Battery cell structure of secondary battery

Abstract

The present disclosure relates to a battery cell structure of a secondary battery. The present disclosure provides a battery pre-lithiation component, which includes an anode having a first hole and a cathode having a second hole. The first hole and the second hole are configured to allow an electrolyte to pass therethrough. In addition, the first hole and the second hole are configured to allow Li+ ions associated with the lithium metal to move during the pre-lithiation process. The lithium metal may be coated on the anode (e.g., coated on the active material of the anode), or the lithium metal may correspond to at least one lithium metal electrode, such as a first lithium metal electrode and a second lithium metal electrode disposed on opposite sides of an electrode stack (e.g., a jelly roll) including the anode, the cathode, and the separator.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 541,552, filed on September 29, 2023, entitled “Cell Structure for Secondary Batteries,” which is incorporated herein by reference in its entirety for all purposes. Background Art

[0003] The present disclosure relates generally to batteries, such as secondary or rechargeable batteries (eg, lithium-ion batteries), and more particularly to the structure and pre-lithiation processes of such batteries.

[0004] Certain batteries, such as those described above, may undergo a pre-lithiation process, causing Li+ ions to react with the anode of the battery during battery formation (e.g., before the battery is used to power a load). The pre-lithiation process may employ a redox reaction to reduce or mitigate initial active lithium loss that occurs during a cycling phase (e.g., an early cycling phase) of the battery, improve local voltage uniformity, and / or maintain stability and performance of the battery cell. Unfortunately, conventional pre-lithiation processes may be cumbersome, expensive, inadequate, and / or ineffective. Therefore, it is now recognized that improved systems and methods are desired. Summary of the invention

[0005] The following describes a summary of certain embodiments disclosed herein. It should be understood that these aspects are presented only to provide the reader with a concise summary of these specific embodiments, and these aspects are not intended to limit the scope of the present disclosure. In fact, the present disclosure may encompass a number of aspects that may not be described below.

[0006] In one embodiment, a battery pre-lithiation assembly includes a lithium metal electrode, an anode and a cathode. The anode includes a first hole configured to allow an electrolyte to pass therethrough and configured to allow Li+ ions associated with the lithium metal electrode to move during a pre-lithiation process. The cathode includes a second hole configured to allow the electrolyte to pass therethrough and configured to allow the Li+ ions associated with the lithium metal electrode to move during the pre-lithiation process.

[0007] In another embodiment, a battery pre-lithiation component includes an anode coated with lithium metal and having a first pore configured to allow an electrolyte to pass therethrough and configured to allow Li+ ions associated with the lithium metal to move during a pre-lithiation process. The battery pre-lithiation component also includes a cathode having a second pore configured to allow an electrolyte to pass therethrough and configured to allow the Li+ ions associated with the lithium metal to move during the pre-lithiation process.

[0008] In another embodiment, a method of forming a battery cell includes: disposing a lithium metal electrode in a housing; disposing an anode in the housing; and disposing a cathode in the housing. The method also includes disposing an electrolyte in the housing so that the electrolyte passes through a first hole in the anode and a second hole in the cathode to form a channel that enables Li+ ions (e.g., Li+ ions associated with the lithium metal electrode) to move within the housing and react with the anode during pre-lithiation.

[0009] In another embodiment, a method of forming a battery cell includes: coating an anode with lithium metal; disposing the anode in a housing; and disposing a cathode in the housing. The method also includes disposing an electrolyte in the housing so that the electrolyte passes through a first hole in the anode and a second hole in the cathode to form a channel that enables Li+ ions (e.g., Li+ ions associated with the lithium metal) to move within the housing during pre-lithiation and enables the Li+ ions to react with the anode.

[0010] With respect to various aspects of the present disclosure, there may be various improvements to the above-mentioned features. Other features may also be incorporated into these various aspects. These improvements and additional features may exist individually or in any combination. For example, the various features discussed below with respect to one or more embodiments in the illustrated embodiments may be incorporated into any of the above-mentioned aspects of the present disclosure individually or in any combination. The brief summary presented above is intended only to familiarize the reader with certain aspects and contexts of the embodiments of the present disclosure, without limiting the claimed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Various aspects of the present disclosure may be better understood upon reading the following detailed description and referring to the drawings described below, in which like reference numerals refer to like parts.

[0012] Figure 1 is a block diagram of an electronic device according to an embodiment of the present disclosure;

[0013] Figure 2is a schematic perspective view of a battery after pre-lithiation according to an embodiment of the present disclosure, wherein the battery is configured as Figure 1 Powering electronic devices;

[0014] Figure 3 are schematic diagrams of various types of batteries after pre-lithiation according to embodiments of the present disclosure;

[0015] Figure 4 is a method for producing, for example, Figure 2 A schematic cross-sectional view of a battery pre-lithiation assembly of a battery, wherein the battery pre-lithiation assembly includes at least one lithium metal electrode;

[0016] Figure 5 is a method for producing, for example, Figure 2 A schematic cross-sectional view of a battery pre-lithiation assembly of a battery of , wherein the battery pre-lithiation assembly includes at least one lithium metal electrode, and the battery pre-lithiation assembly includes a misalignment between anode pores and cathode pores;

[0017] Fig. 6A According to the embodiments of the present disclosure Figure 4 or Figure 5 A schematic cross-sectional view of the layered structure of the cathode of a battery pre-lithiation component;

[0018] Figure 6B According to the embodiments of the present disclosure Figure 4 or Figure 5 A schematic cross-sectional view of another layered structure of a cathode of a pre-lithiation component of a battery;

[0019] Figure 7 According to the embodiments of the present disclosure Figure 4 or Figure 5 The battery pre-lithiation components are produced along the way, e.g. Figure 2 A schematic diagram of additional aspects of the various stages of the battery;

[0020] Figure 8 is a method for producing, for example, Figure 2 A schematic cross-sectional view of a battery pre-lithiation assembly of a battery, wherein the battery pre-lithiation assembly includes lithium metal coated on one or more anodes;

[0021] Fig. 9 is a method for producing, for example, Figure 2 A schematic cross-sectional view of a battery pre-lithiation assembly of a battery of , wherein the battery pre-lithiation assembly includes lithium metal coated on one or more anodes, and the battery pre-lithiation assembly includes a misalignment between anode pores and cathode pores;

[0022] Fig.10 According to the embodiments of the present disclosure, for example, in the use Figure 4 or Figure 8 After the battery pre-lithiation component Figure 2 A schematic cross-sectional view of a battery;

[0023] Fig.11 According to the embodiments of the present disclosure, for example, in the use Figure 5 or Fig. 9 After the pre-lithiation component Figure 2 A schematic cross-sectional view of a battery;

[0024] Fig.12 is an example of an embodiment according to the present disclosure Figure 4 or Figure 5 Production of battery pre-lithiation components such as Figure 2 A process flow chart of a method for producing a battery;

[0025] Fig.13 is an example of an embodiment according to the present disclosure Figure 8 or Fig. 9 Production of battery pre-lithiation components such as Figure 2 A process flow diagram of a method for producing a battery; and

[0026] Fig.14 is an example of an embodiment according to the present disclosure Figure 8 or Fig. 9 Production of battery pre-lithiation components such as Figure 2 A process flow chart of a battery method. DETAILED DESCRIPTION

[0027] When introducing the elements of various embodiments of the present disclosure, the articles "one", "an" and "the" are intended to mean one or more elements present in the elements. The terms "include", "comprise" and "have" are intended to be inclusive, and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that the reference to "one embodiment" or "embodiment" of the present disclosure is not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the features. In addition, specific features, structures or characteristics can be combined in any appropriate manner in one or more embodiments. The use of the terms "roughly", "close to", "about", "close to" and / or "substantially" should be understood to mean including close to a target (e.g., design, value and amount), such as within the limits of any suitable or conceivable error (e.g., within 0.1% of a target, within 1% of a target, within 5% of a target, within 10% of a target, within 25% of a target, etc.). Furthermore, it should be understood that any exact values, numbers, measurements, etc. provided herein should be construed to include approximations of the exact values, numbers, measurements, etc. (eg, within a tolerance of appropriate or conceivable errors).

[0028] The present disclosure relates to batteries, such as secondary or rechargeable batteries (eg, lithium-ion batteries). More specifically, the present disclosure relates to the structure and pre-lithiation process of such batteries.

[0029] Among other features, the battery may include electrodes (e.g., at least one anode and at least one cathode), a separator, an electrolyte, and a housing in which the electrodes, separator, and electrolyte are disposed. In some embodiments, the electrodes and separator may form a jelly roll, while in other embodiments, the electrodes and separator may be in a stacked configuration. In addition, the electrodes may be electrically coupled to terminals of the battery (e.g., via electrode tabs), wherein the terminals are configured to be coupled to a load to enable the battery to power the load.

[0030] Secondary batteries (e.g., rechargeable batteries) such as lithium-ion (Li-ion) batteries can be cycled through various discharge and charge sequences during the life of the battery. Initial active lithium loss may occur in some such cycles, which may affect the stability, performance, and / or energy density of the battery. According to the present disclosure, a pre-lithiation process can be applied that introduces a lithium source in a battery pre-lithiation component, wherein the lithium source mitigates initial active lithium loss and improves local voltage uniformity, battery performance, and battery stability, among other technical benefits.

[0031] As described in detail with reference to the accompanying drawings, the lithium source may include lithium metal used as one or more electrodes separated from the anode and cathode, or lithium metal used as a coating on the active material of the anode. The lithium source may be arranged in a housing together with the anode, cathode, separator and electrolyte. In an embodiment using a lithium metal electrode (e.g., as opposed to a lithium metal coating), a voltage may be applied to the lithium metal electrode in order to initiate a pre-lithiation process. In an embodiment using a lithium metal coating, a period of electrolyte aging may be used to initiate and / or perform a pre-lithiation process. The pores (e.g., openings) in the anode and cathode and the pores in the separator may allow the electrolyte to pass therethrough, which forms a channel that promotes the movement of Li+ ions associated with or corresponding to the lithium metal source around the interior of the housing of the battery pre-lithiation component. A redox reaction may occur between the Li+ ions and the anode, causing the active lithium to be transferred to the anode, thereby reducing, eliminating or otherwise preventing initial active lithium loss and / or local voltage non-uniformity.

[0032] As described above and described in more detail below, the currently disclosed systems and techniques can improve local voltage uniformity, reduce initial active lithium loss, and improve battery performance, stability, and energy density compared to conventional systems and techniques. In addition, the currently disclosed systems and techniques may be cheaper and more cumbersome than conventional techniques. It should be noted that although certain embodiments of the present disclosure are discussed in the context of lithium-ion (Li-ion) batteries, similar systems and techniques may also be used in other batteries having other material compositions. These and other aspects of the present disclosure are described in detail below with reference to the accompanying drawings.

[0033] Now continue to refer to the accompanying drawings, Figure 1 1 is a block diagram of an electronic device 10 according to an embodiment of the present disclosure. The electronic device 10 may include, among other things, one or more processors 12 (collectively referred to herein as a single processor for convenience, which may be implemented in any suitable form of processing circuitry), a memory 14, a non-volatile storage device 16, a display 18, an input structure 22, an input / output (I / O) interface 24, a network interface 26, and a power supply 29. Figure 1 The various functional blocks shown may include hardware elements (including circuits), software elements (including machine executable instructions), or a combination of hardware and software elements (which may be referred to as logical components). Processor 12, memory 14, non-volatile storage device 16, display 18, input structure 22, input / output (I / O) interface 24, network interface 26, and / or power supply 29 may each be directly or indirectly communicatively coupled to each other (e.g., through or via another component, a communication bus, a network) to transmit and / or receive signals between each other. It should be noted that Figure 1 This is merely one example of a particular implementation and is intended to illustrate the types of components that may be present in electronic device 10 .

[0034] By way of example, electronic device 10 may include any suitable computing device, including a desktop or laptop computer, a portable electronic or handheld electronic device (such as a wireless electronic device or a smart phone), a tablet computer, a wearable electronic device, and other similar devices. In additional or alternative embodiments, electronic device 10 may include an access point, such as a base station, a router (e.g., a wireless or Wi-Fi router), a hub, a switch, etc. It should be noted that Figure 1 The processor 12 and other related items in the embodiment may be embodied in whole or in part as software, hardware, or both. Figure 1The processor 12 and other related items in the electronic device 10 may be a single contained processing module, or may be fully or partially incorporated into any of the other elements within the electronic device 10. The processor 12 may be implemented using a combination of a general-purpose microprocessor, a microcontroller, a digital signal processor (DSP), a field programmable gate array (FPGA), a programmable logic device (PLD), a controller, a state machine, a gated logic, a discrete hardware component, a dedicated hardware finite state machine, or any other suitable entity that can perform calculations or other manipulations of information. The processor 12 may include one or more application processors, one or more baseband processors, or both, and perform various functions described herein.

[0035] exist Figure 1 In the electronic device 10, the processor 12 may be operably coupled to the memory 14 and the non-volatile storage device 16 to execute various algorithms. Such programs or instructions executed by the processor 12 may be stored in any suitable article including one or more tangible computer-readable media. The tangible computer-readable medium may include the memory 14 and / or the non-volatile storage device 16, individually or collectively, to store instructions or routines. The memory 14 and the non-volatile storage device 16 may include any suitable article for storing data and executable instructions, such as random access memory, read-only memory, rewritable flash memory, hard drive, and optical disk. In addition, the program (e.g., operating system) encoded on such a computer program product may also include instructions that can be executed by the processor 12 to enable the electronic device 10 to provide various functions.

[0036] In certain embodiments, display 18 may facilitate a user viewing images generated on electronic device 10. In some embodiments, display 18 may include a touch screen that may facilitate a user interacting with a user interface of electronic device 10. Furthermore, it should be understood that in some embodiments, display 18 may include one or more liquid crystal displays (LCDs), light emitting diode (LED) displays, organic light emitting diode (OLED) displays, active matrix organic light emitting diode (AMOLED) displays, or some combination of these and / or other display technologies.

[0037] The input structures 22 of the electronic device 10 may enable a user to interact with the electronic device 10 (e.g., pressing a button to increase or decrease a volume level). As with the network interface 26, the I / O interface 24 may enable the electronic device 10 to interact with a variety of other electronic devices. In some embodiments, the I / O interface 24 may include an I / O port for a hardwired connection for charging and / or content manipulation using a standard connector and protocol, such as a Lightning connector, a universal serial bus (USB), or other similar connectors and protocols. The network interface 26 may include, for example, one or more interfaces for: a personal area network (PAN), such as an ultra-wideband (UWB) or Bluetooth network; a local area network (LAN) or a wireless local area network (WLAN), such as a network that adopts one of the IEEE 802.11x series of protocols (e.g., WI-FI); and / or a wide area network (WAN), such as any standard related to the Third Generation Partnership Project (3GPP), including, for example, a 3rd generation (3G) cellular network, a universal mobile telecommunications system (UMTS), a 4th generation (4G) cellular network, a long term evolution (LTE) cellular network, a long term evolution licensed assisted access (LTE-LAA) cellular network, a 5th generation (5G) cellular network and / or a new radio (NR) cellular network, a 6th generation (6G) or beyond 6G cellular network, a satellite network, a non-terrestrial network, etc. Specifically, the network interface 26 may include, for example, one or more interfaces for using a cellular communication standard that defines and / or implements a frequency range for wireless communication including a millimeter wave (mmWave) frequency range (e.g., 24.25 gigahertz (GHz) to 300 GHz) of the 5G specification. The network interface 26 of the electronic device 10 may allow communication via the aforementioned networks (e.g., 5G, Wi-Fi, LTE-LAA, etc.).

[0038] The network interface 26 may also include, for example, one or more interfaces for broadband fixed wireless access networks (e.g., WIMAX), mobile broadband wireless networks (mobile WIMAX), asynchronous digital subscriber lines (e.g., ADSL, VDSL), digital video broadcasting-terrestrial (DVB-H) networks and their extensions, DVB handheld (DVB-T) networks, ultra-wideband (UWB) networks, alternating current (AC) power lines, etc.

[0039] The power source 29 of the electronic device 10 may include any suitable power source, such as a rechargeable lithium polymer (Li-poly) battery and / or an alternating current (AC) power converter. According to the present disclosure, a battery pre-lithiation component is used to produce a battery, such as a secondary battery or a rechargeable battery (e.g., a lithium ion battery). The pre-lithiation component includes a lithium source (e.g., lithium metal) that is used as one or more electrodes separated from one or more anodes and one or more cathodes of the battery, or as a coating on the active material of the anode. The holes (e.g., openings) in the anode and cathode and the pores in one or more separators can allow the electrolyte to pass therethrough, which forms a channel that promotes the movement of Li+ ions associated with or corresponding to the lithium metal source around the interior of the housing of the battery pre-lithiation component. A redox reaction may occur between the Li+ ions and the anode, causing the active lithium to be transferred to the anode, thereby reducing, eliminating or otherwise preventing initial active lithium loss and / or local voltage non-uniformity. In this way, the currently disclosed systems and techniques can improve local voltage uniformity, reduce initial active lithium loss, and improve battery performance, stability, and energy density compared to conventional systems and techniques. Furthermore, the currently disclosed systems and techniques may be less expensive and less cumbersome than conventional techniques.These and other aspects of the disclosure are described in detail below with reference to the accompanying drawings.

[0040] Figure 2 4 is a schematic perspective view of one embodiment of a battery 40 (e.g., a lithium-ion battery) that includes a jelly roll 42 having at least one anode 44, at least one cathode 46, and at least one separator 48 (e.g., a porous separator) disposed between the anode 44 and the cathode 46. The jelly roll 42 and the electrolyte of the battery 40 are disposed in a housing 50. In addition, the jelly roll 42 is electrically coupled to a first terminal 52 (e.g., a positive terminal) of the battery 40 and a second terminal 54 (e.g., a negative terminal) of the battery 40, wherein the first terminal 52 and the second terminal 54 are configured to be coupled to a load to enable the battery 40 to power the load. Although the presently disclosed embodiments relate to a battery 40 including a jelly roll 42, it should be understood that similar techniques may be employed in the context of a battery having stacked electrodes. In addition, while the first terminal 52 and the second terminal 54 are illustrated as extending from or through a cover 56 (the cover is configured to be coupled to (or form a part of) the housing 50), other arrangements are possible.

[0041] In use Figure 2Before the battery 40 supplies power to the load, a pre-lithiation process is applied via a battery pre-lithiation assembly having most of the same components as the battery 40. As previously described, the battery pre-lithiation assembly and the corresponding process may be relatively inexpensive compared to conventional systems and techniques, and may reduce initial active lithium loss and improve local voltage uniformity, performance, stability, and energy density of the battery 40. Various embodiments of the battery pre-lithiation assembly and the process corresponding to the pre-lithiation assembly according to the present disclosure are described in detail below.

[0042] Figure 3 is a schematic diagram of various embodiments (eg, types) of a battery after pre-lithiation. For example, although certain aspects of the pre-lithiation described in detail below may be referred back to Figure 2 40, but it should be understood that some or all of such features may be used Figure 3 In some or all of the various embodiments or types of batteries exemplified in . Figure 3 For example, a cylindrical battery cell 40a, a pouch-shaped battery cell 40b, and a prismatic battery cell 40c are included. Figure 3 As shown, the cylindrical battery cell 40a may include a wound jelly roll 42a, the pouch battery cell 40b may include a flat-wound jelly roll 42b or a stacked electrode assembly 42c (in some cases referred to as a stacked jelly roll), and the prismatic battery cell 40c may include a flat-wound jelly roll 42b or a stacked electrode assembly 42c (in some cases referred to as a stacked jelly roll).

[0043] In certain embodiments employing a wound jelly roll 42a, the lithium metal of the pre-lithiation assembly and / or process described below may be coated on the anode of the wound jelly roll 42a. In certain embodiments employing a flat-wound jelly roll 42b, the lithium metal of the pre-lithiation assembly and / or process described below may be coated on the anode of the wound jelly roll 42b, on the center of the wound jelly roll 42b, or on opposite sides of the flat-wound jelly roll 42b. In certain embodiments employing a stacked electrode assembly 42c (e.g., a stacked jelly roll), the lithium metal of the pre-lithiation assembly and / or process described below may be coated on the anode or on opposite sides of the stacked electrode assembly 42c (e.g., a stacked jelly roll). It should be understood that some or all of the pre-lithiation features (e.g., components, methods, processes, etc.) described in detail below with reference to subsequent figures may be used Figure 3 However, for simplicity, reference will be made below to the battery 40 and the jelly roll 42.

[0044] Figure 4 It is used for production Figure 2Schematic cross-sectional view of one embodiment of a battery pre-lithiation assembly 70 of a battery 40, the battery pre-lithiation assembly 70 includes at least one lithium metal electrode, such as a first lithium metal electrode 82 and a second lithium metal electrode 84. The first lithium metal electrode 82 and the second lithium metal electrode 84 act as a Li+ ion source 85 for the battery pre-lithiation assembly 70 (e.g., after or while a voltage is applied to the lithium metal electrodes 82, 84). For example, the lithium metal electrodes 82, 84 may be dissolved as ions. Although the illustrated embodiment includes a first lithium metal electrode 82 and a second lithium metal electrode 84, in other embodiments, only one lithium metal electrode is used (e.g., extending around the jelly roll 42). In certain embodiments, reference numerals 82 and 84 may represent different portions of a lithium metal electrode. In addition, in certain embodiments, the anode 44, the cathode 46, or both face the lithium metal electrode or multiple lithium metal electrodes including the lithium metal electrode.

[0045] like Figure 4 As shown, the battery pre-lithiation component 70 includes Figure 2 4, including an anode 44, a cathode 46, and a separator 48. Anode 44 includes a first active material 72 disposed on (e.g., coated on) a first current collector foil 74 (e.g., having a copper material), and cathode 46 may include a second active material 76 disposed on (e.g., coated on) a second current collector foil 78 (e.g., having an aluminum material). In embodiments employing multiple instances of anode 44 and multiple instances of cathode 46 (such as in a stacked configuration), an anode current collector 77 is coupled to the first current collector foil 74 of each anode 44, and a cathode current collector 79 is coupled to the second current collector foil 78 of each cathode 46.

[0046] In addition, if Figure 4As shown, a first hole 86 is formed in the anode 44, and a second hole 88 is formed in the cathode 46. As shown, the first hole 86 and the second hole 88 may be aligned (e.g., relative to the height direction 90), or in other embodiments, they are not aligned. Each first hole 86 may include a first size dimension 92 (e.g., a first cross-sectional diameter) of approximately 35 microns to 1000 microns, 100 microns to 800 microns, 200 microns to 600 microns, or 300 microns to 400 microns. In addition, each second hole 88 may include a second size dimension 94 (e.g., a second cross-sectional diameter) of approximately 35 microns to 1000 microns, 100 microns to 800 microns, 200 microns to 600 microns, or 300 microns to 400 microns. In some embodiments, the first size dimension 92 of each first hole 86 may be similar (e.g., within + / -3%) or the same as the second size dimension 94 of each second hole 88. In other embodiments, the first size dimension 92 may substantially deviate from the second size dimension 94 (e.g., deviate by more than + / -3%). Generally, the first pores 86 and the second pores 88 are sized to enable the electrolyte to pass therethrough, thereby forming channels that facilitate the movement of Li+ ions 85 therethrough and around the battery pre-lithiation assembly 70, allowing the Li+ ions 85 to react with the anode 44 during the pre-lithiation process. As previously described, the lithium metal electrodes 82, 84 can be a source of Li+ ions 85. The pores of the separator 48 can also enable the electrolyte and Li+ ions 85 to pass therethrough / move therethrough.

[0047] like Figure 4 As shown, the first hole 86 in the anode 44 can be aligned with the second hole 88 in the cathode 46 along the height direction 90 of the battery pre-lithiation component 70. For example, as shown in FIG. Figure 4 As shown, a first straight line 95 may be drawn or passed through the first group of first holes 86 and second holes 88, wherein the first straight line 95 extends transversely to (e.g., perpendicular to) the height direction 90. Similarly, a second straight line 96 may be drawn or passed through the second group of first holes 86 and second holes 88, a third straight line 97 may be drawn or passed through the third group of first holes 86 and second holes 88, a fourth straight line 98 may be drawn or passed through the fourth group of first holes 86 and second holes 88, and so on, wherein the second straight line 96, the third straight line 97, and the fourth straight line 98 extend transversely to (e.g., perpendicular to) the height direction 90. Therefore, the lines 95, 96, 97, 98 that cross the holes 86, 88 may be parallel to each other. In other embodiments, the first hole 86 in the anode 44 may not be aligned with the second hole 88 in the cathode 46 along the height direction 90. For example, Figure 5 Is with Figure 4Schematic cross-sectional view of an embodiment of a battery pre-lithiation assembly 70 having the same or similar features as illustrated in , except that the first hole 86 in the anode 44 is not aligned with the second hole 88 in the cathode 46 along the height direction 90. Figure 5 , the misalignment of the first hole 86 and the second hole 88 makes it impossible to draw a straight line or to allow a straight line to pass through the holes 86, 88, similar to the above description of Figure 4 Those described.

[0048] Fig. 6A and Figure 6B For example Figure 4 or Figure 5 Schematic cross-sectional views of two embodiments of the layered structure 100 of the cathode 46 of the battery pre-lithiation assembly 70. It should be noted that similar layered structures can be used Figure 4 or Figure 5 The anode 44 of the battery pre-lithiation component 70. Fig. 6A and Figure 6B In the embodiment, the layered structure 100 includes a first cathode active material layer 102, a second cathode active material layer 104, a first metal (e.g., aluminum) foil layer 106, a second metal (e.g., aluminum) foil layer 108, and a plastic layer 110. In certain embodiments, the first metal foil layer 106, the second metal foil layer 108, and the plastic layer 110 may be formed together as described above and in Figure 4 or Figure 5 Second current collector foil 78 of cathode 46 is illustrated in FIG. First cathode active material layer 102 and second cathode active material layer 104 may include, for example, a metal oxide such as lithium cobalt oxide, lithium manganese oxide, lithium iron phosphate, or lithium nickel manganese cobalt oxide.

[0049] As shown, the first metal foil layer 106, the second metal foil layer 108, and the plastic layer 110 may be disposed between the first cathode active material layer 102 and the second cathode active material layer 104. In addition, the plastic layer 110 may be disposed between the first metal foil layer 106 and the second metal foil layer 108. As described above, Figure 4 or Figure 5 The anode 44 of the embodiment may adopt a similar layered structure, except that the anode active material layer (e.g., carbon-based material such as graphite and / or silicon) and the metal foil layer (e.g., copper) will use different materials. Figure 8 and Fig. 9 In the more detailed embodiments described above, the layered structure of anode 44 may also include a lithium metal coating on two anode active material layers.

[0050] As previously described, the cathode may include holes formed therethrough, such as Fig. 6A and Figure 6BThe holes 88 in the anode 44 may be formed via the same or similar mechanisms. Figure 6B In the embodiment, the layered structure 100 includes a curved foil (e.g., a first metal foil layer 106, a second metal foil layer 108, and a plastic layer 110) that covers the edge of the second cathode active material layer 104. Generally, at least Figure 6B The layered structure 100 of the cathode 46 in the embodiment can reduce or eliminate metal burrs and / or negative effects associated with metal burrs. It should be noted that other types of anodes and / or cathodes that do not include the layered structure 100 can be used in the battery pre-lithiation assembly described in the present disclosure. It should be noted that in some embodiments, copper or aluminum foil can be used, while in some other embodiments, mixed copper / aluminum foil can be used. In addition, it should be understood that Fig. 6A and Figure 6B The layered structure 100 in FIG. 1 is merely an example of a cathode 46, and other embodiments of a cathode 46 may be employed. Fig. 6A and Figure 6B A layered structure similar to the example in may be used for anode 44, but other embodiments of anode 44 may also be used.

[0051] Figure 7 yes Figure 4 or Figure 5 An embodiment of a battery pre-lithiation assembly 70 is produced along Figure 2 Schematic diagram of additional aspects of various stages of a battery. In stage (a), the jelly roll 42 and the lithium metal electrode 82 are disposed in an air pocket 132 (e.g., a housing). A voltage applicator 130 is employed to apply a voltage to the lithium metal electrode 82 via electrical connector 131 (and, in embodiments employing multiple lithium metal electrodes, to any other lithium metal electrodes employed in the battery pre-lithiation assembly 70 (such as Figure 4 and Figure 5 In stage (b), the gas pocket 132 is trimmed 134 via a cutter 136, the electrical connector 131 and the voltage applicator 130 are withdrawn, and the lithium metal electrode 82 (or multiple lithium metal electrodes) are removed from the assembly, thereby forming the battery 40 in stage (c). Degassing and side sealing can also be performed in stage (c), so that a portion of the gas pocket 132 illustrated at stages (a) and (b) forms the housing 50 of the battery 40.

[0052] Figure 8 It is used for production Figure 2Schematic cross-sectional view of one embodiment of a battery pre-lithiation assembly 140 of a battery 40, wherein the battery pre-lithiation assembly 140 includes a lithium metal layer 142 coated on the anode 44 (e.g., coated on the anode active material 72). Figure 8 The battery pre-lithiation component 140 includes Figure 4 and / or Figure 5 The battery pre-lithiation assembly 70 has many features that are the same or similar. However, Figure 8 The battery pre-lithiation assembly 140 includes a lithium metal layer 142 coated on the anode 44 (e.g., as a source of Li+ ions 85), rather than Figure 4 and / or Figure 5 The lithium metal electrodes 82 and 84 of the battery pre-lithiation component 70. Figure 8 In the embodiment, the lithium metal layer 142 may be depleted during the pre-lithiation process corresponding to the battery pre-lithiation component 140. Figure 4 and Figure 5 Different from the above, it is not necessary to remove lithium metal from the battery pre-lithiation component 140 to form Figure 2 of battery 40. It should be noted that Fig. 6A and / or Figure 6B The layered structure 100 of the cathode 46 can be used Figure 8 Similarly, a similar layered structure (but including a lithium metal layer 142 and a material corresponding to the anode) can be used for Figure 8 Anode 44.

[0053] like Figure 8 As shown, the first hole 86 in the anode 44 may be aligned with the second hole 88 in the cathode 46 along the height direction 90 of the battery pre-lithiation component 140. In other embodiments, the first hole 86 in the anode 44 may not be aligned with the second hole 88 in the cathode 46 along the height direction 90. For example, Fig. 9 Is with Figure 8 Schematic cross-sectional view of an embodiment of a battery pre-lithiation assembly 140 having the same or similar features as illustrated in , except that the first aperture 86 of the anode 44 is not aligned with the second aperture 88 in the cathode 46 along the height direction 90 .

[0054] Fig.10 is using Figure 4 Battery pre-lithiation component 70 or Figure 8 After the battery pre-lithiation component 140 Figure 2 A schematic cross-sectional view of one embodiment of a battery 40. As previously described, when using Figure 4 When the battery pre-lithiation component is 70, Figure 2 During the production of the battery 40, the lithium metal electrodes 82, 84 are removed from the battery pre-lithiation assembly 70. In contrast, when using Figure 8 When the battery pre-lithiation assembly 140 is used, the lithium metal coating 142 may be consumed during the pre-lithiation process, so that the lithium metal does not need to be removed during the production of the battery 40. That is, Figure 2 and Fig.10 The battery 40 can be Figure 4 Battery pre-lithiation component 70 or Figure 8 The battery pre-lithiation component 140 is produced.

[0055] like Fig.10 As shown, the first hole 86 in the anode 44 may be aligned with the second hole 88 in the cathode 46 along the height direction 90 of the battery 40. In other embodiments, the first hole 86 in the anode 44 may not be aligned with the second hole 88 in the cathode 46 along the height direction 90. For example, Fig.11 Is with Fig.10 A schematic cross-sectional view of an embodiment of a battery 40 having the same or similar features as illustrated in FIG. Figure 5 Battery pre-lithiation component 70 or Fig. 9 ), except that the first hole 86 in the anode 44 is not aligned with the second hole 88 in the cathode 46 along the height direction 90.

[0056] Fig.12 This is an example of Figure 4 or Figure 5 Production of battery pre-lithiation components 70 Figure 2 40 . In the illustrated embodiment, the method 150 includes forming an anode and a cathode (block 152). For example, as previously described, the anode can include a current collector foil and an active material disposed on opposite sides of the current collector foil. In some embodiments, the current collector foil includes two layers disposed on opposite sides of a plastic layer. The cathode can be similarly formed, except that the active material of the anode is different from the active material of the cathode, and the material of the current collector foil of the anode is different from the material of the current collector foil of the cathode, as previously described.

[0057] The method 150 also includes perforating the anode with a first hole and the cathode with a second hole (block 154). As previously described, laser perforation or mechanical drilling may be used to create (eg, perforate) the first hole in the anode and create (eg, perforate) the second hole in the cathode.

[0058] The method 150 also includes disposing an anode, a cathode, a separator (e.g., a porous separator), at least one lithium metal electrode, and an electrolyte in a housing (block 156). As previously described, in certain embodiments, the anode, cathode, and separator may form a jelly roll, and the jelly roll may be disposed in the housing. In some embodiments, a first lithium metal electrode and a second lithium metal electrode may be disposed in the housing with the jelly roll. In other embodiments, only one lithium metal electrode is disposed in the housing with the jelly roll. The electrolyte may pass through the first and second holes in the anode and cathode, respectively, to form a channel that facilitates the movement of Li+ ions around the housing, as described below.

[0059] The method 150 also includes applying a voltage to at least one lithium metal electrode to initiate a pre-lithiation process (box 158). For example, during the pre-lithiation process, Li+ ions may be distributed from at least one lithium metal electrode and move around the shell through the above-mentioned channels. In addition, the redox reaction between the Li+ ions and the anode can transfer active lithium to the anode, which reduces or mitigates the initial active lithium loss that would otherwise occur during the cycle stage (e.g., early cycle stage) of the battery. The method 150 also includes removing at least one lithium metal electrode from the shell (e.g., after completing the pre-lithiation process) (box 160). Through the above-mentioned method 150, battery performance, stability, energy density and / or voltage uniformity can be improved at a relatively inexpensive cost (e.g., compared to traditional systems and technologies).

[0060] Fig.13 This is an example of Figure 7 or Figure 8 Production of battery pre-lithiation components 140 Figure 2 4. FIG. 2 is a process flow diagram of one embodiment of a method 200 for forming a battery 40 of the type shown in FIG. 2. In the illustrated embodiment, the method 200 includes forming an anode and a cathode (block 202). Fig.13 Block 202 of method 200 may be similar to that described in more detail above. Fig.12 The same or similar to block 152 of method 150 in FIG.

[0061] The method 200 also includes coating the anode with lithium metal (block 204). For example, a first lithium metal coating can be disposed on the first anode active material layer, and a second lithium metal coating can be disposed on the second anode active material layer. The method 200 also includes perforating the anode with a first hole and the cathode with a second hole (block 206). Fig.13 Block 206 of method 200 may be associated with Fig.12 The method may be the same or similar to block 154 in method 150 of FIG.

[0062] The method 200 also includes disposing an anode, a cathode, a separator (eg, a porous separator), and an electrolyte in a housing (block 208 ). Fig.13Block 208 of method 200 may be associated with Fig.12 The method 150 is the same as or similar to block 156 except that Fig.13 The method 200 in does not include disposing at least one lithium metal electrode in a housing separately from the anode and cathode. Fig.13 In method 200, the lithium metal coating on the anode serves as a lithium source for the pre-lithiation process.

[0063] The method 200 also includes allowing (block 210) the electrolyte to age for a period of time (eg, 1 to 3 days) to initiate and / or perform a pre-lithiation process. Fig.13 In certain embodiments of method 200, it is not necessary to apply a voltage to the lithium metal coating on the anode. Fig.12 The method is 150 different, in Fig.13 In certain embodiments of the method 200, it is not necessary to remove the lithium metal from the housing. In fact, the lithium metal coating disposed on the anode may be consumed by or during the pre-lithiation process.

[0064] Fig.14 is an example of an embodiment according to the present disclosure Figure 7 or Figure 8 The battery pre-lithiation component 140 is produced, for example Figure 2 40. In the illustrated embodiment, the method 250 is a process flow diagram of the method 250 of the battery 40. Fig.13 The method 200 is similar or identical to the method 200, except that Fig.14 In method 250, the pores may be disposed in the anode before the lithium metal coating is disposed on the anode. For example, Fig.14 Box 252 in Fig.10 The same as (or similar to) block 202 in Fig.14 Box 258 in Fig.13 The same as (or similar to) block 208 in Fig.14 The box 260 in Fig.13 The same (or similar) as block 210 in FIG. Fig.14 In the method 250, the first hole is formed on the anode and the second hole is formed on the cathode (block 254), and then the anode is coated with lithium metal (block 256). In this way, the lithium metal coating can react with the anode and the electrolyte, and after the electrolyte is injected, the hole will open by itself.

[0065] It should be pointed out that in Fig.12 , Fig.13 and Fig.14 In methods 150, 200 and 250, the Fig.12 , Fig.13 and Fig.14The steps (e.g., blocks) may be performed in a suitable order other than the order illustrated in and / or described above. In addition, other steps and / or techniques (e.g., steps and / or techniques described in other areas of the present disclosure) may be included in such methods 150, 200. For example, other steps may include electrolyte injection, heat aging, other aspects of fixture forming (e.g., in the case of a battery forming a solid electrolyte interphase or SEI), shell degassing, etc.

[0066] The specific embodiments described above have been shown by way of example, and it should be understood that these embodiments are susceptible to various modifications and alternative forms. It should also be understood that the claims are not intended to be limited to the specific forms disclosed, but are intended to cover all modifications, equivalents and alternatives that fall within the spirit and scope of the present disclosure.

[0067] The technology presented and claimed herein is cited and applied to specific examples of a physical and practical nature that significantly improves the art and is therefore not abstract, intangible, or purely theoretical. In addition, if any claim appended at the end of this specification contains one or more elements designated as "means for [performing] [the function] ..." or "steps for [performing] [the function] ...", it is intended that such elements should be interpreted in accordance with 35 U.S.C. 112(f). However, for any claim containing elements designated in any other manner, it is intended that such elements should not be interpreted in accordance with 35 U.S.C. 112(f).

[0068] It is understood that the use of personally identifiable information should be subject to privacy policies and practices that are generally recognized to meet or exceed industry or government requirements for maintaining user privacy. In particular, personally identifiable information data should be managed and processed to minimize the risk of unintentional or unauthorized access or use, and the nature of the authorized use should be clearly stated to users.

Claims

1. A battery pre-lithiation component, the battery pre-lithiation component comprising: Lithium metal electrode; an anode comprising a first plurality of pores configured to enable passage of an electrolyte therethrough and configured to enable movement of Li+ ions associated with the lithium metal electrode during a pre-lithiation process; and a cathode comprising a second plurality of pores configured to enable the electrolyte to pass therethrough and configured to enable movement of the Li+ ions associated with the lithium metal electrode during the pre-lithiation process.

2. The battery pre-lithiation assembly according to claim 1, wherein: Each first hole in the first plurality of holes has a first size between 35 microns and 1000 microns; and The second size of each second hole in the second plurality of holes is between 35 microns and 1000 microns.

3. The battery pre-lithiation component according to claim 1, comprising a separator disposed between the anode and the cathode, wherein the separator comprises a plurality of pores.

4. The battery pre-lithiation assembly according to claim 3, wherein the battery pre-lithiation assembly comprises a jelly roll, and the jelly roll comprises the anode, the cathode and the separator.

5. The battery pre-lithiation assembly according to claim 1, wherein: The anode comprises a first layered structure having a first anode active material layer, a second anode active material layer, a first copper layer disposed between the first anode active material layer and the second anode active material layer, a second copper layer disposed between the first anode active material layer and the second anode active material layer, and a first plastic layer disposed between the first copper layer and the second copper layer; and The cathode includes a second layered structure having a first cathode active material layer, a second cathode active material layer, a first aluminum layer disposed between the first cathode active material layer and the second cathode active material layer, a second aluminum layer disposed between the first cathode active material layer and the second cathode active material layer, and a second plastic layer disposed between the first aluminum layer and the second aluminum layer. 6 . The battery pre-lithiation assembly according to claim 1 , wherein the anode, the cathode, or both face the lithium metal electrode or a plurality of lithium metal electrodes including the lithium metal electrode.

7. The battery pre-lithiation assembly according to claim 1, comprising an additional lithium metal electrode, wherein: The anode and the cathode are disposed between the lithium metal electrode and the additional lithium metal electrode; The first plurality of pores is configured to enable movement of additional Li+ ions associated with the additional lithium metal electrode during the pre-lithiation process; and The second plurality of pores is configured to enable movement of additional Li+ ions associated with the additional lithium metal electrode during the pre-lithiation process.

8. The battery pre-lithiation assembly of claim 1, wherein the lithium metal electrode is configured to be removed from the battery pre-lithiation assembly after the pre-lithiation process.

9. The battery pre-lithiation assembly of claim 1, wherein the anode comprises a silicon-based active material.

10. The battery pre-lithiation assembly according to claim 1, wherein: The anode includes a first current collector foil and a first active material coated on the first current collector foil; and The cathode includes a second current collector foil and a second active material coated on the second current collector foil.

11. A battery pre-lithiation component, the battery pre-lithiation component comprising: an anode coated with lithium metal and having a first plurality of pores configured to enable passage of an electrolyte therethrough and configured to enable movement of Li+ ions associated with the lithium metal during a pre-lithiation process; and A cathode having a second plurality of pores configured to enable the electrolyte to pass therethrough and configured to enable movement of the Li+ ions associated with the lithium metal during the pre-lithiation process.

12. The battery pre-lithiation assembly of claim 11, wherein the anode comprises an active material, and the lithium metal is coated on the active material.

13. The battery pre-lithiation assembly of claim 12, wherein the active material comprises silicon. 14 . The battery pre-lithiation assembly of claim 11 , comprising a separator disposed between the anode and the cathode, wherein the separator comprises a plurality of pores. 15 . The battery pre-lithiation assembly according to claim 14 , comprising a jelly roll, wherein the jelly roll comprises the anode, the cathode and the separator.

16. The battery pre-lithiation assembly of claim 11, wherein the lithium metal is configured to be depleted during the pre-lithiation process.

17. The battery pre-lithiation assembly according to claim 11, wherein: Each first hole in the first plurality of holes has a first size between 35 microns and 1000 microns; and The second size of each second hole in the second plurality of holes is between 35 microns and 1000 microns.

18. The battery pre-lithiation assembly according to claim 11, wherein: The anode comprises a first layered structure having a first anode active material layer, a second anode active material layer, a first copper layer disposed between the first anode active material layer and the second anode active material layer, a second copper layer disposed between the first anode active material layer and the second anode active material layer, and a first plastic layer disposed between the first copper layer and the second copper layer; and The cathode includes a second layered structure having a first cathode active material layer, a second cathode active material layer, a first aluminum layer disposed between the first cathode active material layer and the second cathode active material layer, a second aluminum layer disposed between the first cathode active material layer and the second cathode active material layer, and a second plastic layer disposed between the first aluminum layer and the second aluminum layer. 19 . The battery pre-lithiation assembly of claim 18 , wherein the lithium metal is coated on the first anode active material layer and the second anode active material layer.

20. A method of forming a battery cell, the method comprising: disposing a lithium metal electrode in the housing; disposing an anode in the housing; disposing a cathode in the housing; as well as An electrolyte is disposed in the shell such that the electrolyte passes through a first plurality of pores in the anode and a second plurality of pores in the cathode to form channels that enable Li+ ions to move within the shell and react with the anode during a pre-lithiation process, wherein the Li+ ions are associated with the lithium metal electrode.

21. The method of claim 20, comprising applying a voltage to the lithium metal electrode to initiate the pre-lithiation process.

22. The method of claim 20, comprising removing the lithium metal electrode from the housing after the pre-lithiation process.

23. A method of forming a battery cell, the method comprising: coating the anode with lithium metal; Disposing the anode in a housing; disposing a cathode in the housing; as well as An electrolyte is disposed in the shell such that the electrolyte passes through a first plurality of pores in the anode and a second plurality of pores in the cathode to form channels that enable Li+ ions to move within the shell and react with the anode during a pre-lithiation process, wherein the Li+ ions are associated with the lithium metal.

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