wherein the series advances along the direction D between the first and second longitudinal end surfaces 122, 124 (see, for example Fig. 12A ;like Figure 4 As shown, the electrode stacking direction D is parallel to Figure 4 In addition, the electrode stacking direction D within each electrode assembly 120 is perpendicular to the stacking direction of the set of electrode assemblies 120 within the set 110 (i.e., the electrode assembly stacking direction); in other words, the electrode assemblies are arranged relative to each other in a direction within the set 110 that is perpendicular to the electrode stacking direction D within a single electrode assembly (e.g., the electrode assembly stacking direction is the direction corresponding to the Z axis of the imaginary Cartesian coordinate system, while the electrode stacking direction D within each electrode assembly is the direction corresponding to the Y axis of the imaginary Cartesian coordinate system).

[0067] Tabs 141, 142 extend out of the battery housing and provide electrical connections between the electrode assemblies of the battery 110 and an energy supply or consumer (not shown). More specifically, in this embodiment, tab 141 is electrically connected to tab extension 143 (using, for example, conductive glue), and tab extension 143 is electrically connected to an electrode included by each electrode assembly 120. Similarly, tab 142 is electrically connected to tab extension 144 (using, for example, conductive glue), and tab extension 144 is electrically connected to a counter electrode included by each electrode assembly 120.

[0068] Figure 4 Each electrode assembly 120 in the illustrated embodiment has an associated constraint 130 to inhibit expansion in the longitudinal direction (i.e., the electrode stacking direction D). Each constraint 130 includes a compression member 132, 134 (see FIG. 1 ) overlying the first and second longitudinal end surfaces 122, 124, respectively. Figure 5A and 5B ), and tension members 133, 135 covering the side surfaces 123, 125, respectively (see Figure 5C and 5D ). The tensioning members 133, 135 pull the compression members 132, 134 toward each other, and the compression members 132, 134 apply a compressive force to the opposing first and second longitudinal end surfaces 122, 124. As a result, expansion of the electrode assembly in the longitudinal direction is suppressed during formation of the battery and / or cycling of the battery between a charged state and a discharged state. In addition, the constraint 130 applies a pressure on the electrode assembly in the longitudinal direction (i.e., the electrode stacking direction D) that exceeds the pressure maintained on the electrode structure in either of two directions that are perpendicular to each other and perpendicular to the longitudinal direction (as shown in the figure, the longitudinal direction corresponds to the direction of the "Y" axis of the imaginary Cartesian coordinate system shown, and the two directions perpendicular to each other and perpendicular to the longitudinal direction correspond to the directions of the X-axis and Z-axis of the imaginary Cartesian coordinate system shown, respectively).

[0069] Reference now Figure 5A , Figure 5B , Figure 5C and Figure 5D , Figure 4Each electrode assembly 120 in the embodiment of has a geometry corresponding to the following geometry of a rectangular prism: first and second longitudinal end surfaces 122, 124 having dimensions X1×Z1, side surfaces 123, 125 having dimensions X1×Y1, and side surfaces 126, 127 having dimensions Y1×Z1 (where X1, Y1, and Z1 are dimensions measured in directions corresponding to the X, Y, and Z axes of a Cartesian coordinate system, respectively). The first and second longitudinal end surfaces 122, 124 therefore have a surface area corresponding to the product of X1 and Z1, the side surfaces 123, 125 each have a surface area corresponding to the product of X1 and Y1, and the side surfaces 126, 127 each have a surface area corresponding to the product of Y1 and Z1. According to one aspect of the present disclosure, the sum of the surface areas of the first and second longitudinal end surfaces is less than 33% of the surface area of ​​the total surface of the electrode assembly, wherein the electrode assembly is a rectangular prism, and the combined surface area of ​​the first and second longitudinal end surfaces is equal to (X1*Z1)+(X1*Z1), and the surface area of ​​the side surface is equal to (X1*Y1)+(X1*Y1)+(Y1*Z1)+(Y1*Z1). For example, in one such embodiment, the sum of the surface areas of the first and second longitudinal end surfaces is less than 25% of the surface area of ​​the total surface of the electrode assembly, wherein the combined surface area of ​​the first and second longitudinal end surfaces is equal to (X1*Z1)+(X1*Z1), and the total surface of the electrode assembly is equal to (X1*Y1)+(X1*Y1)+(Y1*Z1)+(Y1*Z1)+(X1*Z1)+(X1*Z1).

[0070] Each constraint 130 in this embodiment includes a compression member 132, 134 respectively covering the first and second longitudinal end surfaces 122, 124, and at least one tensioning member pulling the compression members toward each other. For example, the constraint may include tensioning members 133, 135 respectively covering the side surfaces 123, 125 of the side surface. Typically, the compression members 132, 134 apply a pressure on the first and second longitudinal end surfaces 122, 124 (i.e., in the electrode stacking direction D) that exceeds the pressure maintained on the side surfaces 123, 125 and the side surfaces 126, 127 of the electrode assembly (i.e., in each of the two directions perpendicular to each other and perpendicular to the electrode stacking direction). For example, in one such embodiment, the constraint applies a pressure on the first and second longitudinal end surfaces 122, 124 (i.e., in the electrode stacking direction D) that exceeds at least 3 times the pressure maintained on the electrode assembly in at least one or even both directions perpendicular to the electrode stacking direction and perpendicular to each other. As another example, in one such embodiment, the constraint applies a pressure on the first and second longitudinal end surfaces 122, 124 (i.e., in the electrode stacking direction D) that exceeds at least 4 times the pressure maintained on the electrode assembly in at least one or even both directions perpendicular to the electrode stacking direction and perpendicular to each other. As another example, in one such embodiment, the constraint applies a pressure on the first and second longitudinal end surfaces 122, 124 (i.e., in the electrode stacking direction D) that exceeds at least 5 times the pressure maintained on the electrode assembly in at least one or even both directions perpendicular to the electrode stacking direction and perpendicular to each other.

[0071] Reference now Fig. 6A In one embodiment, the constraint 130 may be derived from a sheet 107 having a length L1, a width W1, and a thickness t1. To form the constraint, the sheet 107 is simply wrapped around the electrode structure 120 (see Figure 4 and Figures 5A-5D ) and folded at fold line 113 to enclose the electrode structure. The edges 115, 117 overlap each other and are welded, bonded or otherwise fixed to each other to form a constraint, which includes compression members 132, 134 (compression member 134 includes overlapping edges 115, 177 once fixed to each other) and tension members 133, 135. In this embodiment, the constraint has a volume corresponding to the displacement volume of the sheet 107 (i.e., the product of L1, W1 and t1).

[0072] The sheet 107 may include any of a wide range of compatible materials capable of applying the desired force to the electrode structure. Typically, the constraint will typically include a material having an ultimate tensile strength of at least 10,000 psi (>70 MPa), which is compatible with the battery electrolyte, does not significantly corrode under the floating or anode potential of the battery, and does not significantly react or lose mechanical strength at 45°C. For example, the constraint may include any of a wide range of metals, alloys, ceramics, glasses, plastics, or combinations thereof (i.e., composites). In an exemplary embodiment, the constraint includes a metal such as stainless steel (e.g., SS 316, 440C or 440C hard), aluminum (e.g., aluminum 7075-T6, hard H18), titanium (e.g., 6Al-4V), beryllium, beryllium copper (hard), copper (oxygen-free, hard), nickel; however, typically, when the constraint includes a metal, it is generally preferred to be combined in a manner that limits corrosion and creates an electrical short between the electrode and the counter electrode. In another exemplary embodiment, the constraint comprises a ceramic such as alumina (e.g., sintered or Coorstek AD96), zirconia (e.g., Coorstek YZTP), yttria-stabilized zirconia (e.g., ENrG ). In another exemplary embodiment, the restraint comprises glass such as Schott D263 tempered glass. In another exemplary embodiment, the restraint comprises a plastic such as polyetheretherketone (PEEK) (e.g., Aptiv 1102), PEEK with carbon (e.g., Victrex 90HMF40 or Xycomp 1000-04), polyphenylene sulfide (PPS) with carbon (e.g., TepexDynalite 207), polyetheretherketone (PEEK) with 30% glass (e.g., Victrex 90HMF40 or Xycomp 1000-04), polyimide (e.g., ). In another exemplary embodiment, the constraint includes a composite material such as E glass standard fiber / epoxy, 0 degree, E glass UD / epoxy, 0 degree, Kevlar standard fiber / epoxy, 0 degree, Kevlar UD / epoxy, 0 degree, Carbon standard fiber / epoxy, 0 degree, Carbon UD / epoxy, 0 degree, Toyobo HM Fiber / Epoxy. In another exemplary embodiment, the constraint comprises fibers such as Kevlar 49 aramid fiber, S-glass fiber, carbon fiber, Vectran UM LCP fiber, Dyneema, Zylon.

[0073] The thickness (t1) of the constraint will depend on a range of factors, including, for example, the material of the structure of the constraint, the overall size of the electrode assembly, and the composition of the battery anode and cathode. In some embodiments, for example, the constraint will include a sheet having a thickness in the range of about 10 microns to about 100 microns. For example, in one such embodiment, the constraint includes a stainless steel sheet (e.g., SS316) having a thickness of about 30 μm. As another example, in another such embodiment, the constraint includes an aluminum sheet (e.g., 7075-T6) having a thickness of about 40 μm. As another example, in another such embodiment, the constraint includes a zirconium oxide sheet (e.g., Coorstek YZTP) having a thickness of about 30 μm. As another example, in another such embodiment, the constraint includes an E-glass UD / epoxy 0 degree sheet having a thickness of about 75 μm. As another example, in another such embodiment, the constraint includes a 12 μm carbon fiber at a packing density of >50%.

[0074] In certain embodiments, the constrained compression member and / or tensioning member comprises a porous material. Typically, the porous material will allow the electrolyte to easily approach the electrode assembly. For example, in some embodiments, the compression member and / or tensioning member may have a porosity of at least 0.25. As another example, in some embodiments, the compression member and / or tensioning member may have a porosity of at least 0.375. As another example, in some embodiments, the compression member and / or tensioning member may have a porosity of at least 0.5. As another example, in some embodiments, the compression member and / or tensioning member may have a porosity of at least 0.625. As another example, in some embodiments, the compression member and / or tensioning member may have a porosity of at least 0.75.

[0075] In yet another embodiment, the constraint 130 includes one or more compression members within the electrode assembly 120. For example, referring now to Figure 6B , shows a cross-section of an embodiment of an electrode assembly 120 having a constraint 130 with an internal compression member 132a. Figure 6BIn the illustrated embodiment, the constraint 130 may include first and second compression members 132, 134 at the longitudinal end surfaces 122, 124 of the electrode assembly 120, respectively. However, additionally and / or alternatively, the constraint 130 may further include at least one internal compression member 132a, which is located at an internal region of the electrode assembly other than the longitudinal end surfaces 122, 124. The internal compression member 132a may be connected to the tensioning members 133, 135 to apply a compressive pressure to a portion of the electrode assembly 120 between the internal compression member 132a and another compression member (e.g., one or more compression members 132, 134 at the longitudinal end surfaces 122, 124 of the electrode assembly 120 and / or with one or more other internal compression members 132). Reference Figure 6BIn the embodiment shown in , an internal compression member 132a may be provided, which is spaced away from the first and second longitudinal end surfaces 122, 124 of the electrode assembly 120 along the longitudinal axis (stack direction D), respectively, for example, toward the central area of ​​the electrode assembly 120. The internal compression member 132a can be connected to the tensioning member 133, 135 at an internal position away from the electrode assembly end surfaces 122, 124. In one embodiment, in addition to the compression members 132, 134 provided at the electrode assembly end surfaces 122, 124, at least one internal compression member 132a is provided at an internal position away from the end surfaces 122, 124. In another embodiment, the constraint 130 includes an internal compression member 132a at an internal position of the electrode assembly 120, which is spaced away from the longitudinal end surfaces 122, 124, with or without the compression members 132, 134 at the longitudinal end surfaces 122, 124. In yet another embodiment, the constraint 130 includes an internal compression member 132a at an internal position of the electrode assembly that is internally spaced apart from the longitudinal end surfaces 122, 124, where there is no compression member 132, 134 at the longitudinal end surfaces 122, 124. In one embodiment, the internal compression member 132a can be understood to work with one or more of the compression members 132, 134 and / or another internal compression member 132a to apply compression pressure on each portion of the electrode assembly 120 in the longitudinal direction between the internal compression member 132a and the longitudinal surface 122, 124 of the electrode assembly 120 where the compression member 132, 134 is located, and / or on the portion of the electrode assembly 120 in the longitudinal direction between the internal compression member 132a and the other internal compression member 132a. In one version, at least one of the internal compression members 132a includes at least a portion of the electrode or counter electrode structure 151, 152, as described in further detail below. For example, the internal compression member 132a may include a counter electrode active material, a separator, an electrode current collector, a counter electrode current collector, an electrode stem, and at least a portion of the counter electrode stem.

[0076] According to one embodiment, as described above, the constraint 130 may include an internal compression member 132a, which is part of the internal structure of the electrode assembly 120, such as a portion of the electrode 151 and / or the counter electrode structure 152. In one embodiment, by providing compression between structures within the electrode assembly 120, a tightly constrained structure can be achieved to fully compensate for the tension generated by the growth of the electrode structure 120. For example, in one embodiment, one or more internal compression members 132 can work with compression members 132, 134 at the longitudinal end surfaces 122, 124 of the electrode assembly 120 to constrain growth in a direction parallel to the longitudinal direction by being in tension with each other via connecting tensioning members 133, 135. In another embodiment, the growth of the electrode structure 151 (e.g., an anode structure) can be offset by compression of one or more internal compression members 132a corresponding to a portion of the counter electrode structure 152 (e.g., a cathode), which are in tension with each other via tensioning members 133, 135.

[0077] Generally, in some embodiments, the components of the constraint 130 can be implemented as electrodes 151 and / or counter electrode structures 152 within the electrode assembly 120, respectively, not only providing effective constraints, but also more effectively utilizing the volume of the electrode assembly 120 without excessively increasing the size of the secondary battery having the electrode assembly 120. For example, in one embodiment, the constraint 130 can include tensioning members 133, 135 attached to one or more electrode structures 151 and / or counter electrode structures 152 acting as internal compression members 132a. As a further example, in some embodiments, at least one internal compression member 132a can be implemented as a group of electrode structures 151. As a further example, in some embodiments, at least one internal compression member 132a can be implemented as a group of counter electrode structures 152.

[0078] Reference now Figure 6C , a Cartesian coordinate system having a vertical axis (Z axis), a longitudinal axis (Y axis) and a transverse axis (X axis) is shown; wherein the X axis is oriented out of the plane of the page; and the stacking direction D as described above is designated to be parallel to the Y axis. More specifically, Figure 7A cross-section of an electrode assembly 120 is shown having a constraint 130 having compression members 132, 134 at its longitudinal surface and at least one internal compression member 132a. The constraint 130 includes compression members 132, 134 and an internal compression member implemented as a group of electrode structures 151 and / or a group of counter electrode structures 152; therefore, in this embodiment, at least one internal compression member 132a, electrode structure 151 and / or counter electrode structure 152 can be understood to be interchangeable. Moreover, the diaphragm 150 can also form a part of the internal compression member 132a. More specifically, Figure 6C 1 is an embodiment of a flush connection of an internal compression member 132a corresponding to an electrode 151 or a counter electrode structure 152. The flush connection may further include an adhesive layer 182 otherwise adhered between the tensioning members 133, 135 and the internal compression member 132a. The adhesive layer 182 fixes the internal compression member 132a to the tensioning members 133, 135 so that the internal compression member 132a can maintain tension with other compression members (such as other internal compression members or compression members at the longitudinal end surface of the electrode assembly 120).

[0079] exist Figure 6C As further shown in FIG. 1 , in one embodiment, the components of the electrode group 151 include an electrode active material layer 160, an electrode current collector 163 (such as an ion-porous electrode current collector), and an electrode backbone 165 supporting the electrode active material layer 160 and the electrode current collector 163. Similarly, in one embodiment, as Figure 6C As shown, the components of the counter electrode group 152 include a counter electrode active material layer 167 , a counter electrode current collector 169 , and a counter electrode trunk 171 supporting the counter electrode active material layer 167 and the counter electrode current collector 169 .

[0080] Not bound by any particular theory (e.g. Figure 6CIn the case of restraint (as shown), in some embodiments, the components of the electrode group 151 include an electrode active material layer 160, an electrode current collector 163, and an electrode trunk 165 supporting the electrode active material layer 160 and the electrode current collector 163. Similarly, in some embodiments, the components of the counter electrode group 152 include a counter electrode active material layer 167, a counter electrode current collector 169, and a counter electrode trunk 171 supporting the counter electrode active material layer 167 and the counter electrode current collector 169. In one embodiment, at least a portion of any one of the electrode and counter electrode structures 151, 152, such as the current collectors 163, 169, the trunks 165, 171, the counter electrode active material layer 167, and the separator 130 can be used as part or all of the internal compression member 132a, such as by being connected to the tensioning members 133, 135 or otherwise in tension with one or more other internal or external compression members 132, 134. In one embodiment, the inner compression member 132a can be connected to the tension members 133, 135 by at least one of bonding, welding, bonding, adhering, or the like. Figure 6C 132a corresponding to the electrode and counter electrode structures 151, 152 (i.e., both the electrode and counter electrode structures are in tension with each other by being connected to the tensioning members 133, 135), in alternative embodiments, only one of the electrode and / or counter electrode structures is used as the internal compression member 132a, and / or only a portion of the electrode or counter electrode structures 151, 152 can be used as the internal compression member 132a, such as by being adhered to the tensioning members 133, 135. For example, in one embodiment, at least one of the electrode current collector 163 and / or the counter electrode current collector 152 can be used as the internal compression member 132, such as by being adhered to the tensioning members 133, 135.

[0081] Reference again Figure 4, to complete the manufacture of the secondary battery 100, the battery housing 102 is filled with a non-aqueous electrolyte (not shown), and the cover 104 is folded (along the fold line 106) and sealed to the upper surface 108. When fully assembled, the sealed secondary battery occupies a volume constrained by its outer surface (i.e., a displacement volume), the secondary battery housing 102 occupies a volume corresponding to the displacement volume of the battery (including the cover 104) minus its internal volume (i.e., the prismatic volume constrained by the inner surface 103A, 103B, 103C, 103D, 103E and the cover 104), and each constraint 130 of the set 110 occupies a volume corresponding to its corresponding displacement volume. Therefore, in combination, the battery housing and the constraint occupy no more than 75% of the volume constrained by the outer surface of the battery housing (i.e., the displacement volume of the battery). For example, in one such embodiment, the constraint and the battery housing combination occupy no more than 60% of the volume constrained by the outer surface of the battery housing. As a further example, in one such embodiment, the constraint and the battery housing combination occupy no more than 45% of the volume constrained by the outer surface of the battery housing. As a further example, in one such embodiment, the constraint and battery housing combination occupy no more than 30% of the volume bounded by the outer surface of the battery housing. As a further example, in one such embodiment, the constraint and battery housing combination occupy no more than 20% of the volume bounded by the outer surface of the battery housing.

[0082] In order to facilitate Figure 4 , the secondary battery 100 includes only one set 110 of electrode assemblies, and the set includes only six electrode assemblies 120. In practice, the secondary battery may include more than one set of electrode assemblies, wherein each set is disposed laterally relative to each other (e.g., located at Figure 4 ), or each set is disposed perpendicularly relative to each other (e.g., in a direction substantially parallel to the XY plane of the Cartesian coordinate system). Figure 4In the direction of the Z-axis of the Cartesian coordinate system of the secondary battery). In addition, in each of these embodiments, each set of electrode assemblies may include one or more electrode assemblies. For example, in certain embodiments, a secondary battery may include one, two, or more sets of electrode assemblies, each such set including one or more electrode assemblies (e.g., 1, 2, 3, 4, 5, 6, 10, 15, or more electrode assemblies within each such set), and when the battery includes two or more such sets, the sets may be arranged laterally or vertically relative to the electrode assemblies of other sets comprising the secondary battery. In each of these various embodiments, each individual electrode assembly may have its own constraint (i.e., a 1:1 relationship between the electrode assembly and the constraint), two or more electrode assemblies may have a common constraint (i.e., a single constraint for the two or more electrode assemblies), or two or more electrode assemblies may share components of the constraint (i.e., the two or more electrode assemblies may have a common compression member and / or tensioning member).

[0083] Reference now Fig. 12A In an exemplary embodiment, the electrode assembly 120 includes first and second longitudinal end surfaces 122, 124 and side surfaces including side surfaces 123, 125, 126, 127. The electrode assembly 120 also includes a group of electrode structures 151 and a group of counter electrode structures 152, which are stacked in an electrode stacking direction D parallel to the longitudinal axis A, extending between the first and second opposite longitudinal end surfaces 121, 122. The electrode and counter electrode structures 151, 152 are stacked in an alternating order (e.g., interdigitated with each other), wherein substantially each member of the electrode group is between two members of the counter electrode group, and substantially each member of the counter electrode group is between two members of the electrode group. For example, except for the first and last electrode or counter electrode structures in an alternating series, in one embodiment, each electrode structure in the alternating series is between two counter electrode structures, and each counter electrode structure in the series is between two electrode structures. Additionally, in a hypothetical backplane (e.g., sides 126, 127, respectively), the ratio of the surface area of ​​the non-layered electrode and counter electrode structures to their respective geometric coverage can be at least about 5, at least about 10, at least about 50, at least about 100, or even at least about 500 as previously described.

[0084] like Fig. 12AAs shown, with one exception, each member 151 of the group of electrode structures is between two members 152 of the counter electrode group, and with one exception, each member 152 of the group of counter electrode structures is between two members 151 of the group of electrode structures. More generally, in one embodiment, the electrode and counter electrode groups each have N members, each of the N-1 electrode group members is between two counter electrode structures, each of the N-1 counter electrode group members is between the electrode structures, and N is at least 2. For example, in one embodiment, N is at least 4 (e.g., Figure 4 as shown), at least 5, at least 10, at least 25, at least 50 or even at least 100.

[0085] Reference now Fig. 12B and Fig. 12C , the projections of the components of the electrode and counter electrode group on the first longitudinal end surface 122 surround the first projected area 162, and the projections of the components of the electrode and counter electrode group on the second longitudinal end surface 124 surround the second projected area 164. Typically, the first and second projected areas 162, 164 will typically include a substantial portion of the surface area of ​​the first and second longitudinal end surfaces 122, 124, respectively. For example, in one embodiment, the first and second projected areas each include at least 50% of the surface area of ​​the first and second longitudinal end surfaces, respectively. As another example, in one such embodiment, the first and second projected areas each include at least 75% of the surface area of ​​the first and second longitudinal end surfaces, respectively. As another example, in one such embodiment, the first and second projected areas each include at least 90% of the surface area of ​​the first and second longitudinal end surfaces, respectively.

[0086] The components of the electrode and counter electrode groups include electroactive materials capable of absorbing and releasing carrier ions (such as lithium, sodium, potassium, calcium, magnesium or aluminum ions). In some embodiments, the component 151 of the electrode structure group includes an anode-active electroactive material (sometimes referred to as a negative electrode), and the component 152 of the counter electrode structure group includes a cathode-active electroactive material (sometimes referred to as a positive electrode). In other embodiments, the component 151 of the electrode structure group includes a cathode-active electroactive material, and the component 152 of the counter electrode structure group includes an anode-active electroactive material. In each of the embodiments and examples described in this paragraph, the negative electrode active material can be a particle aggregate electrode or a monomer electrode.

[0087] Exemplary anode active electroactive materials include carbon materials, such as graphite and soft or hard carbon, or any of a range of metals, semi-metals, alloys, oxides, and composites that can form alloys with lithium. Specific examples of metals or semi-metals that can form anode materials include tin, lead, magnesium, aluminum, boron, gallium, silicon, indium, zirconium, germanium, bismuth, cadmium, antimony, silver, zinc, arsenic, hafnium, yttrium, and palladium. In an exemplary embodiment, the anode active material includes aluminum, tin, or silicon, or an oxide, nitride, fluoride, or other alloy thereof. In another exemplary embodiment, the anode active material includes silicon or an alloy thereof.

[0088] Exemplary cathode active materials include any one of a wide range of cathode active materials. For example, for lithium ion batteries, the cathode active material may include a cathode material selected from transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides, and lithium-transition metal nitrides. The transition metal elements of these transition metal oxides, transition metal sulfides, and transition metal nitrides may include metal elements with d-shells or f-shells. Specific examples of such metal elements are Sc, Y, lanthanides, actinides, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pb, Pt, Cu, Ag, and Au. Other cathode active materials include LiCoO2, LiNi 0.5 Mn 1.5 O4、Li(Ni x Co y Al2)O2, LiFePO4, Li2MnO4, V2O5, molybdenum oxysulfide, phosphates, silicates, vanadates and combinations thereof.

[0089] In one embodiment, the anode active material is microstructured to provide a significant void volume fraction to accommodate volume expansion and contraction caused by the binding of lithium ions (or other carrier ions) to or from the negative electrode active material during the charge and discharge process. Typically, the void volume fraction of the negative electrode active material is at least 0.1. However, typically the void volume fraction of the negative electrode active material is no greater than 0.8. For example, in one embodiment, the void volume fraction of the negative electrode active material is about 0.15 to about 0.75. As another example, in one embodiment, the void volume fraction of the negative electrode active material is about 0.2 to about 0.7. As another example, in one embodiment, the void volume fraction of the negative electrode active material is about 0.25 to about 0.6.

[0090] Depending on the composition of the microstructured negative active material and the method of its formation, the microstructured negative active material may contain a macroporous, microporous or mesoporous material layer or a combination thereof, such as a combination of micropores and mesopores or a combination of mesopores and macropores. Microporous materials are generally characterized by: pore sizes less than 10nm, wall sizes less than 10nm, pore depths of 1-50 microns, and pore morphology that is generally characterized by a "sponge-like" and irregular appearance, non-smooth walls and branched pores. Mesoporous materials are generally characterized by: pore sizes of 10-50nm, wall sizes of 10-50nm, pore depths of 1-100 microns, and pore morphology that is generally characterized by slightly well-defined branched pores or dendritic pores. Macroporous materials are generally characterized by: pore sizes greater than 50nm, wall sizes greater than 50nm, pore depths of 1-500 microns, and pore morphologies that can be variable, continuous, branched or dendritic, and smooth or rough walls. In addition, the void volume can include open or closed voids or a combination thereof. In one embodiment, the void volume includes open voids, that is, the negative electrode active material contains voids with openings at the side surfaces of the negative electrode active material, through which lithium ions (or other carrier ions) can enter or leave the negative electrode active material; for example, lithium ions can enter the negative electrode active material through the void openings after leaving the positive electrode active material. In another embodiment, the void volume includes closed voids, that is, the negative electrode active material contains voids surrounded by the negative electrode active material. Generally, open voids can provide a larger interfacial surface area for carrier ions, while closed voids are often less susceptible to the solid electrolyte interface, and each provides space for the expansion of the negative electrode active material when carrier ions enter. Therefore, in some embodiments, it is preferred that the negative electrode active material includes a combination of open and closed voids.

[0091] In one embodiment, the negative electrode active material includes porous aluminum, tin or silicon or its alloy. The porous silicon layer can be formed, for example, by anodization, etching (for example, by depositing a precious metal such as gold, platinum, silver or gold / palladium on the (100) surface of single crystal silicon, and etching the surface with a mixture of hydrofluoric acid and hydrogen peroxide), or by other methods known in the art (such as patterned chemical etching). In addition, the porous negative electrode active material will generally have a porosity of at least about 0.1 but less than 0.8, and have a thickness of about 1 to about 100 microns. For example, in one embodiment, the negative electrode active material includes porous silicon, having a thickness of about 5 to about 100 microns, and having a porosity of about 0.15 to about 0.75. As another example, in one embodiment, the negative electrode active material includes porous silicon, having a thickness of about 10 to about 80 microns, and having a porosity of about 0.15 to about 0.7. As another example, in one embodiment, the negative electrode active material comprises porous silicon, having a thickness of about 20 to about 50 microns, and having a porosity of about 0.25 to about 0.6. As another example, in one embodiment, the negative electrode active material comprises a porous silicon alloy (such as nickel silicide), having a thickness of about 5 to about 100 microns, and having a porosity of about 0.15 to about 0.75.

[0092] In another embodiment, the negative active material includes fibers of aluminum, tin or silicon or alloys thereof. A single fiber may have a diameter (thickness dimension) of about 5 nm to about 10,000 nm and a length generally corresponding to the thickness of the negative active material. Silicon fibers (nanowires) may be formed by the following methods: for example, by chemical vapor deposition or other techniques known in the art, such as vapor-liquid-solid (VLS) growth and solid-liquid-solid (SLS) growth. In addition, the negative active material will generally have a porosity of at least about 0.1 but less than 0.8 and a thickness of about 1 to about 200 microns. For example, in one embodiment, the negative active material includes silicon nanowires having a thickness of about 5 to about 100 microns and having a porosity of about 0.15 to about 0.75. As another example, in one embodiment, the negative active material includes silicon nanowires having a thickness of about 10 to about 80 microns and having a porosity of about 0.15 to about 0.7. As another example, in one embodiment, the negative electrode active material comprises silicon nanowires having a thickness of about 20 to about 50 microns and having a porosity of about 0.25 to about 0.6. As another example, in one embodiment, the negative electrode active material comprises nanowires of a silicon alloy (such as nickel silicide) having a thickness of about 5 to about 100 microns and having a porosity of about 0.15 to about 0.75.

[0093] In one embodiment, the components of the electrode group include an electrode active material layer, an electrode current collector, and an electrode trunk supporting the electrode active material layer and the electrode current collector. Similarly, in one embodiment, the components of the electrode group include an electrode active material layer, an electrode current collector, and an electrode trunk supporting the electrode active material layer and the electrode current collector.

[0094] In one embodiment, each member of the electrode set has a bottom, a top, and a longitudinal axis (A) extending from the bottom to the top. E ), and the longitudinal axis (A E ) in a direction generally perpendicular to the direction in which the alternating sequence of electrode structures and counter electrode structures proceeds. In addition, each member of the electrode set has a longitudinal axis (A E )Measured length (L E ), the width (W) measured in the direction of the alternating sequence of electrode structures and the counter electrode structure E ), and the length perpendicular to the measurement (L E ) and width (W E ) in each direction. E Each member of the electrode assembly also has a perimeter (P E ), which corresponds to the sum of the lengths of the sides of the projection of the electrode in a plane perpendicular to its longitudinal axis.

[0095] The length of the electrode assembly member (L E ) will vary depending on the energy storage device and its intended use. However, in general, the members of the electrode assembly will typically have a length (L) in the range of about 5 mm to about 500 mm. E For example, in one such embodiment, the components of the electrode assembly have a length (L) of about 10 mm to about 250 mm. E As another example, in one such embodiment, the members of the electrode assembly have a length (L) of about 25 mm to about 100 mm. E ).

[0096] The width of the electrode assembly member (W E ) will also vary depending on the energy storage device and its intended use. However, in general, each member of the electrode group will typically have a width (W) in the range of about 0.01 mm to 2.5 mm. E For example, in one embodiment, the width (W) of each member of the electrode group E ) will be in the range of about 0.025 mm to about 2 mm. As another example, in one embodiment, the width (W) of each member of the electrode group E ) will be in the range of about 0.05 mm to about 1 mm.

[0097] The height of the electrode assembly components (H E ) will also vary depending on the energy storage device and its intended use. However, in general, the members of the electrode assembly will typically have a height (H) in the range of about 0.05 mm to about 10 mm. E For example, in one embodiment, the height (H) of each member of the electrode assembly is E ) will be in the range of about 0.05 mm to about 5 mm. As another example, in one embodiment, the height (H) of each member of the electrode group E ) will be in the range of about 0.1 mm to about 1 mm.

[0098] The circumference of the electrode assembly member (P E ) will similarly vary depending on the energy storage device and its intended use. However, in general, the members of the electrode group will typically have a circumference (P) in the range of about 0.025 mm to about 25 mm. E For example, in one embodiment, the perimeter (P E ) will be in the range of about 0.1 mm to about 15 mm. As another example, in one embodiment, the perimeter (P E ) will be in the range of about 0.5 mm to about 10 mm.

[0099] Typically, the electrode assembly has a member having a substantially greater width (W E ) and its height (H E ) of each of the lengths (L E ). For example, in one embodiment, for each member of the electrode set, L E With W E and H E The ratio of each of them is at least 5:1 (i.e., L E With W E The ratio is at least 5:1, respectively, L E With H E As another example, in one embodiment, L E With W E and H E The ratio of each of is at least 10:1. As another example, in one embodiment, L E With W E and H E The ratio of each of is at least 15:1. As another example, in one embodiment, for each member of the electrode set, L E With W E and H E The ratio of each is at least 20:1.

[0100] Additionally, it is generally preferred that the components of the electrode assembly have a length substantially greater than their circumference (P E ) length (L E ); For example, in one embodiment, for each member of the electrode group, L E With P E As another example, in one embodiment, for each member of the electrode group, L E With P E As another example, in one embodiment, for each member of the electrode group, L E With P E The ratio is at least 3.75:1 respectively.

[0101] In one embodiment, the height (H) of the components of the electrode assembly E ) and width (W E ) are at least 0.4:1. For example, in one embodiment, for each member of the electrode set, H E With W E The ratio of H will be at least 2:1 respectively. As another example, in one embodiment, H E With W E The ratio of H to NH will be at least 10:1 respectively. As another example, in one embodiment, H E With W E The ratio of H E With W E The ratio of H is usually less than 1000:1. E With W E As another example, in one embodiment, H E With W E As another example, in one embodiment, H E With W E As another example, in one embodiment, for each member of the electrode set, H E With W E The ratios will be in the range of about 2:1 to about 100:1, respectively.

[0102] Each member of the electrode set has a bottom, a top, and a longitudinal axis (A) extending from the bottom to the top. CE ), and the longitudinal axis (A CE ) in a direction generally perpendicular to the direction in which the alternating sequence of electrode structures and counter electrode structures proceeds. In addition, each member of the counter electrode set has a longitudinal axis (ACE )Measured length (L CE ), the width (W) measured in the direction of the alternating sequence of electrode structures and the counter electrode structure CE ), and the length perpendicular to the measurement (L CE ) and width (W CE ) in each direction. CE Each member of the electrode set also has a perimeter (P CE ), which corresponds to the sum of the lengths of the sides of the projection of the electrode in a plane perpendicular to its longitudinal axis.

[0103] The length of the electrode assembly (L CE ) will vary depending on the energy storage device and its intended use. However, in general, each member of the electrode set will typically have a length (L) in the range of about 5 mm to about 500 mm. CE For example, in one such embodiment, each member of the electrode set has a length (L) of about 10 mm to about 250 mm. CE As another example, in one such embodiment, each member of the electrode set has a length (L) of about 25 mm to about 100 mm. CE ).

[0104] The width of the electrode assembly member (W CE ) will also vary depending on the energy storage device and its intended use. However, in general, the members of the electrode set will typically have a width (W) in the range of about 0.01 mm to 2.5 mm. CE For example, in one embodiment, the width (W) of each member of the electrode group CE ) will be in the range of about 0.025 mm to about 2 mm. As another example, in one embodiment, the width (W) of each member of the electrode set is CE ) will be in the range of about 0.05 mm to about 1 mm.

[0105] The height of the electrode assembly member (H CE ) will also vary depending on the energy storage device and its intended use. However, in general, the members of the electrode set will typically have a height (H) in the range of about 0.05 mm to about 10 mm. CE For example, in one embodiment, the height (H CE ) will be in the range of about 0.05 mm to about 5 mm. As another example, in one embodiment, the height (H) of each member of the electrode set is CE ) will be in the range of about 0.1 mm to about 1 mm.

[0106] The circumference of the electrode assembly member (PCE ) will also vary depending on the energy storage device and its intended use. However, in general, the members of the electrode set will typically have a circumference (P) in the range of about 0.025 mm to about 25 mm. CE For example, in one embodiment, the perimeter (P CE ) will be in the range of about 0.1 mm to about 15 mm. As another example, in one embodiment, the perimeter (P CE ) will be in the range of about 0.5 mm to about 10 mm.

[0107] Typically, each member of the electrode set has a width (W CE ) and is substantially greater than its height (H CE ) length (L CE ). For example, in one embodiment, for each member of the electrode set, L CE With W CE and H CE The ratio of each of them is at least 5:1 (i.e., L CE With W CE The ratio is at least 5:1, respectively, L CE With H CE As another example, in one embodiment, for each member of the electrode set, L CE With W CE and H CE As another example, in one embodiment, for each member of the electrode set, L CE With W CE and H CE As another example, in one embodiment, for each member of the electrode set, L CE With W CE and H CE The ratio of each is at least 20:1.

[0108] Additionally, it is generally preferred that the member of the electrode assembly have a substantially greater perimeter (P CE ) length (L CE ); For example, in one embodiment, for each member of the electrode set, L CE With P CE As another example, in one embodiment, for each member of the electrode set, L CE With P CEAs another example, in one embodiment, for each member of the electrode set, L CE With P CE The ratio is at least 3.75:1 respectively.

[0109] In one embodiment, the height (H) of the member of the electrode assembly CE ) and width (W CE ) are at least 0.4:1, respectively. For example, in one embodiment, for each member of the counter electrode set, H CE With W CE As another example, in one embodiment, for each member of the counter electrode set, H CE With W CE As another example, in one embodiment, for each member of the counter electrode set, H CE With W CE The ratio of H to NH will be at least 20:1, respectively. However, typically, for each member of the electrode assembly, H CE With W CE The ratio of H will generally be less than 1000:1, respectively. For example, in one embodiment, for each member of the counter electrode set, H CE With W CE As another example, in one embodiment, H CE With W CE As another example, in one embodiment, H CE With W CE As another example, in one embodiment, for each member of the electrode set, H CE With W CE The ratios will be in the range of about 2:1 to about 100:1, respectively.

[0110] Reference again Fig. 12A, the electrically insulating membrane layer 153 surrounds and electrically isolates each member 151 of the electrode structure group from each member 152 of the counter electrode structure group. The electrically insulating membrane layer 153 will generally include a microporous membrane material that can be permeated by a non-aqueous electrolyte; for example, in one embodiment, the microporous membrane material contains pores with a diameter of at least 50 angstroms, more typically, a diameter in the range of about 2500 angstroms, and a porosity in the range of about 25% to about 75%, more typically, in the range of about 35-55%. In addition, the microporous membrane material is permeated with a non-aqueous electrolyte to allow carrier ions to be conducted between adjacent members of the electrode and counter electrode groups. In one embodiment, for example, and ignoring the porosity of the microporous membrane material, at least 70 vol% of the electrically insulating membrane material layer 153 between a member 151 of an electrode structure group and a nearest member 152 of a counter electrode structure group (i.e., an "adjacent pair") for ion exchange during charge or discharge is microporous membrane material; in other words, the microporous membrane material constitutes at least 70 vol% of the electrically insulating membrane material layer between a member 151 of an electrode structure group and a nearest member 152 of a counter electrode structure group. As another example, in one embodiment, ignoring the porosity of the microporous membrane material, the microporous membrane material constitutes at least 75 vol% of the electrically insulating membrane material layer between adjacent pairs of members 151 and members 152 of the electrode structure group and the counter electrode structure group, respectively. As another example, in one embodiment, and ignoring the porosity of the microporous membrane material, the microporous membrane material constitutes at least 80 vol% of the electrically insulating membrane material layer between adjacent pairs of members 151 and members 152 of the electrode structure group and the counter electrode structure group, respectively. As another example, in one embodiment, and ignoring the porosity of the microporous membrane material, the microporous membrane material constitutes at least 85 vol% of the electrically insulating membrane material layer between adjacent pairs of members 151 and members 152 of the electrode structure group and the counter electrode structure group, respectively. As another example, in one embodiment, and ignoring the porosity of the microporous membrane material, the microporous membrane material constitutes at least 90 vol% of the electrically insulating membrane material layer between adjacent pairs of members 151 and members 152 of the electrode structure group and the counter electrode structure group, respectively. As another example, in one embodiment, and ignoring the porosity of the microporous membrane material, the microporous membrane material constitutes at least 95 vol% of the electrically insulating membrane material layer between adjacent pairs of members 151 and members 152 of the electrode structure group and the counter electrode structure group, respectively. As another example, in one embodiment, and ignoring the porosity of the microporous membrane material, the microporous membrane material constitutes at least 99 vol% of the electrically insulating membrane material layer between adjacent pairs of members 151 and members 152 of the electrode structure group and the counter electrode structure group, respectively.

[0111] In one embodiment, the microporous membrane material comprises a particulate material and a binder and has a porosity (voidness) of at least about 20 vol%. The pores of the microporous membrane material will have a diameter of at least 50 angstroms and will generally fall within the range of about 250 to 2500 angstroms. The microporous membrane material will generally have a porosity of less than about 75%. In one embodiment, the microporous membrane material has a porosity (voidness) of at least about 25 vol%. In one embodiment, the microporous membrane material will have a porosity of about 35-55%.

[0112] The adhesive for microporous membrane material can be selected from a wide range of inorganic or polymer materials. For example, in one embodiment, the adhesive is an inorganic material selected from the group including: silicate, phosphate, aluminate, aluminosilicate and hydroxide (such as magnesium hydroxide, calcium hydroxide, etc.). For example, in one embodiment, the adhesive is a fluorine-containing polymer derived from a monomer comprising vinylidene fluoride, hexafluoropropylene, tetrafluoropropylene, etc. In another embodiment, the adhesive is a polyolefin, such as polyethylene, polypropylene or polybutylene, which has different molecular weights and densities in any range. In another embodiment, the adhesive is selected from the group including: ethylene-diene-propylene terpolymer, polystyrene, polymethyl methacrylate, polyethylene glycol, polyvinyl acetate, polyvinyl butyral, polyacetal and polyethylene glycol diacrylate. In another embodiment, the adhesive is selected from the group including: methylcellulose, carboxymethyl cellulose, styrene rubber, butadiene rubber, styrene-butadiene rubber, isoprene rubber, polyacrylamide, polyvinyl ether, polyacrylic acid, polymethacrylic acid and polyethylene oxide. In another embodiment, the binder is selected from the group consisting of acrylates, styrenes, epoxies, and siloxanes. In another embodiment, the binder is a copolymer or blend of two or more of the foregoing polymers.

[0113] The particulate material included in the microporous membrane material can also be selected from a wide range of materials. Typically, such materials have relatively low electronic and ionic conductivity at operating temperatures and will not corrode at the operating voltage of the battery electrode or current collector in contact with the microporous membrane material. For example, in one embodiment, the particulate material has a relative low conductivity of less than 1×10 -4 S / cm of the carrier ion (e.g., lithium). As another example, in one embodiment, the particle material has a conductivity of less than 1×10 -5 As another example, in one embodiment, the particle material has a conductivity of less than 1×10 -6The electrical conductivity of the carrier ion of s / cm. Exemplary granular materials include granular polyethylene, polypropylene, TiO2-polymer composites, silica aerogel, pyrogenic silica, silica gel, silica hydrogel, silica xerogel, silica sol, colloidal silica, aluminum oxide, titanium dioxide, magnesium oxide, kaolin, talc, diatomaceous earth, calcium silicate, aluminum silicate, calcium carbonate, magnesium carbonate or a combination thereof. For example, in one embodiment, the granular material includes a granular oxide or nitride such as TiO2, SiO2, Al2O3, GeO2, B2O3, Bi2O3, BaO, ZnO, ZrO2, BN, Si3N4, Ge3N4, for example, referring to P.Aroraand J.Zhang, "Battery Separators" Chemical Reviews 2004, 104, 4419-4462. In one embodiment, the particulate material will have an average particle size of about 20 nm to 2 microns, more typically 200 nm to 1.5 microns. In one embodiment, the particulate material will have an average particle size of about 500 nm to 1 micron.

[0114] In an alternative embodiment, the particulate material comprised by the microporous separator material may be bonded by techniques such as sintering, bonding, curing, etc. while maintaining the electrolyte in the required porosity to provide ionic conductivity for battery function.

[0115] The microporous membrane material can be deposited, for example, by electrophoretic deposition of a particulate membrane material, in which the particles are bound by surface energy (such as electrostatic attraction or van der Waals forces), slurry deposition (including spin coating or spray coating) of the particulate membrane material, screen printing, dip coating, and electrostatic spray deposition. A binder can be included in the deposition process; for example, the particulate material can be slurry deposited with a dissolved binder that precipitates upon evaporation of the solvent, electrophoretically deposited in the presence of a dissolved binder material, or co-electrophoretically deposited with a binder and insulating particles, etc. Alternatively or additionally, a binder can be added after the particles are deposited into or onto the electrode structure; for example, the particulate material can be dispersed in an organic binder solution and dip coated or sprayed, and then the binder material can be dried, melted, or cross-linked to provide bonding strength.

[0116] In the assembled energy storage device, the microporous separator material is infiltrated with a non-aqueous electrolyte suitable for use as a secondary battery electrolyte. Typically, the non-aqueous electrolyte comprises a lithium salt dissolved in an organic solvent. Exemplary lithium salts include inorganic lithium salts such as LiClO4, LiBF4, LiPF6, LiAsF6, LiCl, and LiBr; and organic lithium salts such as LiB(C6H5)4, LiN(SO2CF3)2, LiN(SO2CF3)3, LiNSO2CF3, LiNSO2CF5, LiNSO2C4F9, LiNSO2C5F11 、LiNSO2C6F 13 and LiNSO2C7F 15 . Exemplary organic solvents for dissolving lithium salts include cyclic esters, chain esters, cyclic ethers, and chain ethers. Specific examples of cyclic esters include propylene carbonate, butylene carbonate, γ-butyrolactone, vinylene carbonate, 2-methyl-γ-butyrolactone, acetyl-γ-butyrolactone, and γ-valerolactone. Specific examples of chain esters include dimethyl carbonate, diethyl carbonate, dibutyl carbonate, dipropyl carbonate, ethyl methyl carbonate, methyl butyl carbonate, methyl propyl carbonate, ethyl butyl carbonate, ethyl propyl carbonate, butyl propyl carbonate, alkyl propionate, dialkyl malonate, and alkyl acetate. Specific examples of cyclic ethers include tetrahydrofuran, alkyltetrahydrofuran, dialkyltetrahydrofuran, alkoxytetrahydrofuran, dialkoxytetrahydrofuran, 1,3-dioxolane, alkyl-1,3-dioxolane, and 1,4-dioxolane. Specific examples of the chain ethers include 1,2-dimethoxyethane, 1,2-diethoxyethane, diethyl ether, ethylene glycol dialkyl ether, diethylene glycol dialkyl ether, triethylene glycol dialkyl ether, and tetraethylene glycol dialkyl ether.

[0117] Reference again Fig. 12A , 12B and 12C, the regions 122, 124 of the longitudinal end surfaces of the electrode assembly that coincide with the projections of the electrodes and components of the electrode assembly onto the longitudinal end surfaces 122, 124, respectively (i.e., the "projected surface areas"), will be subject to the constraints 130 (see Figure 4) applied by the electrode assembly. For example, in one embodiment, the areas of the longitudinal end surface of the electrode assembly that coincide with the projections of the electrodes and the components of the electrode assembly onto the longitudinal end surface will each be subjected to a compressive load of at least 0.7 kPa (averaged over the surface area of ​​each of the first and second projected surface areas, respectively). As another example, in one such embodiment, the areas of the longitudinal end surface of the electrode assembly that coincide with the projections of the electrodes and the components of the electrode assembly onto the longitudinal end surface will each be subjected to a compressive load of at least 1.75 kPa (averaged over the surface area of ​​each of the first and second projected surface areas, respectively). As another example, in one such embodiment, the areas of the longitudinal end surface of the electrode assembly that coincide with the projections of the electrodes and the components of the electrode assembly onto the longitudinal end surface will each be subjected to a compressive load of at least 2.8 kPa (averaged over the surface area of ​​each of the first and second projected surface areas, respectively). As another example, in one such embodiment, the areas of the longitudinal end surface of the electrode assembly that coincide with the projections of the electrodes and the components of the electrode assembly onto the longitudinal end surface will each be subjected to a compressive load of at least 3.5 kPa (averaged over the surface area of ​​each of the first and second projected surface areas, respectively). As another example, in one such embodiment, the areas of the longitudinal end surface of the electrode assembly that coincide with the projections of the electrodes and the components of the electrode group onto the longitudinal end surface will each be subjected to a compressive load of at least 5.25 kPa (averaged over the surface area of ​​each of the first and second projected surface areas, respectively). As another example, in one such embodiment, the areas of the longitudinal end surface of the electrode assembly that coincide with the projections of the electrodes and the components of the electrode group onto the longitudinal end surface will each be subjected to a compressive load of at least 7 kPa (averaged over the surface area of ​​each of the first and second projected surface areas, respectively). As another example, in one such embodiment, the areas of the longitudinal end surface of the electrode assembly that coincide with the projections of the electrodes and the components of the electrode group onto the longitudinal end surface will each be subjected to a compressive load of at least 8.75 kPa (averaged over the surface area of ​​each of the first and second projected surface areas, respectively). However, typically, the areas of the longitudinal end surface of the electrode assembly that coincide with the projections of the electrodes and the components of the electrode group onto the longitudinal end surface will each be subjected to a compressive load of no more than about 10 kPa (averaged over the surface area of ​​each of the first and second projected surface areas, respectively). In each of the foregoing exemplary embodiments, the longitudinal end surfaces of the secondary battery of the present disclosure will experience such a compressive load when the battery is charged to at least about 80% of its rated capacity.

[0118] In certain embodiments, substantially the entire longitudinal end surface of the electrode assembly will be subjected to a significant compressive load (and not necessarily just the first and second projected surface areas). For example, in some embodiments, typically, each of the longitudinal end surfaces of the electrode assembly will be subjected to a compressive load of at least 0.7 kPa (averaged over the total surface area of ​​each of the longitudinal end surfaces, respectively). For example, in one embodiment, each of the longitudinal end surfaces of the electrode assembly will be subjected to a compressive load of at least 1.75 kPa (averaged over the total surface area of ​​each of the longitudinal end surfaces, respectively). As another example, in one such embodiment, each of the longitudinal end surfaces of the electrode assembly will be subjected to a compressive load of at least 2.8 kPa (averaged over the total surface area of ​​each of the longitudinal end surfaces, respectively). As another example, in one such embodiment, each of the longitudinal end surfaces of the electrode assembly will be subjected to a compressive load of at least 3.5 kPa (averaged over the total surface area of ​​each of the longitudinal end surfaces, respectively). As another example, in one such embodiment, each of the longitudinal end surfaces of the electrode assembly will be subjected to a compressive load of at least 5.25 kPa (averaged over the total surface area of ​​each of the longitudinal end surfaces, respectively). As another example, in one such embodiment, each of the longitudinal end surfaces of the electrode assembly will be subjected to a compressive load of at least 7 kPa (averaged over the total surface area of ​​each of the longitudinal end surfaces, respectively). As another example, in one such embodiment, each of the longitudinal end surfaces of the electrode assembly will be subjected to a compressive load of at least 8.75 kPa (averaged over the total surface area of ​​each of the longitudinal end surfaces, respectively). However, typically, the longitudinal end surfaces of the electrode assembly will be subjected to a compressive load of no more than about 10 kPa (averaged over the total surface area of ​​each of the longitudinal end surfaces, respectively). In each of the foregoing exemplary embodiments, the longitudinal end surfaces of the electrode assembly will experience such a compressive load when the battery is charged to at least about 80% of its rated capacity.

[0119] In one embodiment, each of the first and second longitudinal end surfaces of the electrode assembly is subjected to a compressive load of at least 100 psi. For example, in one embodiment, each of the first and second longitudinal end surfaces is subjected to a compressive load of at least 200 psi. As another example, in one embodiment, each of the first and second longitudinal end surfaces is subjected to a compressive load of at least 300 psi. As another example, in one embodiment, each of the first and second longitudinal end surfaces is subjected to a compressive load of at least 400 psi. As another example, in one embodiment, each of the first and second longitudinal end surfaces is subjected to a compressive load of at least 500 psi. As another example, in one embodiment, each of the first and second longitudinal end surfaces is subjected to a compressive load of at least 600 psi. As another example, in one embodiment, each of the first and second longitudinal end surfaces is subjected to a compressive load of at least 700 psi. As another example, in one embodiment, each of the first and second longitudinal end surfaces is subjected to a compressive load of at least 800 psi. As another example, in one embodiment, each of the first and second longitudinal end surfaces is subjected to a compressive load of at least 900 psi. In another example, each of the first and second longitudinal end surfaces is subjected to a compressive load of at least 1000 psi.

[0120] Reference again Figure 4 and 5A , 5B, 5C and 5D, and according to one aspect of the present disclosure, the tension members 133, 135 are preferably relatively close to the side surfaces to suppress buckling of the electrode assembly in response to a compressive force applied to the longitudinal end surfaces. Figures 5A-5DIn the illustrated embodiment, for example, the tension members 133, 135 contact the side surfaces 123, 125, respectively. However, in other embodiments, there may be a gap between the tension member and the side surface. However, typically, the distance between the tension member and the side surface of the electrode assembly is less than 50% of the minimum Feret's diameter of the electrode assembly, where the Feret's diameter is measured in the same direction as the distance between the tension member and the side surface of the electrode assembly. As another example, in one such embodiment, the distance between the tension member and the side surface of the electrode assembly is less than 40% of the minimum Feret's diameter of the electrode assembly, where the Feret's diameter is measured in the same direction as the distance between the tension member and the side surface of the electrode assembly. As another example, in one such embodiment, the distance between the tension member and the side surface of the electrode assembly is less than 30% of the minimum Feret's diameter of the electrode assembly, where the Feret's diameter is measured in the same direction as the distance between the tension member and the side surface of the electrode assembly. As another example, in one such embodiment, the distance between the tension member and the side surface of the electrode assembly is less than 20% of the minimum Feret's diameter of the electrode assembly, wherein the Feret's diameter is measured in the same direction as the distance between the tension member and the side surface of the electrode assembly. As another example, in one such embodiment, the distance between the tension member and the side surface of the electrode assembly is less than 10% of the minimum Feret's diameter of the electrode assembly, wherein the Feret's diameter is measured in the same direction as the distance between the tension member and the side surface of the electrode assembly. As another example, in one such embodiment, the distance between the tension member and the side surface of the electrode assembly is less than 5% of the minimum Feret's diameter of the electrode assembly, wherein the Feret's diameter is measured in the same direction as the distance between the tension member and the side surface of the electrode assembly.

[0121] Reference now Figure 7 , an exploded view of an alternative embodiment of a secondary battery of the present disclosure can be seen, generally indicated at 100. The secondary battery includes a battery housing 102 and a collection 110 of electrode assemblies 120 within the battery housing 102, each of the electrode assemblies having a first longitudinal end surface 122, an opposite second longitudinal end surface 124 (along a line parallel to Figure 7 The longitudinal axis (not shown) of the imaginary Cartesian coordinate system "'Y axis" is separated from the first longitudinal end surface 122), and the side surface includes side surfaces 123, 125, 126, 127 (see Figure 4 ).and Figure 41. In contrast to the embodiment shown, in this embodiment, a separate constraint 130 applies a compressive force on the first and second longitudinal surfaces of each of the electrode assemblies in the set 110. As previously described, the combined surface area of ​​the opposing first and second longitudinal end surfaces of each of the electrode assemblies in the set 110 is less than 50% of the total surface area of ​​each of the electrode assemblies in the set, respectively. The tensioning members of the constraint 130 tend to pull the compression members toward each other, thereby applying a compressive force to each of the opposing first and second longitudinal end surfaces of each electrode assembly in the set 110, which in turn inhibits expansion of each electrode assembly in the set 110 in the longitudinal direction (which coincides with the electrode stacking direction of each electrode assembly as described heretofore). In addition, after the battery is formed, the constraint applies a pressure on each electrode assembly in the set 110 in the longitudinal direction (i.e., the electrode stacking direction) that exceeds the pressure maintained on each corresponding electrode assembly in either of the two directions that are mutually perpendicular to each other and perpendicular to the longitudinal direction.

[0122] Reference now Figure 8 , 9 , 10A and 10B, in an alternative embodiment, the constraint 130 is formed by a sheet 107 including a slot 109, a connection region 111 and a folding region 113. To form the constraint, the sheet 107 is simply wrapped around the electrode structure 120 (at Fig. 9 , without the electrode structure 120), is folded along the fold region 113, and the overlapping edges 115, 117 are welded, bonded or otherwise secured to one another to form a constraint including compression members 132, 134 (compression members 134 including overlapping edges 115, 177 once secured to one another) and tensioning members 133, 135. In one such embodiment, the constraint 130 is stretched in the stacking direction D to place the connection region 111 under tension, which in turn causes a compressive force to be applied to the longitudinal end surfaces 122, 124. In an alternative embodiment, instead of stretching the connection region 111 to place it in tension, the connection region is pre-tensioned prior to installation over the electrode assembly. In another alternative embodiment, the connection region 111 is not initially in tension when installed over the electrode assembly, but rather the formation of the battery causes the electrode assembly to expand and induce tension in the connection tensioning members (i.e., self-tensioning).

[0123] Reference now Fig.11A and Fig. 11BIn an alternative embodiment, the constraint 130 includes one or more serpentine tension members 121 in addition to the slots 109 and the connection regions 111. The serpentine tension members 121 provide a second tensioning force in those embodiments, where the force is greater during forming than during cycling. In such embodiments, the straight members provide greater resistance and yielding during forming, while the serpentine tension members apply less tension during cycling. As previously described, the constraint 130 can be formed by wrapping the sheet 107 around the electrode structure 120, folding it along the fold region 113, and securing the overlapping edges 115, 117 ( Fig.11A and Fig. 11B , without the electrode structure 20). When the sheet 107 is wrapped around the electrode structure, the constraint 130 is stretched in the stacking direction D to place the connection area 111 and the serpentine tensioning member 121 under tension, which in turn exerts a compressive force on the electrode structure 120 in the stacking direction D.

[0124] In general, constraints with high strength and stiffness can inhibit the rapid growth of the electrode assembly during battery formation, while constraints with much lower strength and stiffness allow changes in the volume of the electrode assembly due to changes in lithiation encountered at different states of charge. In addition, constraints with lower stiffness and higher preload (or starting load) help control the impedance of the battery by maintaining a minimum force between the cathode and the anode. One way to address these competing demands according to an embodiment of the present disclosure is to construct a constraint from two components. These components can be made of any of the following (i) similar materials with different geometries or (ii) materials with different elastic moduli and the same geometry, (iii) certain combinations of elastic moduli and geometric properties to achieve the desired stiffness. In both cases, the first component ("element 1") utilizes a higher stiffness design (material or geometric drive) than the second component ("element 2"), and deforms elastically and then plastically, but does not break under the load, which it experiences during battery formation. Element 2 will preferably deform only elastically. In both cases, the first element should prevent the second element from displacing more than itself by encapsulating the second element or otherwise supporting the second element.

[0125] In one embodiment, the constraint includes an elastically deformable material located between the longitudinal surface of the electrode assembly and the compression member. In this embodiment, the elastically deformable material elastically deforms to accommodate the expansion of the electrode and elastically recovers to its original thickness and shape as the electrode contracts. As a result, as the electrode and / or the counter electrode expands and contracts during the cycle of the secondary battery, a minimum force can be maintained on the electrode assembly in the longitudinal direction.

[0126] Reference now Fig.16In one exemplary embodiment, the constraint 130 includes first and second elements 136, 137. In this embodiment, the compression member 132 includes compression regions 132A, 132B of the first and second elements 136, 137, respectively, which overlie the longitudinal end surface 122, and the compression member 134 includes compression regions 134A and 134B of the first and second elements 136, 137, respectively, which overlie the longitudinal end surface 124. In addition, the tension member 133 includes tension member regions 133A, 133B of the first and second elements 136, 137, respectively, which overlie the side 123, and the tension member 135 includes tension member regions 135A and 135B of the first and second elements 136, 137, respectively, which overlie the side 125. In this exemplary embodiment, the first element 136 is used to limit the maximum growth of the electrode assembly during battery formation or battery cycling, and the element 137 is used to maintain a preload in the direction of the electrode stacking direction D during the discharge state. In this exemplary embodiment, element 136 is not preloaded (no force is applied on the electrode assembly) before formation. Element 137 is preloaded onto the electrode assembly to apply compressive force on the first and second longitudinal end surfaces 122, 124. As the electrode assembly expands (e.g., during the charging step, the silicon-containing anode expands when carrier ions are bound), the force on element 136 grows rapidly due to its higher stiffness, while the force on the lower stiffness element 137 rises slowly due to its displacement being limited by element 136. Above a certain force, element 136 will yield or move from elasticity to plastic (permanent) deformation, while element 137 remains within the elastic range. As the force continues to rise, the length of element 136 increases permanently. Later, when the force is reduced to a smaller value (e.g., during the discharge step, the silicon-containing anode shrinks when carrier ions are removed), element 136 has been permanently deformed and may no longer contact electrode assembly 120, and element 137 can return to near its initial preload level.

[0127] Reference now Fig.13 In an alternative embodiment, the secondary battery 100 includes a battery housing 102 and a set of electrode assemblies 120 within the battery housing 102. As previously described, each of the electrode assemblies has a first longitudinal end surface and an opposite second longitudinal end surface separated along the longitudinal axis, and a side surface around the longitudinal axis (see Figure 4 and 12A). In addition, the set has an associated constraint 130, which includes a top constraint member 130T and a bottom constraint member 130B to inhibit expansion in the electrode stacking direction D of each of the electrode assemblies in the set. The top constraint member 130T and the bottom constraint member 130B respectively include interlocking tabs 132D, 132C, which in combination constitute a compression member 132. The top constraint member 130T and the bottom constraint member 130B respectively include interlocking tabs, which in combination constitute a compression member 134 (not shown). As in other embodiments, each of the compression members applies a compressive force to the opposing first and second longitudinal end surfaces, and the tensioning member includes the narrow groove 109 and the connecting area 111 as described above.

[0128] Reference now Fig.14 In an alternative embodiment, the secondary battery 100 includes a battery housing 102, a set of electrode assemblies within the battery housing 102 (not shown), and an associated constraint 130 to inhibit expansion of each of the electrode assemblies within the set in the electrode stacking direction. The constraint 130 includes first and second shells 130R, 130L that respectively encapsulate the first and second longitudinal halves of the set of electrode assemblies. As in other embodiments, a first compression member 132 including elements 132E and 132F is overlaid on a first longitudinal end surface (not shown) of the electrode assembly within the set, a second compression member (not shown) is overlaid on a second longitudinal end surface (not shown) of the electrode assembly within the set, and a tensioning member overlaid on a side surface of the electrode assembly. As in other embodiments, each of the compression members applies a compressive force to the opposing first and second longitudinal end surfaces, and the tensioning member includes a slot 109 and a connection area 111 as described above.

[0129] Reference now Fig.15 In an alternative embodiment, the secondary battery 100 includes a battery housing 102, a set of electrode assemblies 120 within the battery housing 102, and an associated constraint 130 to inhibit expansion of each of the electrode assemblies within the set in the electrode stacking direction. The constraint 130 includes a series of bands 151 surrounding each electrode assembly and a cap 153 inserted between the band 151 and the first and second longitudinal end surfaces (not shown) of each electrode assembly 120 within the set. In this embodiment, the portion of the band covering the longitudinal end surface and the cap constitute the compression member of the present disclosure, and the portion of the band covering the side surface of the electrode assembly constitutes a tensioning member. As in other embodiments, as previously described, each of the compression members applies a compressive force to the first and second longitudinal end surfaces relative to each other.

[0130] In other embodiments numbered 1-122 below, aspects of the present disclosure include:

[0131] Embodiment 1:

[0132] 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 non-aqueous liquid electrolyte within the battery housing, and a constraint that maintains pressure on the electrode assembly as the secondary battery cycles between a charged state and a discharged state, the electrode assembly comprising a group of electrode structures, a group of counter-electrode structures, and an electrically insulating microporous membrane material between members of the electrode and counter-electrode groups, wherein

[0133] The electrode assembly has first and second opposing longitudinal end surfaces separated along the longitudinal axis, and side surfaces surrounding the longitudinal axis and connecting the first and second longitudinal end surfaces, the surface areas of the first and second longitudinal end surfaces being less than 33% of the surface area of ​​the electrode assembly,

[0134] The components of the electrode group and the components of the counter electrode group are arranged in an alternating order in a stacking direction parallel to the longitudinal axis within the electrode assembly,

[0135] The projections of the components of the electrode group and the counter electrode group on the first longitudinal surface surround a first projection area, and the projections of the components of the electrode group and the counter electrode group on the second longitudinal surface surround a second projection area,

[0136] The restraint includes first and second compression members overlying the first and second projected areas, respectively, the compression members being connected by a tension member overlying the side surfaces of the electrode assembly and pulling the compression members toward each other, and

[0137] The restraint maintains a pressure on the electrode assembly in the stacking direction that exceeds a pressure maintained on the electrode assembly in each of two directions that are perpendicular to each other and to the stacking direction.

[0138] Embodiment 2:

[0139] The secondary battery according to Embodiment 1, wherein the constraint applies an average compressive force of at least 0.7 kPa to each of the first and second projected areas, averaged over surface areas of the first and second projected areas, respectively.

[0140] Embodiment 3:

[0141] The secondary battery according to Embodiment 1, wherein the constraint applies an average compressive force of at least 1.75 kPa to each of the first and second projected areas, averaged over surface areas of the first and second projected areas, respectively.

[0142] Embodiment 4:

[0143] The secondary battery according to Embodiment 1, wherein the constraint applies an average compressive force of at least 2.8 kPa to each of the first and second projected areas, averaged over surface areas of the first and second projected areas, respectively.

[0144] Embodiment 5:

[0145] The secondary battery according to Embodiment 1, wherein the constraint applies an average compressive force of at least 3.5 kPa to each of the first and second projected areas, averaged over surface areas of the first and second projected areas, respectively.

[0146] Embodiment 6:

[0147] The secondary battery according to Embodiment 1, wherein the constraint applies an average compressive force of at least 5.25 kPa to each of the first and second projected areas, averaged over surface areas of the first and second projected areas, respectively.

[0148] Embodiment 7:

[0149] The secondary battery according to Embodiment 1, wherein the constraint applies an average compressive force of at least 7 kPa to each of the first and second projected areas, averaged over surface areas of the first and second projected areas, respectively.

[0150] Embodiment 8:

[0151] The secondary battery according to Embodiment 1, wherein the constraint applies an average compressive force of at least 8.75 kPa to each of the first and second projected areas, averaged over surface areas of the first and second projected areas, respectively.

[0152] Embodiment 9:

[0153] The secondary battery according to Embodiment 1, wherein the constraint applies an average compressive force of at least 10 kPa to each of the first and second projected areas, averaged over surface areas of the first and second projected areas, respectively.

[0154] Embodiment 10:

[0155] The secondary battery according to any one of the preceding embodiments, wherein the surface areas of the first and second longitudinal end surfaces are less than 25% of the surface area of ​​the electrode assembly.

[0156] Embodiment 11:

[0157] The secondary battery according to any one of the preceding embodiments, wherein the surface areas of the first and second longitudinal end surfaces are less than 20% of the surface area of ​​the electrode assembly.

[0158] Embodiment 12:

[0159] The secondary battery according to any one of the preceding embodiments, wherein the surface areas of the first and second longitudinal end surfaces are less than 15% of the surface area of ​​the electrode assembly.

[0160] Embodiment 13:

[0161] The secondary battery according to any one of the preceding embodiments, wherein the surface areas of the first and second longitudinal end surfaces are less than 10% of the surface area of ​​the electrode assembly.

[0162] Embodiment 14:

[0163] The secondary battery according to any of the preceding embodiments, wherein the constraint and housing have a combined volume that is less than 60% of the volume enclosed by the battery housing.

[0164] Embodiment 15:

[0165] The secondary battery according to any of the preceding embodiments, wherein the constraint and housing have a combined volume that is less than 45% of the volume enclosed by the battery housing.

[0166] Embodiment 16:

[0167] The secondary battery according to any of the preceding embodiments, wherein the constraint and housing have a combined volume that is less than 30% of the volume enclosed by the battery housing.

[0168] Embodiment 17:

[0169] The secondary battery according to any of the preceding embodiments, wherein the constraint and the housing have a combined volume that is less than 20% of the volume enclosed by the battery housing.

[0170] Embodiment 18:

[0171] The secondary battery according to any one of the preceding embodiments, wherein each member of the electrode group has a bottom, a top, a length L E , Width W E , height H E and a central longitudinal axis A extending from the bottom to the top of each such member and in a direction generally transverse to the stacking direction. E , the length L of each member of the electrode group E At its central longitudinal axis A E The width W of each member of the electrode assembly is measured in the direction of E The height H of each member of the electrode assembly is measured in the stacking direction. E At right angles to the central longitudinal axis A of each such member E and measured in the direction perpendicular to the stacking direction, L E The W of each member of the electrode group E and H EThe ratio of each of the H of each member of the electrode group is at least 5:1. E With W E The ratios are between 0.4:1 and 1000:1 respectively.

[0172] Embodiment 19:

[0173] The secondary battery according to any of the preceding embodiments, wherein the microporous separator material comprises a particulate material and a binder, has a porosity of at least 20 vol%, and is permeated by a non-aqueous liquid electrolyte.

[0174] Embodiment 20:

[0175] The secondary battery according to any one of the preceding embodiments, wherein the tension member is sufficiently close to the side surface to inhibit buckling of the electrode assembly when the secondary battery is cycled between a charged state and a discharged state.

[0176] Embodiment 21:

[0177] The secondary battery according to any of the foregoing embodiments, wherein the distance between the tension member and the side surface is less than 50% of the minimum Feret diameter of the electrode assembly, wherein the Feret diameter is measured in the same direction as the distance between the tension member and the side surface of the electrode assembly.

[0178] Embodiment 22:

[0179] The secondary battery according to any of the preceding embodiments, wherein the distance between the tension member and the side surface is less than 40% of a minimum Feret diameter of the electrode assembly, wherein the Feret diameter is measured in the same direction as the distance between the tension member and the side surface of the electrode assembly.

[0180] Embodiment 23:

[0181] The secondary battery according to any of the preceding embodiments, wherein the distance between the tension member and the side surface is less than 30% of a minimum Feret diameter of the electrode assembly, wherein the Feret diameter is measured in the same direction as the distance between the tension member and the side surface of the electrode assembly.

[0182] Embodiment 24:

[0183] The secondary battery according to any of the preceding embodiments, wherein the distance between the tension member and the side surface is less than 20% of a minimum Feret diameter of the electrode assembly, wherein the Feret diameter is measured in the same direction as the distance between the tension member and the side surface of the electrode assembly.

[0184] Embodiment 25:

[0185] The secondary battery according to any of the preceding embodiments, wherein the distance between the tension member and the side surface is less than 10% of a minimum Feret diameter of the electrode assembly, wherein the Feret diameter is measured in the same direction as the distance between the tension member and the side surface of the electrode assembly.

[0186] Embodiment 26:

[0187] The secondary battery according to any of the preceding embodiments, wherein the distance between the tension member and the side surface is less than 5% of a minimum Feret's diameter of the electrode assembly, wherein the Feret's diameter is measured in the same direction as the distance between the tension member and the side surface of the electrode assembly.

[0188] Embodiment 27:

[0189] The secondary battery according to any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces withstands a compressive load of at least 100 psi.

[0190] Embodiment 28:

[0191] The secondary battery according to any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces withstands a compressive load of at least 200 psi.

[0192] Embodiment 29:

[0193] The secondary battery according to any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces withstands a compressive load of at least 300 psi.

[0194] Embodiment 30:

[0195] The secondary battery according to any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces withstands a compressive load of at least 400 psi.

[0196] Embodiment 31:

[0197] The secondary battery according to any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces withstands a compressive load of at least 500 psi.

[0198] Embodiment 32:

[0199] The secondary battery according to any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces withstands a compressive load of at least 600 psi.

[0200] Embodiment 33:

[0201] The secondary battery according to any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces withstands a compressive load of at least 700 psi.

[0202] Embodiment 34:

[0203] The secondary battery according to any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces withstands a compressive load of at least 800 psi.

[0204] Embodiment 35:

[0205] The secondary battery according to any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces withstands a compressive load of at least 900 psi.

[0206] Embodiment 36:

[0207] The secondary battery according to any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces withstands a compressive load of at least 1000 psi.

[0208] Embodiment 37:

[0209] The secondary battery according to any of the preceding embodiments, wherein the secondary battery has a rated capacity, and the first and second longitudinal end surfaces are subjected to such a compressive load when the secondary battery is charged to at least 80% of its rated capacity.

[0210] Embodiment 38:

[0211] The secondary battery according to any of the preceding embodiments, wherein the electrode structure comprises an anode-active electroactive material and the counter electrode structure comprises a cathode-active electroactive material.

[0212] Embodiment 39:

[0213] The secondary battery according to any of the preceding embodiments, wherein the electrode structure comprises an anode-active electroactive material comprising silicon, and the counter-electrode structure comprises a cathode-active electroactive material.

[0214] Embodiment 40:

[0215] The secondary battery according to any one of the preceding embodiments, wherein the secondary battery comprises a set of electrode assemblies, the set comprising at least two electrode assemblies.

[0216] Embodiment 41:

[0217] The secondary battery according to any one of embodiments 1-39, wherein the secondary battery includes a set of at least two electrode assemblies, and the restraint maintains pressure on the electrode assemblies within the set as the secondary battery is cycled between a charged state and a discharged state.

[0218] Embodiment 42:

[0219] A secondary battery according to any one of embodiments 1-39, wherein the secondary battery includes a set of at least two electrode assemblies, and the secondary battery includes a corresponding number of constraints, wherein each of the constraints maintains pressure on one of the electrode assemblies in the set as the secondary battery cycles between a charge state and a discharge state.

[0220] Embodiment 43:

[0221] According to any one of the aforementioned embodiments, the secondary battery, wherein the electrode assembly includes at least 5 electrode structures and at least 5 counter electrode structures.

[0222] Embodiment 44:

[0223] The secondary battery according to any one of the aforementioned embodiments, wherein the electrode assembly includes at least 10 electrode structures and at least 10 counter electrode structures.

[0224] Embodiment 45:

[0225] The secondary battery according to any one of the aforementioned embodiments, wherein the electrode assembly includes at least 50 electrode structures and at least 50 counter electrode structures.

[0226] Embodiment 46:

[0227] The secondary battery according to any one of the aforementioned embodiments, wherein the electrode assembly includes at least 100 electrode structures and at least 100 counter electrode structures.

[0228] Embodiment 47:

[0229] The secondary battery according to any one of the aforementioned embodiments, wherein the electrode assembly includes at least 500 electrode structures and at least 500 counter electrode structures.

[0230] Embodiment 48:

[0231] The secondary battery according to any of the preceding embodiments, wherein the constraint comprises a material having an ultimate tensile strength of at least 10,000 psi (>70 MPa).

[0232] Embodiment 49:

[0233] The secondary battery according to any of the preceding embodiments, wherein the constraint comprises a material that is compatible with the battery electrolyte.

[0234] Embodiment 50:

[0235] The secondary battery according to any of the preceding embodiments, wherein the constraint comprises a material that does not significantly corrode at the floating or anode potential of the battery.

[0236] Embodiment 51:

[0237] The secondary battery according to any of the preceding embodiments, wherein the constraint comprises a material that does not significantly react or lose mechanical strength at 45°C.

[0238] Embodiment 52:

[0239] The secondary battery according to any of the preceding embodiments, wherein the constraint comprises metal, metal alloy, ceramic, glass, plastic or a combination thereof.

[0240] Embodiment 53:

[0241] The secondary battery according to any of the preceding embodiments, wherein the constraint comprises a sheet of material having a thickness in a range of about 10 microns to about 100 microns.

[0242] Embodiment 54:

[0243] The secondary battery according to any of the preceding embodiments, wherein the constraint comprises a sheet of material having a thickness in a range of about 30 microns to about 75 microns.

[0244] Embodiment 55:

[0245] The secondary battery according to any of the preceding embodiments, wherein the constraint comprises carbon fibers with >50% packing density.

[0246] Embodiment 56:

[0247] The secondary battery according to any of the foregoing embodiments, wherein the compression member applies a pressure on the first and second longitudinal end surfaces that exceeds at least 3 times the pressure maintained on the electrode assembly in each of two directions perpendicular to each other and to the stacking direction.

[0248] Embodiment 57:

[0249] The secondary battery according to any of the foregoing embodiments, wherein the compression member applies a pressure on the first and second longitudinal end surfaces that exceeds at least 3 times the pressure maintained on the electrode assembly in each of two directions perpendicular to each other and to the stacking direction.

[0250] Embodiment 58:

[0251] The secondary battery according to any of the foregoing embodiments, wherein the compression member applies a pressure on the first and second longitudinal end surfaces that exceeds at least 4 times the pressure maintained on the electrode assembly in each of two directions perpendicular to each other and perpendicular to the stacking direction.

[0252] Embodiment 59:

[0253] According to the secondary battery of any of the foregoing embodiments, the compression member applies a pressure on the first and second longitudinal end surfaces that exceeds at least 5 times the pressure maintained on the electrode assembly in each of two directions perpendicular to each other and to the stacking direction.

[0254] Embodiment 60:

[0255] An energy storage device for cycling between a charged state and a discharged state, the energy storage device comprising a housing, an electrode assembly and a non-aqueous liquid electrolyte within the housing, and a constraint that maintains pressure on the electrode assembly as the energy storage device cycles between a charged state and a discharged state, the electrode assembly comprising a set of electrode structures, a set of counter-electrode structures, and an electrically insulating microporous membrane material between members of the electrode and counter-electrode sets, wherein

[0256] The electrode assembly has first and second opposing longitudinal end surfaces separated along a longitudinal axis, and side surfaces surrounding the longitudinal axis and connecting the first and second longitudinal end surfaces, a combined surface area of ​​the first and second longitudinal end surfaces being less than 33% of a combined surface area of ​​the side surfaces and the first and second longitudinal end surfaces,

[0257] The components of the electrode group and the components of the counter electrode group are arranged in an alternating order in a stacking direction parallel to the longitudinal axis within the electrode assembly,

[0258] The restraint includes first and second compression members connected by at least one tensioning member that pulls the compression members toward each other, and

[0259] The restraint maintains a pressure on the electrode assembly in the stacking direction that exceeds a pressure maintained on the electrode assembly in each of two directions that are perpendicular to each other and to the stacking direction.

[0260] Example 61:

[0261] An energy storage device according to embodiment 60, wherein the energy storage device is a secondary battery.

[0262] Embodiment 62:

[0263] An energy storage device according to Example 60, wherein the restraint includes first and second compression members overlying longitudinal end surfaces of the electrode assembly.

[0264] Embodiment 63:

[0265] The energy storage device of any of the preceding embodiments, wherein the constraint comprises at least one compression member internal to the longitudinal end surface.

[0266] Embodiment 64:

[0267] An energy storage device according to any of the aforementioned embodiments, wherein the projections of the components of the electrode group and the counter electrode group on the first longitudinal surface surround a first projection area, and the projections of the components of the electrode group and the counter electrode group on the second longitudinal surface surround a second projection area, and wherein the first and second projection areas each include at least 50% of the surface area of ​​the first and second longitudinal end surfaces, respectively.

[0268] Embodiment 65:

[0269] An energy storage device according to any of the foregoing embodiments, wherein projections of the electrode group and components of the electrode group on the first longitudinal surface surround a first projection area, and projections of the electrode group and components of the electrode group on the second longitudinal surface surround a second projection area, and wherein the constraint applies an average compressive force of at least 0.7 kPa to each of the first and second projection areas, averaged over surface areas of the first and second projection areas, respectively.

[0270] Embodiment 66:

[0271] The energy storage device of any of the preceding embodiments, wherein the constraint applies an average compressive force of at least 1.75 kPa to each of the first and second projected areas, averaged over the surface areas of the first and second projected areas, respectively.

[0272] Embodiment 67:

[0273] The energy storage device of any of the preceding embodiments, wherein the constraint applies an average compressive force of at least 2.8 kPa to each of the first and second projected areas, averaged over the surface areas of the first and second projected areas, respectively.

[0274] Embodiment 68:

[0275] The energy storage device of any of the preceding embodiments, wherein the constraint applies an average compressive force of at least 3.5 kPa to each of the first and second projected areas, averaged over the surface areas of the first and second projected areas, respectively.

[0276] Embodiment 69:

[0277] The energy storage device of any of the preceding embodiments, wherein the constraint applies an average compressive force of at least 5.25 kPa to each of the first and second projected areas, averaged over the surface areas of the first and second projected areas, respectively.

[0278] Embodiment 70:

[0279] The energy storage device of any of the preceding embodiments, wherein the constraint applies an average compressive force of at least 7 kPa to each of the first and second projected areas, averaged over the surface areas of the first and second projected areas, respectively.

[0280] Embodiment 71:

[0281] The energy storage device of any of the preceding embodiments, wherein the constraint applies an average compressive force of at least 8.75 kPa to each of the first and second projected areas, averaged over the surface areas of the first and second projected areas, respectively.

[0282] Embodiment 72:

[0283] An energy storage device according to any of the preceding embodiments, wherein the constraint applies an average compressive force of at least 10 kPa to each of the first and second projected areas, averaged over the surface areas of the first and second projected areas, respectively.

[0284] Embodiment 73:

[0285] The energy storage device of any of the preceding embodiments, wherein a combined surface area of ​​the first and second longitudinal end surfaces is less than 25% of a surface area of ​​the electrode assembly.

[0286] Embodiment 74:

[0287] The energy storage device of any of the preceding embodiments, wherein a combined surface area of ​​the first and second longitudinal end surfaces is less than 20% of a surface area of ​​the electrode assembly.

[0288] Embodiment 75:

[0289] The energy storage device of any of the preceding embodiments, wherein a combined surface area of ​​the first and second longitudinal end surfaces is less than 15% of a surface area of ​​the electrode assembly.

[0290] Embodiment 76:

[0291] The energy storage device of any of the preceding embodiments, wherein a combined surface area of ​​the first and second longitudinal end surfaces is less than 10% of a surface area of ​​the electrode assembly.

[0292] Embodiment 77:

[0293] The energy storage device of any of the preceding embodiments, wherein the constraint and the enclosure have a combined volume that is less than 60% of the volume enclosed by the enclosure.

[0294] Embodiment 78:

[0295] The energy storage device of any preceding embodiment, wherein the constraint and the enclosure have a combined volume that is less than 45% of the volume enclosed by the enclosure.

[0296] Embodiment 79:

[0297] The energy storage device of any preceding embodiment, wherein the constraint and the enclosure have a combined volume that is less than 30% of the volume enclosed by the enclosure.

[0298] Embodiment 80:

[0299] The energy storage device of any of the preceding embodiments, wherein the constraint and the enclosure have a combined volume that is less than 20% of the volume enclosed by the enclosure.

[0300] Embodiment 81:

[0301] The energy storage device according to any of the preceding embodiments, wherein each member of the electrode group has a bottom, a top, a length L E , Width W E , height H E and a central longitudinal axis A extending from the bottom to the top of each such member and in a direction generally transverse to the stacking direction. E , the length L of each member of the electrode group E At its central longitudinal axis A E The width W of each member of the electrode assembly is measured in the direction of E The height H of each member of the electrode assembly is measured in the stacking direction. E At right angles to the central longitudinal axis A of each such member E and measured in the direction perpendicular to the stacking direction, L E The W of each member of the electrode group E and H E The ratio of each of the H of each member of the electrode group is at least 5:1. E With W E The ratios are between 0.4:1 and 1000:1 respectively.

[0302] Embodiment 82:

[0303] The energy storage device according to any of the preceding embodiments, wherein the microporous membrane material comprises a particulate material and a binder, has a porosity of at least 20 vol%, and is permeated by a non-aqueous liquid electrolyte.

[0304] Embodiment 83:

[0305] The energy storage device according to any of the preceding embodiments, wherein the tension member is sufficiently close to the side surface to inhibit buckling of the electrode assembly when the energy storage device is cycled between a charged state and a discharged state.

[0306] Embodiment 84:

[0307] The energy storage device of any of the preceding embodiments, wherein a distance between the tension member and the side surface is less than 50% of a minimum Feret diameter of the electrode assembly.

[0308] Embodiment 85:

[0309] The energy storage device of any of the preceding embodiments, wherein a distance between the tension member and the side surface is less than 40% of a minimum Feret diameter of the electrode assembly.

[0310] Embodiment 86:

[0311] The energy storage device of any of the preceding embodiments, wherein a distance between the tension member and the side surface is less than 30% of a minimum Feret diameter of the electrode assembly.

[0312] Embodiment 87:

[0313] The energy storage device of any of the preceding embodiments, wherein a distance between the tension member and the side surface is less than 20% of a minimum Feret diameter of the electrode assembly.

[0314] Embodiment 88:

[0315] The energy storage device of any of the preceding embodiments, wherein a distance between the tension member and the side surface is less than 10% of a minimum Feret diameter of the electrode assembly.

[0316] Embodiment 89:

[0317] The energy storage device of any of the preceding embodiments, wherein a distance between the tension member and the side surface is less than 5% of a minimum Feret diameter of the electrode assembly.

[0318] Embodiment 90:

[0319] The energy storage device of any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces is subject to a compressive load of at least 100 psi.

[0320] Embodiment 91:

[0321] The energy storage device of any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces is subject to a compressive load of at least 200 psi.

[0322] Embodiment 92:

[0323] The energy storage device of any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces is subject to a compressive load of at least 300 psi.

[0324] Embodiment 93:

[0325] The energy storage device of any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces is subject to a compressive load of at least 400 psi.

[0326] Embodiment 94:

[0327] The energy storage device of any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces is subject to a compressive load of at least 500 psi.

[0328] Embodiment 95:

[0329] The energy storage device of any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces is subject to a compressive load of at least 600 psi.

[0330] Embodiment 96:

[0331] The energy storage device of any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces is subject to a compressive load of at least 700 psi.

[0332] Embodiment 97:

[0333] The energy storage device of any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces is subject to a compressive load of at least 800 psi.

[0334] Embodiment 98:

[0335] The energy storage device of any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces is subject to a compressive load of at least 900 psi.

[0336] Embodiment 99:

[0337] The energy storage device of any of the preceding embodiments, wherein each of the first and second longitudinal end surfaces is subjected to a compressive load of at least 1000 psi.

[0338] Embodiment 100:

[0339] The energy storage device of any of the preceding embodiments, wherein the energy storage device has a rated capacity, and wherein the first and second longitudinal end surfaces are subject to such a compressive load when the energy storage device is charged to at least 80% of its rated capacity.

[0340] Embodiment 101:

[0341] The energy storage device according to any of the preceding embodiments, wherein the electrode structure comprises an anode-active electroactive material and the counter electrode structure comprises a cathode-active electroactive material.

[0342] Embodiment 102:

[0343] The energy storage device of any of the preceding embodiments, wherein the electrode structure comprises an anode-active electroactive material comprising silicon, and the counter electrode structure comprises a cathode-active electroactive material.

[0344] Embodiment 103:

[0345] The energy storage device according to any of the preceding embodiments, wherein the energy storage device comprises a set of electrode assemblies, the set comprising at least two electrode assemblies.

[0346] Embodiment 104:

[0347] The energy storage device of any of Embodiments 60-103, wherein the energy storage device comprises a set of at least two electrode assemblies, and the restraint maintains pressure on the electrode assemblies within the set as the energy storage device cycles between a charge state and a discharge state.

[0348] Embodiment 105:

[0349] An energy storage device according to any of embodiments 1-60-103, wherein the energy storage device includes a set of at least two electrode assemblies, and the energy storage device includes a corresponding number of constraints, wherein, and as the energy storage device cycles between a charge state and a discharge state, each of the constraints maintains pressure on one of the electrode assemblies in the set.

[0350] Embodiment 106:

[0351] The energy storage device according to any of the preceding embodiments, wherein the electrode assembly comprises at least 5 electrode structures and at least 5 counter electrode structures.

[0352] Embodiment 107:

[0353] The energy storage device according to any of the preceding embodiments, wherein the electrode assembly comprises at least 10 electrode structures and at least 10 counter electrode structures.

[0354] Embodiment 108:

[0355] The energy storage device according to any of the preceding embodiments, wherein the electrode assembly comprises at least 50 electrode structures and at least 50 counter electrode structures.

[0356] Embodiment 109:

[0357] The energy storage device according to any of the preceding embodiments, wherein the electrode assembly comprises at least 100 electrode structures and at least 100 counter electrode structures.

[0358] Embodiment 110:

[0359] The energy storage device according to any of the preceding embodiments, wherein the electrode assembly comprises at least 500 electrode structures and at least 500 counter electrode structures.

[0360] Embodiment 111:

[0361] The energy storage device of any preceding embodiment, wherein the constraint comprises a material having an ultimate tensile strength of at least 10,000 psi (>70 MPa).

[0362] Embodiment 112:

[0363] The energy storage device of any preceding embodiment, wherein the constraint comprises a material that is compatible with the electrolyte.

[0364] Embodiment 113:

[0365] The energy storage device of any preceding embodiment, wherein the constraint comprises a material that does not significantly corrode at a floating or anodic potential of the energy storage device.

[0366] Embodiment 114:

[0367] An energy storage device according to any of the preceding embodiments, wherein the constraint comprises a material that does not significantly react or lose mechanical strength at 45°C.

[0368] Embodiment 115:

[0369] The energy storage device according to any of the preceding embodiments, wherein the confinement comprises a metal, a metal alloy, a ceramic, a glass, a plastic, or a combination thereof.

[0370] Embodiment 116:

[0371] The energy storage device of any of the preceding embodiments, wherein the constraint comprises a sheet of material having a thickness in a range of about 10 microns to about 100 microns.

[0372] Embodiment 117:

[0373] The energy storage device of any of the preceding embodiments, wherein the constraint comprises a sheet of material having a thickness in a range of about 30 microns to about 75 microns.

[0374] Embodiment 118:

[0375] The energy storage device of any preceding embodiment, wherein the constraint comprises carbon fibers at >50% packing density.

[0376] Embodiment 119:

[0377] An energy storage device according to any of the foregoing embodiments, wherein the compression member applies a pressure on the first and second longitudinal end surfaces that exceeds at least 3 times the pressure maintained on the electrode assembly in each of two directions perpendicular to each other and perpendicular to the stacking direction.

[0378] Embodiment 120:

[0379] An energy storage device according to any of the foregoing embodiments, wherein the compression member applies a pressure on the first and second longitudinal end surfaces that exceeds at least 3 times the pressure maintained on the electrode assembly in each of two directions perpendicular to each other and perpendicular to the stacking direction.

[0380] Embodiment 121:

[0381] An energy storage device according to any of the preceding embodiments, wherein the compression member applies a pressure on the first and second longitudinal end surfaces that exceeds at least 4 times the pressure maintained on the electrode assembly in each of two directions perpendicular to each other and perpendicular to the stacking direction.

[0382] Embodiment 122:

[0383] According to the energy storage device of any of the preceding embodiments, the compression member applies a pressure on the first and second longitudinal end surfaces that exceeds at least 5 times the pressure maintained on the electrode assembly in each of two directions perpendicular to each other and perpendicular to the stacking direction.

[0384] As various changes could be made in the above articles, combinations and methods without departing from the scope of the present disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

[0385] All directional descriptors such as top, bottom, left, right, etc. are used only for easy reference with respect to the drawings and are not meant to be limiting.

Claims

1. A structure for an energy storage device, the structure comprising a housing, a non-aqueous electrolyte within the housing, an electrode assembly within the housing, and a constraint within the housing, The electrode assembly includes a group of electrode structures, a group of counter electrode structures and A group of electrically insulating microporous membrane material structures, a member of the group of electrically insulating microporous membrane material structures is between a member of the group of electrode structures and a member of the group of counter electrode structures, wherein The electrode assembly has opposing first and second longitudinal end surfaces separated along a longitudinal axis and a side surface surrounding the longitudinal axis and connecting the first and second longitudinal end surfaces, the first surface area being less than 33% of the second surface area, wherein The first surface area is the surface area of ​​the first longitudinal end surface and the second longitudinal end surface, and the second surface area is the surface area of ​​the electrode assembly. The members of the group of electrode structures and the members of the group of counter electrode structures are arranged in an alternating order to form an arrangement, wherein the arrangement is in a stacking direction of the electrode assembly along the longitudinal axis, wherein each member of the group of electrode structures has a bottom, a top, a length L E , Width W E , height H E and a central longitudinal axis A extending from the bottom to the top of each member of the set of electrode structures and in a direction transverse to the stacking direction E , the length L of each member of the electrode structure group E At its central longitudinal axis A E The width W of each member of the electrode structure group is measured in the direction of E The height H of each member of the set of electrode structures is measured in the stacking direction. E At a point perpendicular to the central longitudinal axis A of each member of the electrode structure group E and measured in a direction perpendicular to the stacking direction, L E The W of each member of the group with the electrode structure E and H E The ratio of each of them is at least 5:1, and the H of each member of the group of electrode structures is E With W E The ratios are between 0.4:1 and 1000:

1. The members of the group of electrode structures and the members of the group of counter electrode structures are projected on the first longitudinal end surface as a first projection, the first projection enclosing a first projection area, and the members of the group of electrode structures and the members of the group of counter electrode structures are projected on the second longitudinal end surface as a second projection, the second projection enclosing a second projection area, The constraint includes a first compression member and a second compression member overlying the first projected area and the second projected area, respectively, at least one compression member is inside the first longitudinal end surface and the second longitudinal end surface, the at least one compression member includes the first compression member and the second compression member, the at least one compression member is connected by a tension member overlying a side surface of the electrode assembly, and the tension member is configured to pull the first compression member and the second compression member toward each other, and During use of the structure, the constraint is configured to maintain a first pressure on the electrode assembly in the stacking direction that exceeds a second pressure maintained on the electrode assembly in each of two directions perpendicular to each other and to the stacking direction.

2. The structure of claim 1 , wherein the first surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 25% of the surface area of ​​the electrode assembly, less than 20% of the surface area of ​​the electrode assembly, less than 15% of the surface area of ​​the electrode assembly, or less than 10% of the surface area of ​​the electrode assembly.

3. A structure according to any one of the preceding claims 1 or 2, wherein each of the first longitudinal end surface and the second longitudinal end surface withstands a compressive load of at least 689 kPa (100 psi), a compressive load of at least 1379 kPa (200 psi), a compressive load of at least 2068 kPa (300 psi), a compressive load of at least 2758 kPa (400 psi), a compressive load of at least 3447 kPa (500 psi), a compressive load of at least 4137 kPa (600 psi), a compressive load of at least 4826 kPa (700 psi), a compressive load of at least 5516 kPa (800 psi), a compressive load of at least 6205 kPa (900 psi), or a compressive load of at least 6895 kPa (1000 psi).

4. A structure according to any one of the preceding claims 1 or 2, wherein (i) the electrode assembly includes at least 5 members of the electrode structure group and at least 5 members of the counter electrode structure group, (ii) the electrode assembly includes at least 10 members of the electrode structure group and at least 10 members of the counter electrode structure group, (iii) the electrode assembly includes at least 50 members of the electrode structure group and at least 50 members of the counter electrode structure group, (iv) the electrode assembly includes at least 100 members of the electrode structure group and at least 100 members of the counter electrode structure group, or (v) the electrode assembly includes at least 500 members of the electrode structure group and at least 500 members of the counter electrode structure group.

5. The structure of any of the preceding claims 1 or 2, wherein the constraint comprises a material having an ultimate tensile strength of >70 MPa.

6. The structure of any of the preceding claims 1 or 2, wherein the restraint comprises a material having an ultimate tensile strength of at least 10,000 psi.

7. The structure of any of the preceding claims 1 or 2, wherein the constraint comprises elemental metal, metal alloy, ceramic, glass, plastic, or combinations thereof and / or wherein the constraint comprises carbon fibers at >50% packing density.

8. The structure of any of the preceding claims 1 or 2, wherein the constraint comprises a sheet of material having a thickness in the range of 10 microns to 100 microns or a sheet of material having a thickness in the range of 10 microns to 100 microns.

9. A structure according to any one of the preceding claims 1 or 2, wherein the first compression member and the second compression member apply a third pressure on the first longitudinal end surface and the second longitudinal end surface, the third pressure exceeds the second pressure by at least 3 times, at least 4 times or at least 5 times, and the second pressure is the pressure maintained on the electrode assembly in each of two directions perpendicular to each other and perpendicular to the stacking direction.

10. The structure of any preceding claim 1 or 2, wherein the set of electrode structures comprises an anode electroactive material comprising silicon and the set of counter electrode structures comprises a cathode electroactive material.

11. A structure according to any one of the preceding claims 1 or 2, wherein members of the set of electrically insulating microporous membrane material structures are permeated with a non-aqueous electrolyte.

12. The structure according to claim 11, wherein: The components of the group of electrically insulating microporous membrane material structures include a granular material and a binder, have a porosity of at least 20% by volume, and are permeated by a non-aqueous liquid electrolyte.

13. A secondary battery comprising the structure according to any one of the preceding claims 1 to 12.

14. The secondary battery of claim 13, further comprising a battery housing and a non-aqueous liquid electrolyte within the battery housing, the constraint being configured to maintain the first pressure on the electrode assembly as the secondary battery cycles between a charged state and a discharged state.

15. The secondary battery according to claim 14, wherein The constraint and the housing have a combined volume of less than 60% of the volume enclosed by the housing, less than 45% of the volume enclosed by the housing, less than 30% of the volume enclosed by the housing, or less than 20% of the volume enclosed by the housing, where the percentages are volume percentages. 16 . The secondary battery according to claim 14 , wherein the secondary battery has a rated capacity, and when the secondary battery is charged to at least 80% of its rated capacity, the first longitudinal end surface and the second longitudinal end surface are subjected to a compressive load.

17. A sealed secondary battery for cycling between a charging state and a discharging state, the sealed secondary battery comprising: a housing sealing the contents of the secondary battery, an electrode assembly within the housing and a nonaqueous liquid electrolyte within the housing, and a constraint within the housing that maintains pressure on the electrode assembly as the secondary battery cycles between the charged state and the discharged state, the electrode assembly comprising a group of electrode structures, a group of counter-electrode structures, and a group of electrically insulating microporous diaphragm material structures, members of the group of electrically insulating microporous diaphragm material structures being between members of the group of electrode structures and members of the group of counter-electrode structures, wherein The electrode assembly has a first longitudinal end surface and a second longitudinal end surface that are opposite and separated along a longitudinal axis, and a side surface that surrounds the longitudinal axis and connects the first longitudinal end surface and the second longitudinal end surface, the combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is a first surface area, the first surface area is less than 33% of the second surface area, and the second surface area is a combined surface area of ​​the side surface, the first longitudinal end surface, and the second longitudinal end surface, The members of the group of electrode structures and the members of the group of counter-electrode structures are arranged in an alternating sequence to form an arrangement, the arrangement being arranged in a stacking direction of the electrode assembly parallel to the longitudinal axis, The constraint includes a first compression member and a second compression member respectively covering the first longitudinal end surface and the second longitudinal end surface, the first compression member and the second compression member are connected by at least one tensioning member, the at least one tensioning member covering the side surface, the compression members include the first compression member and the second compression member, the tensioning member is configured to pull the compression members toward each other, during use of the secondary battery, the constraint is configured to maintain a first pressure on the electrode assembly in a stacking direction, the pressure exceeding a second pressure maintained on the electrode assembly in each of two directions perpendicular to each other and perpendicular to the stacking direction, Wherein the secondary battery has a rated capacity, and when the secondary battery is charged to at least 80% of its rated capacity, the constraint subjects the first and second longitudinal end surfaces to a compressive load of at least 100 psi.

18. The secondary battery according to claim 17, wherein Each component of each electrode structure group includes an anode active material, and the anode active material includes any one of a metal, an alloy, an oxide, and a composite capable of forming an alloy with lithium.

19. The secondary battery according to claim 17, wherein Each component of each electrode group includes a layer of electrode active material including graphite.

20. The secondary battery according to claim 17, wherein Each component of each electrode group includes a layer of electrode active material including silicon.

21. The secondary battery according to claim 17, wherein The constraint includes at least one compression member within a longitudinal end surface including the first longitudinal end surface and the second longitudinal end surface.

22. The secondary battery according to claim 17, wherein The combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 25% of the surface area of ​​the electrode assembly.

23. The secondary battery according to claim 17, wherein The combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 15% of the surface area of ​​the electrode assembly.

24. The secondary battery according to claim 17, wherein The constraint and the enclosure have a combined volume that is less than 30% of a volume enclosed by the enclosure.

25. The secondary battery according to claim 17, wherein Each member of the electrode structure group has a bottom, a top, a length L E , Width W E , height H E and a central longitudinal axis A extending from the bottom to the top of each such member in a direction transverse to the stacking direction E , the length L of each member of the electrode structure group E At its central longitudinal axis A E The width W of each member of the electrode structure group is measured in the direction of E The height H of each member of the set of electrode structures is measured in the stacking direction. E At a point perpendicular to the central longitudinal axis A of each such member E and measured in a direction perpendicular to the stacking direction, L E The W of each member of the group with the electrode structure E and H E The ratio of each of them is at least 5:1, and the H of each member of the group of electrode structures is E With W E The ratios are between 0.4:1 and 1000:1 respectively.

26. The secondary battery according to claim 17, wherein The member of the group of electrically insulating microporous membrane materials comprises a particulate material and a binder, has a porosity of at least 20%, and is penetrated by the non-aqueous liquid electrolyte, the percentage being by volume.

27. The secondary battery according to claim 17, wherein The distance between the at least one tension member and the side surface is less than 50% of a minimum Feret's diameter of the electrode assembly, wherein the minimum Feret's diameter is measured in the same direction as the distance between the at least one tension member and the side surface of the electrode assembly.

28. The secondary battery according to claim 17, wherein The distance between the at least one tension member and the side surface is less than 30% of a minimum Feret's diameter of the electrode assembly, wherein the minimum Feret's diameter is measured in the same direction as the distance between the at least one tension member and the side surface of the electrode assembly.

29. The secondary battery according to claim 17, wherein The distance between the at least one tension member and the side surface is less than 10% of a minimum Feret's diameter of the electrode assembly, wherein the minimum Feret's diameter is measured in the same direction as the distance between the at least one tension member and the side surface of the electrode assembly.

30. The secondary battery according to claim 17, wherein The secondary battery has a rated capacity, and the first and second longitudinal end surfaces are subjected to a compressive load of at least 300 psi when the secondary battery is charged to at least 80% of its rated capacity.

31. The secondary battery according to claim 17, wherein The secondary battery has a rated capacity, and the first and second longitudinal end surfaces are subjected to a compressive load of at least 500 psi when the secondary battery is charged to at least 80% of its rated capacity.

32. The secondary battery according to claim 17, wherein The secondary battery has a rated capacity, and the first and second longitudinal end surfaces are subjected to a compressive load of at least 700 psi when the secondary battery is charged to at least 80% of its rated capacity.

33. The secondary battery according to claim 17, wherein: The first longitudinal end surface and the second longitudinal end surface are subjected to a compressive load of at least 900 psi when the secondary battery is charged to at least 80% of its rated capacity.

34. The secondary battery according to claim 17, wherein The set of electrodes includes an anode electroactive material and the set of counter electrodes includes a cathode electroactive material.

35. The secondary battery according to claim 17, wherein The set of electrode structures includes an anode electroactive material comprising silicon, and the set of counter electrode structures includes a cathode electroactive material.

36. The secondary battery according to claim 17, wherein The secondary battery includes a set of at least two electrode assemblies, and the constraint maintains pressure on the at least two electrode assemblies within the set as the secondary battery cycles between the charge state and the discharge state.

37. The secondary battery according to claim 17, wherein: The electrode assembly includes at least five members of the group of electrode structures and at least five members of the group of counter electrode structures.

38. The secondary battery according to claim 17, wherein The electrode assembly includes at least 50 members of the group of electrode structures and at least 50 members of the group of counter electrode structures.

39. The secondary battery according to claim 17, wherein: The electrode assembly includes at least 500 members of the group of electrode structures and at least 500 members of the group of counter electrode structures.

40. The secondary battery according to claim 17, wherein The restraint comprises a material having an ultimate tensile strength of at least 10,000 psi.

41. The secondary battery according to claim 17, wherein The constraint includes a material that is compatible with the non-aqueous liquid electrolyte.

42. The secondary battery according to claim 17, wherein The constraints include materials that do not significantly corrode at the floating or anode potential of the secondary battery.

43. The secondary battery according to claim 17, wherein The constraints include materials that do not significantly react or lose mechanical strength at a temperature of 45°C.

44. The secondary battery according to claim 17, wherein The constraint comprises a sheet of material having a thickness in the range of 10 microns to 100 microns.

45. The secondary battery according to claim 17, wherein The constraint comprises a sheet of material having a thickness in the range of 30 microns to 75 microns.

46. ​​The secondary battery according to claim 17, wherein The constraint includes carbon fibers with >50% packing density, where the percentage is by volume.

47. The secondary battery according to claim 17, wherein The at least one tension member includes a plurality of tension members, and the plurality of tension members are in contact with the side surface.

48. The secondary battery according to claim 17, wherein The constraint and the enclosure have a combined volume that is less than 60% of a volume enclosed by the enclosure.

49. A sealed secondary battery for cycling between a charge state and a discharge state, the sealed secondary battery comprising a housing that seals the contents of the secondary battery, an electrode assembly within the housing and a non-aqueous liquid electrolyte within the housing, and a constraint within the housing that maintains pressure on the electrode assembly as the sealed secondary battery cycles between the charge state and the discharge state, the electrode assembly comprising a group of electrode structures, a group of counter-electrode structures, and a group of electrically insulating microporous diaphragm material structures, members of the group of electrically insulating microporous diaphragm material structures being between members of the group of electrode structures and members of the group of counter-electrode structures, wherein The electrode assembly has a first longitudinal end surface and a second longitudinal end surface that are opposite and separated along a longitudinal axis, and a side surface that surrounds the longitudinal axis and connects the first longitudinal end surface and the second longitudinal end surface, a first combined surface area is less than 33% of a second combined surface area, the first combined surface area is a combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface, and the second combined surface area is a combined surface area of ​​the first longitudinal end surface, the second longitudinal end surface, and the side surface, The members of the group of electrode structures and the members of the group of counter-electrode structures are arranged in an alternating sequence to form an arrangement, the arrangement being arranged in a stacking direction of the electrode assembly along the longitudinal axis, The constraint includes a first compression member and a second compression member connected by at least one tensioning member that pulls the compression members toward each other, and The first and second compression members are respectively overlaid on the first and second longitudinal end surfaces, the first and second compression members are connected by at least one tensioning member overlaid on the side surface, the at least one tensioning member is configured to pull the first and second compression members toward each other, the constraint is configured to maintain a first pressure on the electrode assembly in the stacking direction, the pressure exceeding a second pressure maintained on the electrode assembly in each of two directions perpendicular to each other and perpendicular to the stacking direction, in, The constraint includes elemental metal, metal alloy, ceramic, glass, plastic or a combination thereof, the secondary battery has a rated capacity, and when the secondary battery is charged to at least 80% of its rated capacity, the constraint places the first longitudinal end surface and the second longitudinal end surface under a compressive load of at least 100 psi.

50. The secondary battery of claim 49, wherein the constraint comprises at least one of: stainless steel, aluminum, titanium, beryllium, beryllium copper, copper, nickel, or a combination thereof.

51. The secondary battery of claim 49, wherein the confinement comprises at least one of: aluminum oxide, zirconium oxide, yttria-stabilized zirconium oxide, glass, or a combination thereof.

52. The secondary battery of claim 49, wherein the constraint comprises at least one of: polyetheretherketone (PEEK), polyetheretherketone (PEEK) with carbon, polyphenylene sulfide (PPS) with carbon, polyetheretherketone (PEEK) with 30% glass, polyimide, or a combination thereof.

53. The secondary battery of claim 49, wherein the constraint comprises at least one of: Kevlar 49 aramid fiber, S-glass fiber, carbon fiber, or a combination thereof.

54. The secondary battery of claim 49, wherein the constraint comprises a composite material of at least one of the following and epoxy resin: E glass standard fiber, 0 degree, E glass UD, 0 degree, Kevlar standard fiber, 0 degree, Kevlar UD, 0 degree, carbon standard fiber, 0 degree, carbon UD, 0 degree, or Toyobo HM fiber. 55 . The secondary battery of claim 49 , wherein a combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 25% of a surface area of ​​the electrode assembly. 56 . The secondary battery of claim 49 , wherein a combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 15% of a surface area of ​​the electrode assembly.

57. A sealed secondary battery for cycling between a charge state and a discharge state, the sealed secondary battery comprising a housing that seals the contents of the secondary battery, an electrode assembly within the housing, a non-aqueous liquid electrolyte within the housing, and a constraint within the housing, the constraint maintaining pressure on the electrode assembly as the secondary battery cycles between the charge state and the discharge state, the electrode assembly comprising a group of electrode structures, a group of counter-electrode structures, and a group of electrically insulating microporous diaphragm material structures, the group of electrically insulating microporous diaphragm material structures being between components of the group of electrode structures and components of the group of counter-electrode structures, wherein The electrode assembly has a first longitudinal end surface and a second longitudinal end surface that are opposite to each other and separated along a longitudinal axis, and a side surface that surrounds the longitudinal axis and connects the first longitudinal end surface and the second longitudinal end surface, the combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is a first combined surface area, the first combined surface area is less than 33% of the second combined area, and the second combined surface area is a combined surface area of ​​the side surface, the first longitudinal end surface, and the second longitudinal end surface of the electrode assembly, The members of the group of electrode structures and the members of the group of counter-electrode structures are arranged in an alternating sequence to form an arrangement, the arrangement being in a stacking direction of the electrode assembly along the longitudinal axis, and The constraint includes a first compression member and a second compression member respectively covering the first longitudinal end surface and the second longitudinal end surface, the first compression member and the second compression member are connected by at least one tensioning member covering the side surface, and the at least one tensioning member pulls the compression members toward each other, the constraint maintains a first pressure on the electrode assembly in the stacking direction, the first pressure exceeds a second pressure maintained on the electrode assembly in each of two directions perpendicular to each other and perpendicular to the stacking direction, and wherein the constraint includes a material having an ultimate tensile strength of at least 10,000 psi.

58. The secondary battery according to claim 57, wherein The components of each electrode structure group include an anode active material including any one of an elemental metal, an alloy, an oxide, and a composite capable of forming an alloy with lithium.

59. The secondary battery according to claim 57, wherein The components of each electrode structure group include a layer of electrode active material including graphite.

60. The secondary battery according to claim 57, wherein The components of each electrode structure group include a layer of electrode active material including silicon.

61. The secondary battery according to claim 57, wherein The constraint includes at least one compression member internal to the first longitudinal end surface and the second longitudinal end surface.

62. The secondary battery according to claim 57, wherein The combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 33% of the surface area of ​​the electrode assembly.

63. The secondary battery according to claim 57, wherein: The combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 25% of the surface area of ​​the electrode assembly.

64. The secondary battery according to claim 57, wherein The combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 15% of the surface area of ​​the electrode assembly.

65. The secondary battery according to claim 57, wherein The constraint and the enclosure have a combined volume that is less than 30% of a volume enclosed by the enclosure.

66. The secondary battery according to claim 57, wherein Each member of the electrode structure group has a bottom, a top, a length L E , Width W E , height H E and a central longitudinal axis A extending from the bottom to the top of each such member in a direction transverse to the stacking direction E , the length L of each member of the electrode structure group E At its central longitudinal axis A E The width W of each member of the electrode structure group is measured in the direction of E The height H of each member of the set of electrode structures is measured in the stacking direction. E At a point perpendicular to the central longitudinal axis A of each member of the electrode structure E and measured in a direction perpendicular to the stacking direction, L E The W of each member of the group with the electrode structure E and H E The ratio of each of them is at least 5:1, and the H of each member of the group of electrode structures is E With W E The ratios are between 0.4:1 and 1000:1 respectively.

67. The secondary battery according to claim 57, wherein: The member of the group of electrically insulating microporous membrane materials comprises a particulate material and a binder, has a porosity of at least 20%, and is penetrated by the non-aqueous liquid electrolyte, the percentage being by volume.

68. The secondary battery according to claim 57, wherein The distance between the at least one tensioning member and the side surface is less than 50% of a minimum Feret's diameter of the electrode assembly, wherein the minimum Feret's diameter is measured in the same direction as the distance between the at least one tensioning member and the side surface of the electrode assembly.

69. The secondary battery according to claim 57, wherein The distance between the at least one tension member and the side surface is less than 30% of a minimum Feret's diameter of the electrode assembly, wherein the minimum Feret's diameter is measured in the same direction as the distance between the at least one tension member and the side surface of the electrode assembly.

70. The secondary battery according to claim 57, wherein The distance between the at least one tension member and the side surface is less than 10% of a minimum Feret's diameter of the electrode assembly, wherein the minimum Feret's diameter is measured in the same direction as the distance between the at least one tension member and the side surface of the electrode assembly.

71. The secondary battery according to claim 57, wherein The secondary battery has a rated capacity, and the first and second longitudinal end surfaces are subjected to a compressive load of at least 300 psi when the secondary battery is charged to at least 80% of its rated capacity.

72. The secondary battery according to claim 57, wherein The secondary battery has a rated capacity, and the first and second longitudinal end surfaces are subjected to a compressive load of at least 500 psi when the secondary battery is charged to at least 80% of its rated capacity.

73. The secondary battery according to claim 57, wherein The secondary battery has a rated capacity, and the first and second longitudinal end surfaces are subjected to a compressive load of at least 700 psi when the secondary battery is charged to at least 80% of its rated capacity.

74. The secondary battery according to claim 57, wherein The first longitudinal end surface and the second longitudinal end surface are subjected to a compressive load of at least 900 psi when the secondary battery is charged to at least 80% of its rated capacity.

75. The secondary battery according to claim 57, wherein The set of electrode structures includes an anode electroactive material and the set of counter electrode structures includes a cathode electroactive material.

76. The secondary battery according to claim 57, wherein The electrode structure includes an anode electroactive material comprising silicon, and the counter electrode structure includes a cathode electroactive material.

77. The secondary battery according to claim 57, wherein The secondary battery includes a set of at least two electrode assemblies, and the constraint is configured to maintain pressure on the electrode assemblies within the set as the secondary battery cycles between the charge state and the discharge state.

78. The secondary battery according to claim 57, wherein The electrode assembly includes at least five members of the group of electrode structures and at least five members of the group of counter electrode structures.

79. The secondary battery according to claim 57, wherein The electrode assembly includes at least 50 members of the group of electrode structures and at least 50 members of the group of counter electrode structures.

80. The secondary battery according to claim 57, wherein The electrode assembly includes at least 500 members of the group of electrode structures and at least 500 members of the group of counter electrode structures.

81. The secondary battery according to claim 57, wherein The constraint includes a material that is compatible with the non-aqueous liquid electrolyte.

82. The secondary battery according to claim 57, wherein The constraints include materials that do not significantly corrode at the floating or anode potential of the secondary battery.

83. The secondary battery according to claim 57, wherein The constraints include materials that do not significantly react or lose mechanical strength at 45°C.

84. The secondary battery according to claim 57, wherein The confinement includes an elemental metal, a metal alloy, a ceramic, a glass, a plastic, or a combination thereof.

85. The secondary battery according to claim 57, wherein The constraint comprises a sheet of material having a thickness in the range of 10 microns to 100 microns.

86. The secondary battery according to claim 57, wherein The constraint comprises a sheet of material having a thickness in the range of 30 microns to 75 microns.

87. The secondary battery according to claim 57, wherein The constraint includes greater than 50% or higher percentage of packed density of carbon fibers.

88. The secondary battery according to claim 57, wherein The at least one tension member includes a plurality of tension members, and the plurality of tension members are in contact with the side surface.

89. The secondary battery according to claim 57, wherein The constraint and the enclosure have a combined volume that is less than 60% of a volume enclosed by the enclosure.

90. The secondary battery of claim 57, wherein the constraint comprises at least one of: stainless steel, aluminum, titanium, beryllium, beryllium copper, copper, nickel, or a combination thereof.

91. The secondary battery of claim 57, wherein the confinement comprises at least one of: aluminum oxide, zirconium oxide, yttria-stabilized zirconium oxide, glass, or a combination thereof.

92. The secondary battery of claim 57, wherein the constraint comprises at least one of: polyetheretherketone (PEEK), polyetheretherketone (PEEK) with carbon, polyphenylene sulfide (PPS) with carbon, polyetheretherketone (PEEK) with 30% glass, polyimide, or a combination.

93. The secondary battery of claim 57, wherein the constraint comprises at least one of: Kevlar 49 aramid fiber, S-glass fiber, carbon fiber, and combinations thereof.

94. The secondary battery of claim 57, wherein the constraint comprises a composite material of at least one of the following with epoxy resin: E glass standard fiber, 0 degree, E glass UD, 0 degree, Kevlar standard fiber, 0 degree, Kevlar UD, 0 degree, Carbon standard fiber, 0 degree, Carbon UD, 0 degree, or Toyobo HM fiber.

95. The secondary battery of claim 57, wherein a combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 25% of a surface area of ​​the electrode assembly.

96. The secondary battery of claim 57, wherein a combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 15% of a surface area of ​​the electrode assembly.

97. A sealed secondary battery for cycling between a charge state and a discharge state, the sealed secondary battery comprising a housing that seals the contents of the secondary battery, an electrode assembly within the housing and a non-aqueous liquid electrolyte within the housing, and a constraint within the housing that maintains pressure on the electrode assembly as the secondary battery cycles between the charge state and the discharge state, the electrode assembly comprising a group of electrode structures, a group of counter-electrode structures, and a group of electrically insulating microporous diaphragm material structures, the group of electrically insulating microporous diaphragm material structures being between components of the group of electrode structures and components of the group of counter-electrode structures, wherein The electrode assembly has first and second opposing longitudinal end surfaces separated along a longitudinal axis and side surfaces surrounding the longitudinal axis and connecting the first and second longitudinal end surfaces, the combined surface area of ​​the first and second longitudinal end surfaces being less than 33% of the combined surface area of ​​the first, second and side surfaces, The members of the group of electrode structures and the members of the group of counter-electrode structures are arranged in an alternating sequence to form an arrangement, the arrangement being in a stacking direction parallel to the longitudinal axis, and The constraint includes a first compression member and a second compression member respectively covering the first and second longitudinal end surfaces and the second longitudinal end surface, the first compression member and the second compression member are connected by at least one tensioning member covering the side surface, the tensioning member is configured to pull the first compression member and the second compression member toward each other, the constraint is configured to maintain a first pressure on the electrode assembly in the stacking direction, the first pressure exceeds a second pressure maintained on the electrode assembly in each of two directions perpendicular to each other and perpendicular to the stacking direction, The constraint comprises elemental metal, metal alloy, ceramic, glass, plastic or any combination thereof.

98. The secondary battery according to claim 97, wherein: Each component of each electrode structure group includes an anode active material including any one selected from the group consisting of elemental metals, alloys, oxides, and composites capable of forming an alloy with lithium.

99. The secondary battery according to claim 97, wherein: The components of each electrode structure group include a layer of electrode active material including graphite.

100. The secondary battery according to claim 97, wherein: The components of each electrode structure group include a layer of electrode active material including silicon.

101. The secondary battery according to claim 97, wherein The constraint includes at least one compression member interior to the longitudinal end surface.

102. The secondary battery according to claim 97, wherein: The combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 33% of the surface area of ​​the electrode assembly.

103. The secondary battery according to claim 97, wherein: The combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 25% of a surface area of ​​the electrode assembly.

104. The secondary battery according to claim 97, wherein: The combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 15% of a surface area of ​​the electrode assembly.

105. The secondary battery according to claim 97, wherein The constraint and the enclosure have a combined volume that is less than 30% of a volume enclosed by the enclosure.

106. The secondary battery according to claim 97, wherein: Each member of the electrode structure group has a bottom, a top, a length L E , Width W E , height H E and a central longitudinal axis A extending from the bottom to the top of each such member in a direction transverse to the stacking direction E , the length L of each member of the electrode structure group E At its central longitudinal axis A E The width W of each member of the electrode structure group is measured in the direction of E The height H of each member of the set of electrode structures is measured in the stacking direction. E At a point perpendicular to the central longitudinal axis A of each such member E and measured in a direction perpendicular to the stacking direction, L E The W of each member of the group with the electrode structure E and H E The ratio of each of them is at least 5:1, and the H of each member of the group of electrode structures is E With W E The ratios are between 0.4:1 and 1000:1 respectively.

107. The secondary battery according to claim 97, wherein: The electrically insulating microporous separator material comprises a particulate material and a binder, has a porosity of at least 20%, and is infiltrated by the non-aqueous liquid electrolyte, the percentage being a volume percentage.

108. The secondary battery according to claim 97, wherein: The distance between the at least one tension member and the side surface is less than 50% of a minimum Feret's diameter of the electrode assembly, wherein the minimum Feret's diameter is measured in the same direction as the distance between the at least one tension member and the side surface of the electrode assembly.

109. The secondary battery according to claim 97, wherein: The distance between the at least one tension member and the side surface is less than 30% of a minimum Feret diameter of the electrode assembly, wherein the Feret diameter is measured in the same direction as the distance between the at least one tension member and the side surface of the electrode assembly.

110. The secondary battery according to claim 97, wherein The distance between the at least one tension member and the side surface is less than 10% of a minimum Feret's diameter of the electrode assembly, wherein the minimum Feret's diameter is measured in the same direction as the distance between the at least one tension member and the side surface of the electrode assembly.

111. The secondary battery according to claim 97, wherein: The secondary battery has a rated capacity, and the first and second longitudinal end surfaces are subjected to a compressive load of at least 300 psi when the secondary battery is charged to at least 80% of its rated capacity.

112. The secondary battery according to claim 97, wherein: The secondary battery has a rated capacity, and the first and second longitudinal end surfaces are subjected to a compressive load of at least 500 psi when the secondary battery is charged to at least 80% of its rated capacity.

113. The secondary battery according to claim 97, wherein: The secondary battery has a rated capacity, and the first and second longitudinal end surfaces are subjected to a compressive load of at least 700 psi when the secondary battery is charged to at least 80% of its rated capacity.

114. The secondary battery according to claim 97, wherein: The first longitudinal end surface and the second longitudinal end surface are subjected to a compressive load of at least 900 psi when the secondary battery is charged to at least 80% of its rated capacity.

115. The secondary battery according to claim 97, wherein: The set of electrode structures includes an anode electroactive material and the set of counter electrode structures includes a cathode electroactive material.

116. The secondary battery according to claim 97, wherein: The set of electrode structures includes an anode electroactive material comprising silicon, and the set of counter electrode structures includes a cathode electroactive material.

117. The secondary battery according to claim 97, wherein: The energy storage device includes a set of at least two electrode assemblies, and the constraint maintains pressure on the at least two electrode assemblies within the set as the secondary battery cycles between the charge state and the discharge state.

118. The secondary battery according to claim 97, wherein: The electrode assembly includes at least five members of the group of electrode structures and at least five members of the group of counter electrode structures.

119. The secondary battery according to claim 97, wherein: The electrode assembly includes at least 50 members of the group of electrode structures and at least 50 members of the group of counter electrode structures.

120. The secondary battery according to claim 97, wherein: The electrode assembly includes at least 500 members of the group of electrode structures and at least 500 members of the group of counter electrode structures.

121. The secondary battery according to claim 97, wherein: The constraint includes a material that is compatible with the non-aqueous liquid electrolyte.

122. The secondary battery according to claim 97, wherein The constraints include materials that do not significantly corrode under the floating or anodic potential of the energy storage device.

123. The secondary battery according to claim 97, wherein: The constraints include materials that do not significantly react or lose mechanical strength at 45°C.

124. The secondary battery according to claim 97, wherein: The confinement includes an elemental metal, a metal alloy, a ceramic, a glass, a plastic, or a combination thereof.

125. The secondary battery according to claim 97, wherein The constraint comprises a sheet of material having a thickness in the range of 10 microns to 100 microns.

126. The secondary battery according to claim 97, wherein: The constraint comprises a sheet of material having a thickness in the range of 30 microns to 75 microns.

127. The secondary battery according to claim 97, wherein: The constraints include carbon fibers having a packing density of >50%.

128. The secondary battery according to claim 97, wherein: The at least one tension member includes a plurality of tension members, and the plurality of tension members are in contact with the side surface.

129. The secondary battery according to claim 97, wherein: The constraint and the enclosure have a combined volume that is less than 60% of a volume enclosed by the enclosure.

130. The secondary battery of claim 97, wherein the constraint comprises at least one of: stainless steel, aluminum, titanium, beryllium, beryllium copper, copper, nickel, or a combination thereof.

131. The secondary battery of claim 97, wherein the confinement comprises at least one of: aluminum oxide, zirconium oxide, yttria-stabilized zirconium oxide, glass, or a combination thereof.

132. A secondary battery according to claim 97, wherein the constraint includes at least one of the following: polyetheretherketone (PEEK), polyetheretherketone (PEEK) with carbon, polyphenylene sulfide (PPS) with carbon, polyetheretherketone (PEEK) with 30% glass, polyimide, and a combination thereof.

133. The secondary battery of claim 97, wherein the constraint comprises at least one of: Kevlar 49 aramid fiber, S-glass fiber, carbon fiber, or a combination thereof.

134. The secondary battery of claim 97, wherein the constraint comprises a composite material of at least one of the following with epoxy resin: E glass standard fiber, 0 degree, E glass UD, 0 degree, Kevlar standard fiber, 0 degree, Kevlar UD, 0 degree, Carbon standard fiber, 0 degree, Carbon UD, 0 degree, or Toyobo HM fiber.

135. The secondary battery of claim 97, wherein a combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 25% of a surface area of ​​the electrode assembly.

136. The secondary battery of claim 97, wherein a combined surface area of ​​the first longitudinal end surface and the second longitudinal end surface is less than 15% of a surface area of ​​the electrode assembly.

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