Solid electrolyte having protrusions and all-solid-state battery including same

Abstract

A battery assembly has a plurality of first electrodes, a plurality of second electrodes, and a plurality of solid electrolyte layers. The solid electrolyte layers have protrusions in at least one of the solid electrolyte layers. The protrusion is aligned with the first electrode tab of one of the first electrodes. The folding of the first electrode tab causes the protrusion to be positioned to separate the first electrode tab from the second electrode, thereby preventing a short circuit between the first electrode tab and the second electrode. In one aspect, the present disclosure provides an all-solid-state battery including one or more anodes, one or more cathodes, and one or more solid electrolyte layers having protrusions. The invention also discloses a preparation method of the battery assembly.

Description

[0001] Cross-references

[0002] This application claims priority to US Serial No. 63 / 487,287, filed on February 28, 2023, the entire contents of which are incorporated by reference into this application. Technical Field

[0003] The present disclosure relates to a solid electrolyte layer having protrusions and an all-solid-state battery including the solid electrolyte layer. Background Art

[0004] To ensure good conductivity and low resistivity between the electrodes and electrolyte layers in all-solid-state batteries (ASSBs), high compression is usually applied during assembly. However, this compression increases the risk of internal short circuits, in which part of the anode layer, such as the edge, can contact part of the cathode layer. Notably, such short circuits can occur near the tabs when the anode and cathode current collectors in a multilayer battery are folded and welded together.

[0005] Conventional methods for assembling ASSBs rely on lower levels of pressure and / or uniaxial pressure to reduce the risk of short circuits. However, neither of these situations is ideal. Compared to higher levels of pressure, lower levels of pressure will result in relatively higher internal resistance, thereby reducing battery performance. Uniaxial pressure may lead to unsatisfactory performance. Therefore, there is still a need for technologies to address the short circuit problem. Summary of the invention

[0006] The present disclosure provides a battery assembly having a solid electrolyte having a specific configuration or shape that reduces the risk of short circuiting when high levels of pressure are applied during assembly of an electrochemical device such as an ASSB that includes the solid electrolyte.

[0007] In one aspect, the present disclosure provides a battery assembly comprising:

[0008] 1) a plurality of first electrodes, wherein each first electrode comprises a first electrode tab extending therefrom;

[0009] 2) a solid electrolyte layer comprising a first protrusion; and

[0010] 3) a second electrode,

[0011] wherein the solid electrolyte layer is positioned between a first electrode and a second electrode of the plurality of first electrodes, and

[0012] wherein a first electrode tab of one of the plurality of first electrodes contacts another first electrode of the plurality of first electrodes, and

[0013] The first protrusion of the solid electrolyte layer is positioned to separate a first electrode tab of one of the plurality of first electrodes from a second electrode to prevent a short circuit therebetween. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Non-limiting embodiments of the present disclosure are described by way of example with reference to the accompanying drawings, which are schematic and are not intended to be drawn to scale. In the accompanying drawings, each identical or nearly identical component shown is generally represented by a single numeral. For clarity, not every component is labeled in every drawing, nor is every component of every embodiment of the present disclosure shown, wherein illustration is not necessary for one of ordinary skill in the art to understand the present disclosure.

[0015] Figure 1A-Figure 1C Exemplary structures of an anode layer, a solid electrolyte layer, and a cathode layer according to an embodiment of the present disclosure are respectively shown.

[0016] Figure 2 An exemplary layout of a solid electrolyte layer according to an embodiment of the present disclosure is shown.

[0017] Figure 3A and Figure 3B Representative configurations of a battery assembly before and after folding a tab according to an embodiment of the present disclosure are respectively shown.

[0018] Figure 4A and Figure 4B Representative configurations of a battery assembly before and after folding a tab according to an embodiment of the present disclosure are respectively shown.

[0019] Figure 5 A representative configuration of a protrusion extending from a solid electrolyte layer according to an embodiment of the present disclosure is shown.

[0020] Figure 6A-6F Representative connections between protrusions and a solid electrolyte layer are shown according to some embodiments of the present disclosure.

[0021] Fig. 7A and Figure 7B Representative configurations of a battery assembly before and after folding a tab according to an embodiment of the present disclosure are respectively shown.

[0022] Fig. 8A and Figure 8B Representative configurations of a battery assembly before and after folding a tab according to an embodiment of the present disclosure are respectively shown.

[0023] Fig. 9 A representative configuration of a battery assembly according to an embodiment of the present disclosure is shown.

[0024] Fig. 10A and Fig. 10B A representative solid electrolyte layer according to one embodiment of the present disclosure is shown.

[0025] Fig.11 A representative configuration of a battery assembly according to an embodiment of the present disclosure is shown.

[0026] Fig.12 A representative battery assembly including a Z-stacked solid electrolyte layer according to one embodiment of the present disclosure is shown. DETAILED DESCRIPTION

[0027] A battery assembly is disclosed herein, which allows pressure or extrusion to be applied during manufacturing while minimizing the risk of short circuit. In some embodiments, the present disclosure provides a battery assembly having a plurality of first electrodes, each of which has a first electrode tab extending therefrom; a plurality of solid electrolyte layers, at least one of which has a first protrusion; and a plurality of second electrodes, each of which has a second electrode tab extending therefrom. In some embodiments, the first protrusion of the solid electrolyte layer is aligned with the corresponding first electrode tab, so that when the first electrode tab is folded, the corresponding first protrusion is positioned between the first electrode tab and one of the second electrodes in the second electrode. Positioning the first protrusion of the solid electrolyte layer between the first electrode tab and the second electrode can prevent contact between the first electrode tab and the second electrode, thereby preventing a short circuit therebetween. Similarly, in some embodiments, the solid electrolyte layer may have a second protrusion, and the second protrusion of the solid electrolyte layer is aligned with the corresponding second electrode tab, so that when the second electrode tab is folded, the corresponding second protrusion is positioned between the second electrode tab and one of the first electrodes in the first electrode. Positioning the second protrusion of the solid electrolyte layer between the second electrode tab and the first electrode can prevent the second electrode tab from contacting the first electrode, thereby preventing a short circuit therebetween. The presence of the first protrusion positioned between the first electrode tab and the second electrode and / or the second protrusion positioned between the second electrode tab and the first electrode can also enable the use of a greater compressive force without having to worry about causing a short circuit when folding the first electrode tab and the second electrode tab, which can result in lower internal resistance and better performance in the battery assembly.

[0028] In some embodiments, the first electrode tabs are electrically connected, and the second electrode tabs are electrically connected. In some embodiments, the first electrode and the second electrode refer to the anode and cathode, respectively. In some embodiments, the first electrode and the second electrode refer to the cathode and the anode, respectively. In some embodiments, the protrusion of the solid electrolyte layer is a part of the solid electrolyte layer or a separate component next to the solid electrolyte layer. In some embodiments, the protrusion is bonded or adhered to the solid electrolyte layer.

[0029] In some embodiments, the first protrusion is geometrically aligned with the first electrode tab and / or the second protrusion is geometrically aligned with the second electrode tab.

[0030] In some embodiments, when the first electrode tab and the second electrode tab are folded, the first protrusion is positioned to separate the first electrode tab from the second electrode, and the second protrusion is positioned to separate the second electrode tab from the first electrode layer, thereby preventing a short circuit between the first electrode tab and the second electrode and a short circuit between the second electrode tab and the first electrode.

[0031] Figure 1A-Figure 1C , a first electrode, a solid electrolyte layer, and a second electrode are representatively shown. The anode layer (1) has an anode tab (1-1) extending therefrom. The solid electrolyte layer (2) has a first protrusion (2-1) and a second protrusion (2-2). The cathode layer (3) has a cathode tab (3-2) extending therefrom. In some embodiments, such as, for example Figure 3A and Figure 4A As shown, the layers are stacked to form a battery assembly such that the layers alternate between anode layers (1) and cathode layers (3), and at least one solid electrolyte layer (2) is positioned between each anode layer (1) and cathode layer (3). In some embodiments, one or more first protrusions (2-1) in the battery assembly are geometrically aligned with anode tabs (1-1) in multiple anode layers (e.g., having the same or similar size and / or shape), and / or one or more second protrusions (2-2) in the battery assembly are geometrically aligned with cathode tabs (3-2) in multiple cathode layers (e.g., having the same or similar size and / or shape). In some embodiments, the anode tab (1-1) or cathode tab (3-2) is located in addition to the anode tab (1-1) and cathode tab (3-2). Figure 1A and Figure 1C In some embodiments, the electrode tabs are located on any side of the battery assembly, including the top or bottom. In some embodiments, the electrode tabs are located at the front or rear of the battery assembly. In some embodiments, the anode tab and the cathode tab are located on the same side. In some embodiments, the anode tab and the cathode tab are located on opposite or adjacent sides of the battery assembly.

[0032] like Figure 3B As representatively shown in FIG. 1 , when the anode tab (1-1) is folded, at least one first protrusion (2-1) of the solid electrolyte (2) on either side of the cathode layer (3) can be folded or arranged or otherwise positioned. The folded or arranged protrusions (2-1) are positioned to separate the anode tab (1-1) from the cathode electrode layer (3), which prevents a short circuit therebetween. As shown in FIG. Figure 3BIt can be seen that when the anode tab (1-1) is folded to contact another anode layer (for example, the anode tab of another anode layer), at least one protrusion (2-1) of the solid electrolyte layer (2) on either side of the cathode layer (3) is positioned between the folded anode tab (1-1) and the cathode layer (3), thereby preventing contact and / or short circuit.

[0033] Also like Figure 4B As shown, in some embodiments, when the cathode tab (3-2) is folded, at least one second protrusion (2-1) of the solid electrolyte (2) on either side of the anode layer (1) can be folded or arranged or otherwise positioned. The folded or arranged second protrusion (2-2) is positioned to separate the cathode tab (3-2) from the anode layer (1), which prevents a short circuit therebetween. Figure 4B It can be seen that when the cathode tab (3-2) is folded to contact another cathode layer (for example, the cathode tab of another cathode layer), at least one protrusion (2-2) of the solid electrolyte layer (2) on either side of the anode layer (1) is positioned between the folded cathode tab (3-2) and the anode layer (1), thereby preventing contact and / or short circuit.

[0034] In some embodiments, the first protrusion and the second protrusion (2-1 and 2-2) have the same or different composition as the solid electrolyte layer. In some embodiments, the protrusion is made of an electrically insulating material other than a solid electrolyte. In some embodiments, the first protrusion and the second protrusion have the same composition as the solid electrolyte layer and are made by cutting the solid electrolyte layer (2), wherein the protrusion is an integral part of the solid electrolyte layer (2). In some embodiments, the first protrusion and the second protrusion are joined to the solid electrolyte layer or placed next to the solid electrolyte layer before folding the tab, and after folding the tab, the first protrusion and the second protrusion are arranged or configured in a configuration that physically separates and electrically insulates the tab from the opposing electrode layer, such as, for example Figure 3B and Figure 4B shown.

[0035] In some embodiments, the first protrusion (2-1) or the second protrusion (2-2) or other protrusions have a certain size. Figure 5 As shown, the length, width and thickness of the protrusion are a, b and c, respectively. In some embodiments, as Figure 3B As representatively shown in FIG. 1 , the protrusion ( 2 - 1 ) has a minimum length that allows the folded protrusion ( 2 - 1 ) to at least cover the cathode layer ( 3 ) adjacent to the electrolyte layer ( 2 ). In some embodiments, as Figure 7B As representatively shown in FIG. 1 , the protrusion ( 2 - 1 ) has a maximum length that allows the folded protrusion ( 2 - 1 ) to cover both the cathode layer ( 3 ) adjacent to the electrolyte layer ( 2 ) and another electrolyte layer ( 2 ) below the cathode layer ( 3 ).

[0036] In some embodiments, the first protrusion or the second protrusion has a Figure 5 In some embodiments, the protrusion has a minimum width corresponding to the width of the anode tab (1-1) or the cathode tab (3-2). In some embodiments, as Figure 2 As shown, the first protrusion and the second protrusion are connected to each other and form a single protrusion (2-3). In some embodiments, the width of the single protrusion (2-3) is not greater than the width of the electrode layer.

[0037] In some embodiments, the protrusions have Figure 5 The thickness c shown. In some embodiments, the protrusion has a unique or variable thickness. In some embodiments, the thickness of the protrusion is in the following range: 25% to 125%, 25% to 100%, 25% to 75%, 50% to 125%, 50% to 100%, 75% to 100% or 75% to 100% of the thickness of the electrolyte layer. In some embodiments, the thickness of the cathode layer is in the range of 1 μm to 1000 μm. In some embodiments, the thickness of the cathode layer is in the following range: 1 μm to 850 μm, 1 μm to 650 μm, 1 μm to 500 μm, 1 μm to 300 μm or 1 μm to 250 μm. In some embodiments, the thickness of the cathode layer is in the range of 5 μm to 1000 μm, 10 μm to 1000 μm, 15 μm to 1000 μm, 25 μm to 1000 μm, 50 μm to 1000 μm, 75 μm to 1000 μm, 100 μm to 1000 μm, 150 μm to 1000 μm, or 200 μm to 1000 μm. In some embodiments, the thickness of the cathode layer is in the range of 10 μm to 800 μm, 15 μm to 650 μm, 20 μm to 500 μm, 25 μm to 300 μm, 75 μm to 300 μm, or 100 μm to 300 μm.

[0038] In some embodiments, the thickness of the anode layer is in the range of 1 μm to 1000 μm. In some embodiments, the thickness of the anode layer is in the range of 1 μm to 850 μm, 1 μm to 650 μm, 1 μm to 500 μm, 1 μm to 300 μm, or 1 μm to 250 μm. In some embodiments, the thickness of the anode layer is in the range of 5 μm to 1000 μm, 10 μm to 1000 μm, 15 μm to 1000 μm, 25 μm to 1000 μm, 50 μm to 1000 μm, or 75 μm to 1000 μm. In some embodiments, the thickness of the anode layer is in the range of 1 μm to 500 μm, 2 μm to 500 μm, 5 μm to 500 μm, 7 μm to 500 μm, 10 μm to 500 μm, 10 μm to 450 μm, 12 μm to 400 μm, 15 μm to 400 μm, 15 μm to 350 μm, 20 μm to 300 μm, 20 μm to 250 μm, 20 μm to 200 μm, 25 μm to 200 μm, 25 μm to 150 μm, or 25 μm to 100 μm.

[0039] In some embodiments, the thickness of the solid electrolyte layer is in the range of 1 μm to 1000 μm. In some embodiments, the thickness of the solid electrolyte layer is in the range of 1 μm to 850 μm, 1 μm to 650 μm, 1 μm to 500 μm, 1 μm to 300 μm, 1 μm to 250 μm, 1 μm to 200 μm, or 1 μm to 150 μm. In some embodiments, the thickness of the solid electrolyte layer is in the range of 5 μm to 1000 μm, 10 μm to 1000 μm, 15 μm to 1000 μm, 25 μm to 1000 μm, 50 μm to 1000 μm, or 75 μm to 1000 μm. In some embodiments, the thickness of the solid electrolyte layer is: 10μm to 500μm, 10μm to 450μm, 15μm to 400μm, 15μm to 350μm, 20μm to 300μm, 20μm to 250μm, 20μm to 200μm, 25μm to 200μm, 25μm to 150μm or 25μm to 100μm.

[0040] In some embodiments, the length of the protrusion is in the range of 1 μm to 3000 μm. In some embodiments, the length of the protrusion is in the range of 10 μm to 3000 μm, 20 μm to 3000 μm, 50 μm to 3000 μm, 100 μm to 3000 μm, 150 μm to 3000 μm, 200 μm to 3000 μm, 250 μm to 3000 μm, 300 μm to 3000 μm, 500 μm to 3000 μm, 500 μm to 2500 μm, or 500 μm to 2000 μm. In some embodiments, the length of the protrusions is in the range of 20 μm to 2500 μm, 50 μm to 2500 μm, 100 μm to 2500 μm, 150 μm to 2500 μm, 200 μm to 2500 μm, 250 μm to 2500 μm, 300 μm to 2500 μm, 350 μm to 2500 μm, 400 μm to 2500 μm, or 450 μm to 2500 μm. In some embodiments, the length of the protrusions is in the following range: 25μm to 2000μm, 50μm to 2000μm, 100μm to 2000μm, 150μm to 2000μm, 200μm to 2000μm, 250μm to 2000μm, 300μm to 2000μm, 350μm to 2000μm, 400μm to 2000μm or 450μm to 2000μm or 500μm to 2000μm. In some embodiments, the length of the protrusions is in the range of 25 μm to 1500 μm, 50 μm to 1500 μm, 100 μm to 1500 μm, 150 μm to 1500 μm, 200 μm to 1500 μm, 250 μm to 1500 μm, 300 μm to 1500 μm, 350 μm to 1500 μm, 400 μm to 1500 μm, or 450 μm to 1500 μm, or 500 μm to 1500 μm.

[0041] In some embodiments, the width of the protrusion is in the range of 0.1 mm to 50 mm. In some embodiments, the width of the protrusion is in the range of 0.1 to 40 mm, 0.2 to 40 mm, 0.5 to 40 mm, 1.0 to 40 mm, 2.0 to 40 mm, 4.0 to 40 mm, 5.0 to 40 mm, 7.5 to 40 mm, or 10 to 40 mm. In some embodiments, the width of the protrusion is in the range of 0.1 to 30 mm, 0.2 to 30 mm, 0.5 to 30 mm, 1.0 to 30 mm, 2.0 to 30 mm, 4.0 to 30 mm, 5.0 to 30 mm, 7.5 to 30 mm, or 10 to 30 mm. In some embodiments, the width of the protrusion is in the range of 0.1 to 20 mm, 0.2 to 20 mm, 0.5 to 20 mm, 1.0 to 20 mm, 2.0 to 20 mm, 4.0 to 20 mm, 5.0 to 20 mm, 7.5 to 20 mm, or 10 to 20 mm. In some embodiments, the width of the protrusion is highly dependent on the configuration. For example, Figure 2 The wide protrusions representatively shown in the figure, the protrusions can have a width up to the full width of the solid electrolyte layer. In some embodiments, the width of the protrusions is in the following ranges: 50 to 2000 mm, 100 to 2000 mm, 250 to 2000 mm, 500 to 2000 mm, or 750 to 2000 mm. In some embodiments, the width of the protrusions is in the following ranges: 100 to 1500 mm, 250 to 1500 mm, 500 to 1500 mm, or 750 to 1500 mm.

[0042] In some embodiments, a protrusion such as the first protrusion or the second protrusion is connected or coupled to the solid electrolyte layer via a notch neck to facilitate folding or arrangement of the protrusion. Figure 6A-6F A representative notched neck is shown in FIG. Figure 6B , Fig. 6E and Fig. 6F In some embodiments, the notched neck comprises a notch on one side of the protrusion. Fig. 6A , Figure 6C and Fig.6D As shown representatively in FIG, the notch neck includes notches on both sides of the protrusion. In some embodiments, the notch neck is a U-shape (e.g., Figure 6B ), V-shaped (e.g. Fig. 6F ), triangles (e.g. Fig. 6E ), semicircular or rectangular (e.g. Fig. 6A ) notch. In some embodiments, the notch neck is a rectangle with two opposite or adjacent sides at the portion of the protrusion beside the electrolyte layer (e.g., Figure 6C), triangle, U-shaped (e.g. Fig.6D ), V-shaped, semicircular or notched. In some embodiments, the notched neck is a cylinder having a cross section smaller than the cross section of the protrusion. In some embodiments, the notched neck is a circular notch on both sides of the portion of the protruding neck of the electrolyte layer. In some embodiments, the notched neck is formed during the preparation of the electrolyte layer such as compression molding. In some embodiments, the notched neck is formed by cutting after the preparation of the electrolyte layer.

[0043] In some embodiments, such as Figure 1B As typically shown in FIG. 1 , each electrolyte layer in the battery assembly has a first protrusion and a second protrusion ( 2 - 1 and 2 - 2 ). In some embodiments, as Figure 2 Typically, each electrolyte layer in a battery assembly has a combination of protrusions. In some embodiments, the electrolyte layer is a combination of both. In some embodiments, some electrolyte layers in a battery assembly do not have protrusions as shown in FIG. 1 , if the protrusions on other electrolyte layers are long enough. Figure 7A-7B and Figure 8A-B The protrusions are typically shown in FIG. Fig. 7A Two electrolyte layers (2) are shown on opposite sides of the cathode layer (3), and a first protrusion (2-1) extends from the top of the first electrolyte layer (2), while there is no protrusion on the second electrolyte layer. Figure 7B As shown, the folding of the anode tab (1-1) leads to the folding of the first protrusion (2-1), and the folded first protrusion is positioned so that it covers the cathode layer (3) and the electrolyte layer below the cathode layer. Similarly, Fig. 8A Two electrolyte layers (2) are shown on opposite sides of the anode layer (1), and a second protrusion (2-2) extends from the top of the first electrolyte layer, while there is no protrusion on the second electrolyte layer. As shown in Figure 8b, the folding of the cathode tab (3-2) causes the folding of the second protrusion (2-2), and the folded second protrusion is positioned so that it covers the anode layer (1) and the electrolyte layer below the anode layer.

[0044] In some embodiments, each electrolyte layer in the battery assembly has one protrusion. Fig. 9 As shown, each electrolyte layer has a protrusion, namely 2-1 or 2-2. When the electrode tab is folded down, the protrusion will be folded and occupy Fig. 9 In some embodiments, the electrolyte layer having a single protrusion has a Figure 10A-10B In some embodiments, if the symmetrical design Fig. 10A The protrusion (2-1) and Fig. 10B In some embodiments, Fig. 10AThe solid electrolyte layer having the protrusion (2-1) can be turned over and formed Fig. 10B A solid electrolyte layer having a protrusion (2-2) in. In some embodiments, the protrusion (2-1) and the protrusion (2-2) have different sizes and / or shapes.

[0045] In some embodiments, the present disclosure provides a battery assembly comprising:

[0046] a) a plurality of first electrodes, each first electrode comprising a first electrode tab extending therefrom;

[0047] b) a plurality of second electrodes; and

[0048] c) one or more first solid electrolyte layers each including a first protrusion, wherein the number of the one or more first solid electrolyte layers (N1 SE ) is not greater than the number of all solid electrolyte layers in the battery assembly (N SE )(1≤N1 SE ≤N SE ),

[0049] wherein the first solid electrolyte layer including the first protrusion is sandwiched between one of the first electrodes and one of the second electrodes, and

[0050] wherein a first electrode tab of one of the first electrodes contacts another first electrode tab of another first electrode, and

[0051] The first protrusion of the first solid electrolyte layer is positioned to separate the first electrode tab of one of the first electrodes from the second electrode of the second electrodes to prevent a short circuit therebetween.

[0052] like Fig. 9 As shown representatively in FIG. 1 , the battery assembly includes five solid electrolyte layers, namely N SE =5, and there are 3 first solid electrolyte layers with first protrusions, namely N1 SE =3.

[0053] In some embodiments, the battery assembly includes one or more first solid electrolyte layers each including a first protrusion and a second solid electrolyte layer each including a second protrusion. In one embodiment, the number of the first solid electrolyte layer and the second solid electrolyte layer is N1, respectively. SE and N2 SE , where 1≤N1 SE ≤N SE , and 1≤N2 SE ≤N SE In some embodiments, Fig. 9As typically shown in FIG. 1 , the solid electrolyte layer may include only the first protrusion. In some embodiments, as Fig.11 As shown, the solid electrolyte layer may include a first protrusion and a second protrusion.

[0054] Fig.11 A battery assembly including some solid electrolyte layers having two protrusions and some solid electrolyte layers having no protrusions is shown. Fig.11 It is also shown that the folding direction of the anode tab is different from the folding direction of the cathode tab. Fig. 9 A configuration is shown where the anode tab and cathode tab share the same folding direction.

[0055] In some embodiments, the anode layer comprises an anode active material. Non-limiting specific anode active materials include lithium metal, lithium alloys, graphite, graphene and their modifications and derivatives. Modifications and derivatives include coating with other materials or mixing with other materials, or surface modification via chemical bonding, physical bonding or a combination thereof. In some embodiments, the anode layer also includes a current collector on which the anode active material is positioned. In some embodiments, the current collector of the anode layer may include an anode pole ear (1-1).

[0056] In some embodiments, the cathode layer comprises a cathode active material (CAM). Non-limiting specific cathode active materials include Li x Mn 1-y M y A2 (Formula 1), Li x Mn 1-y M y O 2-z X z (Formula 2), Li x Mn2O 4-z X z (Formula 3), Li x Mn 2-y M y A4 (Formula 4), Li x Co 1-y M y A2 (Formula 5), ​​Li x Co 1-y M y O 2-z X z (Formula 6), Li x Ni 1-y M y A2 (Formula 7), Li x Ni 1-y M y O 2-z X z (Formula 8), Li x Ni 1-y Co y O 2-z X z (Formula 9), Li x Ni 1-y-z Co y M z A a (Formula 10), Li x Ni 1-y-z Co y M z O 2-a X a (Formula 11), Li x Ni 1-y-z Mn y M z A a (Formula 12), Li x Ni 1-y-z Mn y M z O 2-a X a (Formula 13), wherein 0.95≤x≤1.1, 0≤y≤0.5, 0≤z≤0.5, 0≤a≤2; M is selected from the group consisting of Al, Ni, Co, Mn, Cr, Fe, Mg, Sr, V and rare earth elements; A is selected from the group consisting of O, F, S and P; and X is selected from the group consisting of F, S and P. In some embodiments, the average diameter of the CAM particles is 1-15 μm. Its concentration in the cathode layer is between 50 wt% and 99 wt%. In some embodiments, the cathode layer also includes a current collector on which a cathode active material is positioned. In some embodiments, the current collector of the cathode layer may include a cathode tab 3-2.

[0057] In some embodiments, the solid electrolyte layer is a sulfide solid electrolyte. In some embodiments, the sulfide solid electrolyte can be any one of a crystalline material, a glass ceramic, a glass, or a combination thereof. Examples of sulfide solid electrolytes include Li2S-P2S5, Li2S-P2S5-LiHa ("Ha" is one or more halogen elements), Li2S-P2S5-P2O5, Li2S-Li3PO4-P2S5, Li3PS4, Li4P2S6, Li 10 GeP2S 12 , Li 3.25 Ge 0.25 P 0.75 S4、Li7P3S 11 , Li 3.25 P 0.95 S4 and Li 7- x PS 6-x Hax (argyrodite-type solid electrolyte), "Ha" is one or more halogen elements, where x is the mole fraction of the halogen and has a value in the range of 0.2 to 1.8.

[0058] In some embodiments, the anode tab is folded in a first direction, and the cathode tab is folded in a second direction. In some embodiments, the first direction and the second direction are the same or different.

[0059] In one aspect, the present disclosure provides a battery assembly comprising:

[0060] a) a plurality of first electrodes, wherein each first electrode comprises a first electrode tab extending therefrom;

[0061] b) a solid electrolyte layer comprising a first protrusion; and

[0062] c) a second electrode,

[0063] wherein the solid electrolyte layer is positioned between a first electrode and a second electrode of the plurality of first electrodes, and

[0064] wherein a first electrode tab of one of the plurality of first electrodes contacts another first electrode of the plurality of first electrodes, and

[0065] The first protrusion of the solid electrolyte layer is positioned to separate a first electrode tab of one of the plurality of first electrodes from a second electrode to prevent a short circuit therebetween.

[0066] In some embodiments, the present disclosure provides a battery assembly comprising a plurality of first electrodes each comprising a first electrode tab, a plurality of second electrodes each comprising a second electrode tab, and one or more solid electrolyte layers each comprising a first protrusion and a second protrusion, wherein the solid electrolyte layer comprising the first protrusion and the second protrusion is sandwiched between one of the second electrodes and one of the first electrodes, and the second protrusion on the electrolyte layer is positioned to separate the second electrode tab of one of the second electrodes from one of the first electrodes to prevent a short circuit therebetween.

[0067] In some embodiments, the battery component includes a solid electrolyte layer comprising a first protrusion and a second solid electrolyte comprising a second protrusion, wherein the second electrolyte layer is sandwiched between a second electrode and another first electrode among a plurality of first electrodes, and the second protrusion on the second solid electrolyte layer is positioned to separate the second electrode tab of the second electrode from another first electrode among the first electrodes to prevent a short circuit therebetween.

[0068] In some embodiments, the present disclosure is also applicable to battery components including a cathode, an anode, and a solid electrolyte layer. In some embodiments, a single electrode is stacked or wound into a configuration having multiple layers, wherein one or more electrode tabs are distributed along an edge of the electrode layer. In some embodiments, a single electrolyte is stacked or wound into multiple layers, wherein one or more protrusions are distributed along an edge of the electrolyte layer. In some embodiments, one or more protrusions are spatially aligned with the electrode tabs. In some embodiments, as Figure 3A and Figure 3B Typically shown in , the electrodes and electrolyte layers are separate sheets stacked together. In some embodiments, the electrolyte layer with more than one protrusion as disclosed herein is also suitable for battery components prepared by the Z stacking process. In one embodiment, the battery component with Z stacking includes a single electrolyte layer that forms multiple electrolyte sections after Z stacking. Fig.12 Typically shown in, a single solid electrolyte layer is stacked into a Z-shaped configuration and forms multiple electrolyte parts. Each part is similar to a solid electrolyte sheet and is sandwiched between a first electrode sheet and a second electrode sheet. In some embodiments, the present disclosure is also applicable to battery components prepared by cylindrical or prismatic windings, wherein the assembly of the first electrode / electrolyte layer / second electrode is wound into a cylindrical shape or wound into a prismatic shape, and one or more protrusions are distributed along an edge of the solid electrolyte layer, and one of the more than one protrusions is positioned to separate the first electrode pole ear on a portion of the first electrode from a portion of the second electrode to prevent a short circuit therebetween.

[0069] In some embodiments, the battery components disclosed herein can be incorporated into an electrochemical device, such as an all-solid-state battery.

[0070] In one aspect, the present disclosure provides a method for preparing a battery component. In some embodiments, the method includes:

[0071] 1) providing a plurality of first electrodes, wherein each first electrode comprises a first electrode tab extending therefrom;

[0072] 2) providing a plurality of solid electrolyte layers, wherein at least one of the solid electrolyte layers comprises a first protrusion;

[0073] 3) providing a plurality of second electrodes, wherein each second electrode comprises a second electrode tab extending therefrom;

[0074] 4) stacking a plurality of first electrodes, a plurality of solid electrolyte layers, and a plurality of second electrodes in a pattern of one first electrode among the plurality of first electrodes, one solid electrolyte layer among the plurality of solid electrolyte layers, and one second electrode among the plurality of second electrodes to form a battery assembly, wherein each first electrode tab is aligned with one of the first protrusions; and

[0075] 5) Folding each first electrode tab so that the first protrusion aligned with each first electrode tab is positioned to separate the first electrode tab from the second electrode, thereby preventing contact and minimizing short circuits.

[0076] In some embodiments, the first electrode tab is welded or otherwise joined together to electrically connect the first electrode tab. In some embodiments, the second electrode tab is welded or otherwise joined together to electrically connect the second electrode tab. In some embodiments, the electrode tabs can be joined together using ultrasonic welding. As described above, in some embodiments, the stack can include a solid electrolyte layer having only a first protrusion, a solid electrolyte layer having only a second protrusion, or a solid electrolyte layer having both a first protrusion and a second protrusion.

[0077] In some embodiments, the first protrusion prevents a short circuit between the first electrode tab and the second electrode and / or the second protrusion prevents a short circuit between the second electrode tab and the first electrode. In some embodiments, the first electrode is an anode or a cathode. In some embodiments, the second electrode is an anode or a cathode.

[0078] In some embodiments, the present disclosure provides a method for preparing a solid electrolyte layer having more than one protrusion. The method may include loading the solid electrolyte layer on a separator, cutting the solid electrolyte layer with the separator so that the cut shape includes more than one protrusion, and separating the solid electrolyte layer from the separator to obtain a solid electrolyte layer having more than one protrusion. In some embodiments, the solid electrolyte layer is prepared in the absence of a separator.

[0079] In some embodiments, the folding of the first electrode pole ear and / or the second electrode pole ear can be completed by applying pressure to fold the pole ear using a tool or mold. The folding of the first electrode pole ear and / or the second electrode pole ear can also result in the folding, movement or positioning of the corresponding first protrusion or second protrusion. In some embodiments, a balanced pressure can be used. In some embodiments, the pressure can be in the following ranges: 200MPa to 1,000MPa, 300MPa to 1,000MPa, 400MPa to 1,000MPa, 500MPa to 1,000MPa or any and all ranges and sub-ranges therebetween. Sufficient amount or time period of pressure can be applied, for example, in the following ranges: 1 minute to 120 minutes, 5 minutes to 120 minutes, 10 minutes to 120 minutes, 30 minutes to 120 minutes, 45 minutes to 120 minutes, 60 minutes to 120 minutes or any and all ranges and sub-ranges therebetween. Heating may also be provided while applying pressure, for example in the range of 40°C to 100°C, 50°C to 100°C, 60°C to 100°C, 70°C to 100°C, or any and all ranges and sub-ranges therebetween.

[0080] In some embodiments, the battery components can be sealed in a pouch. In some embodiments, the pouch can be incorporated into an electrochemical device.

[0081] In some embodiments, the battery assembly is tested for the presence of a short circuit by measuring the open circuit voltage (OCV) across the electrode tabs.Battery assemblies provided in the present disclosure exhibit reduced short circuits.

[0082] It should be noted that the transitional term "comprising," which is synonymous with "including," "containing," or "characterized by," is inclusive or open-ended and does not exclude additional, unrecited elements or method steps.

[0083] In a first aspect of the present disclosure, a battery component includes: a plurality of first electrodes, wherein each first electrode includes a first electrode tab extending therefrom; a solid electrolyte layer including a first protrusion; and a second electrode, wherein the solid electrolyte layer is positioned between a first electrode among the plurality of first electrodes and the second electrode, and wherein the first electrode tab of a first electrode among the plurality of first electrodes contacts another first electrode among the plurality of first electrodes, and wherein the first protrusion of the solid electrolyte layer is positioned to separate the first electrode tab of a first electrode among the plurality of first electrodes from the second electrode to prevent a short circuit therebetween.

[0084] In a second aspect according to the first aspect, the battery component further includes: a plurality of solid electrolyte layers, wherein each of the plurality of solid electrolyte layers includes a first protrusion and a second protrusion; and a plurality of second electrodes, wherein each of the plurality of second electrodes includes a second electrode tab, wherein the second electrode tab of one of the plurality of second electrodes contacts another second electrode of the plurality of second electrodes, and wherein one of the plurality of solid electrolyte layers is positioned between one of the plurality of second electrodes and one of the plurality of first electrodes, and wherein the second protrusion is positioned to separate the second electrode tab of one of the plurality of second electrodes from one of the plurality of first electrodes to prevent a short circuit therebetween.

[0085] In a third aspect according to the first aspect, the battery assembly further includes a second solid electrolyte layer positioned between the second electrode and another first electrode among the plurality of first electrodes, wherein the second solid electrolyte layer has a first protrusion, and the first protrusion of the solid electrolyte layer and the first protrusion of the second solid electrolyte layer are positioned to separate the first electrode tab of one of the plurality of first electrodes from the second electrode.

[0086] In a fourth aspect according to the preceding aspect, all of the first electrode tabs are electrically connected together.

[0087] In a fifth aspect according to the aforementioned aspect, the first protrusion has the same or different composition as that of the solid electrolyte layer.

[0088] In a sixth aspect according to the aforementioned aspect, the first protrusion has a minimum length covering the second electrode, and has a maximum length covering the second electrode and another solid electrolyte layer below the second electrode.

[0089] In a seventh aspect according to the aforementioned aspect, the thickness of the first protrusion is in the range of 50% to 100% of the thickness of the solid electrolyte layer.

[0090] In an eighth aspect according to the preceding aspect, the first protrusion has a minimum width corresponding to a width of the first electrode tab.

[0091] In a ninth aspect according to the aforementioned aspect, the first protrusion is connected to the solid electrolyte layer via the notch neck.

[0092] In a tenth aspect according to the ninth aspect, the first electrode tab is folded along the first direction, and the second electrode tab is folded along the second direction.

[0093] In an eleventh aspect according to the preceding aspect, the plurality of first electrodes are anodes, and the second electrodes are cathodes.

[0094] In a twelfth aspect according to any one of the first to eleventh aspects, the plurality of first electrodes are cathodes, and the second electrodes are anodes.

[0095] In a thirteenth aspect of the present disclosure, an electrochemical device comprises the battery assembly according to any one of the preceding aspects.

[0096] In the fourteenth aspect of the present disclosure, a method for preparing a battery assembly comprises: providing a plurality of first electrodes, wherein each first electrode comprises a first electrode tab extending therefrom; providing a plurality of solid electrolyte layers, wherein at least one of the solid electrolyte layers comprises a first protrusion; providing a plurality of second electrodes, wherein each second electrode comprises a second electrode tab extending therefrom; stacking the plurality of first electrodes, the plurality of solid electrolyte layers, and the plurality of second electrodes in a pattern of a first electrode among the plurality of first electrodes, a solid electrolyte layer among the plurality of solid electrolyte layers, and a second electrode among the plurality of second electrodes to form a battery assembly, wherein each first electrode tab is aligned with one of the first protrusions; and folding each first electrode tab so that the first protrusion aligned with each first electrode tab is positioned to separate the first electrode tab from the second electrode.

[0097] In a fifteenth aspect according to the fourteenth aspect, the method further comprises welding the first electrode tabs together.

[0098] In a sixteenth aspect according to the fourteenth or fifteenth aspect, the method further comprises sealing the battery assembly in the pouch.

[0099] In a seventeenth aspect according to any one of the fourteenth to sixteenth aspects, the method further comprises applying pressure to the battery assembly at a temperature for a period of time.

[0100] In an eighteenth aspect according to the seventeenth aspect, the pressure is applied uniformly.

[0101] In a nineteenth aspect according to the seventeenth or eighteenth aspect, wherein the temperature is in the range of 40°C to 100°C.

[0102] In a twentieth aspect according to any one of the seventeenth to nineteenth aspects, the period of time is in the range of 1 minute to 120 minutes.

[0103] In a twenty-first aspect according to any one of the seventeenth to twentieth aspects, the pressure is in the range of 200 MPa to 1000 MPa.

Claims

1. A battery assembly comprising: a) a plurality of first electrodes, wherein each first electrode comprises a first electrode tab extending therefrom; b) a solid electrolyte layer comprising a first protrusion; and c) a second electrode, wherein the solid electrolyte layer is positioned between one of the plurality of first electrodes and the second electrode, and wherein the first electrode tab of the one first electrode among the plurality of first electrodes contacts another first electrode among the plurality of first electrodes, and The first protrusion of the solid electrolyte layer is positioned to separate the first electrode tab of the one of the plurality of first electrodes from the second electrode to prevent a short circuit therebetween.

2. The battery assembly according to claim 1, further comprising: a plurality of the solid electrolyte layers, wherein each of the plurality of solid electrolyte layers comprises the first protrusion and the second protrusion; and a plurality of said second electrodes, wherein each of said plurality of second electrodes comprises a second electrode tab, wherein a second electrode tab of one of the plurality of second electrodes contacts another second electrode of the plurality of second electrodes, and wherein one of the plurality of solid electrolyte layers is positioned between the one of the plurality of second electrodes and one of the plurality of first electrodes, and The second protrusion is positioned to separate the second electrode tab of the one of the plurality of second electrodes from the one of the plurality of first electrodes to prevent a short circuit therebetween.

3. The battery assembly according to claim 1 further comprises a second solid electrolyte layer positioned between the second electrode and the other first electrode among the plurality of first electrodes, wherein the second solid electrolyte layer has a first protrusion, and the first protrusion of the solid electrolyte layer and the first protrusion of the second solid electrolyte layer are positioned to separate the first electrode tab of the one first electrode among the plurality of first electrodes from the second electrode. The battery assembly according to claim 1 , wherein all of the first electrode tabs are electrically connected together. 5 . The battery assembly according to claim 1 , wherein the first protrusion has the same or different composition as that of the solid electrolyte layer. 6 . The battery assembly according to claim 1 , wherein the first protrusion has a minimum length covering the second electrode, and has a maximum length covering the second electrode and another solid electrolyte layer below the second electrode. 7 . The battery assembly according to claim 1 , wherein a thickness of the first protrusion is in a range of 50% to 100% of a thickness of the solid electrolyte layer. 8 . The battery assembly of claim 1 , wherein the first protrusion has a minimum width corresponding to a width of the first electrode tab. 9 . The battery assembly according to claim 1 , wherein the first protrusion is connected to the solid electrolyte layer via a notch neck.

10. The battery assembly of claim 2, wherein the first electrode tab is folded along a first direction, and the second electrode tab is folded along a second direction.

11. The battery assembly according to claim 1, wherein the plurality of first electrodes are anodes, and the second electrode is a cathode. 12 . The battery assembly of claim 1 , wherein the plurality of first electrodes are cathodes, and the second electrode is an anode.

13. An electrochemical device comprising the battery assembly according to claim 1.

14. A method for preparing a battery assembly, comprising: a) providing a plurality of first electrodes, wherein each first electrode comprises a first electrode tab extending therefrom; b) providing a plurality of solid electrolyte layers, wherein at least one of the solid electrolyte layers comprises a first protrusion; c) providing a plurality of second electrodes, wherein each second electrode comprises a second electrode tab extending therefrom; d) stacking the plurality of first electrodes, the plurality of solid electrolyte layers, and the plurality of second electrodes in a pattern of one first electrode among the plurality of first electrodes, one solid electrolyte layer among the plurality of solid electrolyte layers, and one second electrode among the plurality of second electrodes to form a battery assembly, wherein each first electrode tab is aligned with one of the first protrusions; and e) folding each first electrode tab such that the first protrusion aligned with the each first electrode tab is positioned to separate the first electrode tab from the second electrode.

15. The method of claim 14, further comprising welding the first electrode tabs together.

16. The method according to claim 14, further comprising: Pressure is applied to the battery assembly at a certain temperature for a period of time.

17. The method of claim 16, wherein the pressure is applied isostatically.

18. The method of claim 16, wherein the temperature is in the range of 40°C to 100°C.

19. The method of claim 16, wherein the period of time is in the range of 1 minute to 120 minutes.

20. The method of claim 16, wherein the pressure is in the range of 200 MPa to 1000 MPa.

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