Battery configuration for hybrid or electric vehicle

Abstract

The invention provides a battery configuration for a hybrid vehicle or an electric vehicle. A battery includes a cathode plate, an anode plate, and an electrolyte. The cathode plate defines a first dome-shaped array of notches. The anode plate defines a second dome-shaped array of notches. The first array of domed notches is positioned opposite the second array of domed notches and faces the second array of domed notches. And the electrolyte is arranged between the negative plate and the positive plate. The electrolyte has a dome-shaped protruding region extending outwardly therefrom. Each dome-shaped protruding region in a first subset of the dome-shaped protruding regions extends into one of the dome-shaped notches in the first array of dome-shaped notches and contacts the cathode within the one of the dome-shaped notches. Each domed projection region in a second subset of the domed projection regions extends into one of the domed notches in the second array of domed notches and contacts the anode within the one of the domed notches.

Description

Technical Field

[0001] The present disclosure relates to hybrid / electric vehicles and batteries for hybrid / electric vehicles. Background Art

[0002] Hybrid / electric vehicles may be propelled by an electric motor that draws power from a battery. Summary of the invention

[0003] A battery includes a cathode plate, an anode plate, and an electrolyte. The cathode plate defines a first dome-shaped recess array. The anode plate defines a second dome-shaped recess array. The first dome-shaped recess array is positioned opposite to and facing the second dome-shaped recess array. The electrolyte is disposed between the cathode plate and the anode plate. The electrolyte has a dome-shaped protruding area extending outwardly therefrom. Each dome-shaped protruding area in a first subset of the dome-shaped protruding areas extends into one of the dome-shaped recesses in the first dome-shaped recess array and contacts the cathode in the one dome-shaped recess. Each dome-shaped protruding area in a second subset of the dome-shaped protruding areas extends into one of the dome-shaped recesses in the second dome-shaped recess array and contacts the anode in the one dome-shaped recess.

[0004] A battery includes a cathode, an anode, and an electrolyte. The cathode defines a first set of notches. The anode defines a second set of notches. The notches in the first set of notches and the second set of notches are partially elliptical. The first set of notches is positioned opposite to and facing the second set of notches. The electrolyte is disposed between the cathode and the anode. The electrolyte has a protruding area extending outward from a first opposing surface and a second opposing surface. Each of the protruding areas extending from the first opposing surface further extends into one of the notches in the first set of notches and contacts the cathode in the one notch. Each of the protruding areas extending from the second opposing surface further extends into one of the notches in the second set of notches and contacts the anode in the one notch.

[0005] A battery includes a positive electrode, a negative electrode, and a solid electrolyte. The positive electrode defines a first set of notches. The negative electrode defines a second set of notches. The first set of notches is positioned opposite to and facing the second set of notches. The solid electrolyte is disposed between the positive electrode and the negative electrode. The solid electrolyte has a circular protruding area extending outwardly from a first surface and a second surface. Each circular protruding area extending from the first surface further extends into one of the notches in the first set of notches. Each protruding area extending from the second surface further extends into one of the notches in the second set of notches. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 is a schematic diagram of a representative powertrain system of an electric vehicle;

[0007] Figure 2 is a schematic diagram of a solid-state battery;

[0008] Figure 3 including a contour plot depicting a hydrostatic pressure distribution of the solid-state battery relative to a solid-state battery having a conventional design;

[0009] Figure 4 including a contour plot depicting the principal stress distribution of the solid-state battery relative to a solid-state battery having a conventional design;

[0010] Figure 5 including a contour plot depicting electrode current density distribution of the solid-state battery relative to a solid-state battery of conventional design at the beginning of constant current charging; and

[0011] Figure 6 Included are contour plots depicting the electrode current density distribution of the solid-state battery relative to a solid-state battery of conventional design at 50% lithiation state in the cathode during constant current charging. DETAILED DESCRIPTION

[0012] Embodiments of the present disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples and that other embodiments may take various and alternative forms. The drawings are not necessarily drawn to scale; some features may be enlarged or minimized to show the details of a particular component. Therefore, the specific structural details and functional details disclosed herein should not be interpreted as limiting, but only as a representative basis for teaching those skilled in the art to adopt the embodiments in different ways. As will be understood by those of ordinary skill in the art, the various features shown and described with reference to any one of the drawings may be combined with the features shown in one or more other drawings to produce embodiments that are not explicitly shown or described. The combination of features shown provides representative embodiments for typical applications. However, for specific applications or implementations, various combinations and modifications of features consistent with the teachings of the present disclosure may be desired.

[0013] refer to Figure 1 , showing a schematic diagram of an electric vehicle 10 according to an embodiment of the present disclosure. Figure 1 Representative relationships between components are shown. The physical layout and orientation of the components within the vehicle may vary. The electric vehicle 10 includes a powertrain 12. The powertrain 12 includes an electric machine, such as an electric motor / generator (M / G) 14, that drives a transmission (or gearbox) 16. More specifically, the M / G 14 may be rotatably connected to an input shaft 18 of the transmission 16. The transmission 16 may be placed in PRNDSL (parking, reverse, neutral, driving, sports, low gear) via a transmission gear selector (not shown). The transmission 16 may have a fixed gear transmission relationship that provides a single gear ratio between the input shaft 18 and the output shaft 20 of the transmission 16. A torque converter (not shown) or a starting clutch (not shown) may be provided between the M / G 14 and the transmission 16. Alternatively, the transmission 16 may be a multi-speed ratio automatic transmission. An associated traction battery 22 is configured to deliver power to or receive power from the M / G 14.

[0014] The M / G 14 is a drive source for the electric vehicle 10, which is configured to propel the electric vehicle 10. The M / G 14 can be implemented by any of a variety of types of electric machines. For example, the M / G 14 can be a permanent magnet synchronous motor. The power electronics 24 regulates the direct current (DC) power provided by the battery 22 according to the requirements of the M / G 14, as will be described below. For example, the power electronics 24 can provide three-phase alternating current (AC) to the M / G 14.

[0015] If the transmission 16 is a multi-ratio automatic transmission, the transmission 16 may include a gear set (not shown) that is selectively placed in different gear ratios by selectively engaging friction elements such as clutches and brakes (not shown) to establish a desired plurality of discrete or stepped gear ratios. The friction elements may be controlled by a shift schedule that connects and disconnects certain elements of the gear set to control the gear ratio between the transmission output shaft 20 and the transmission input shaft 18. The transmission 16 is automatically shifted from one gear ratio to another by an associated controller, such as a powertrain control unit (PCU), based on various vehicle and environmental conditions. Power and torque from the M / G 14 may be delivered to and received by the transmission 16. The transmission 16 then provides the powertrain output power and torque to the output shaft 20.

[0016] It should be understood that the hydraulically controlled transmission 16, which may be coupled to a torque converter (not shown), is merely one example of a gearbox or transmission device; any multi-ratio gearbox that accepts input torque from a power source (e.g., M / G 14) and then provides torque to an output shaft (e.g., output shaft 20) at different gear ratios is acceptable for use with embodiments of the present disclosure. For example, the transmission 16 may be implemented by an automated mechanical (or manual) transmission (AMT) that includes one or more servomotors to translate / rotate a shift fork along a shift rail to select a desired gear ratio. As is generally understood by those of ordinary skill in the art, an AMT may be used, for example, in applications with higher torque requirements.

[0017] like Figure 1 As shown in the representative embodiment of FIG. 1 , the output shaft 20 is connected to a differential 26. The differential 26 drives a pair of drive wheels 28 via respective axles 30 connected to the differential 26. The differential 26 transmits approximately equal torque to each wheel 28, while allowing slight speed differences, such as when the vehicle is turning. Different types of differentials or similar devices can be used to distribute torque from the drivetrain to one or more wheels. In some applications, the torque distribution can vary depending on, for example, a specific operating mode or operating condition.

[0018] The powertrain system 12 also includes an associated controller 32, such as a powertrain control unit (PCU). Although shown as one controller, the controller 32 may be part of a larger control system and may be controlled by various other controllers throughout the vehicle 10, such as a vehicle system controller (VSC). Therefore, it should be understood that the powertrain control unit 32 and one or more other controllers may be collectively referred to as a "controller" that controls various actuators in response to signals from various sensors to control functions such as operating the M / G 14 to provide wheel torque or charging the battery 22, selecting or scheduling transmission shifts, etc. The controller 32 may include a microprocessor or central processing unit (CPU) that communicates with various types of computer-readable storage devices or media. The computer-readable storage devices or media may include, for example, volatile and non-volatile storage devices in read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM is a persistent or non-volatile memory that can be used to store various operating variables when the CPU is powered off. The computer readable storage device or medium may be implemented using any of a number of known memory devices such as a PROM (programmable read-only memory), EPROM (electrical PROM), EEPROM (electrically erasable PROM), flash memory, or any other electrical, magnetic, optical, or combination memory device capable of storing data, some of which represents executable instructions used by the controller to control the engine or vehicle.

[0019] The controller 32 communicates with various vehicle sensors and actuators via an input / output (I / O) interface (including input channels and output channels), which may be implemented as a single integrated interface that provides various raw data or signal conditioning, processing and / or conversion, short circuit protection, etc. Alternatively, one or more dedicated hardware or firmware chips may be used to condition and process specific signals before supplying them to the CPU. Figure 1 As generally shown in the representative embodiment of FIG. 1 , the controller 32 may transmit signals to the M / G 14, the battery 22, the transmission 16, the power electronics 24, and other components of the powertrain 12 that may be included but not shown. Figure 114 and the transmission 16). Although not explicitly shown, one of ordinary skill in the art will recognize the various functions or components within each of the subsystems identified above that may be controlled by the controller 32. Representative examples of parameters, systems, and / or components that may be directly or indirectly actuated using control logic and / or algorithms executed by the controller 32 include front end accessory drive (FEAD) components such as an alternator, an air conditioning compressor, battery charging or discharging, regenerative braking, M / G 14 operation, clutch pressure of the transmission gearbox 16, or any other clutch as part of the powertrain 12, etc. For example, sensors transmitting input through the I / O interface can be used to indicate wheel speed (WS1, WS2), vehicle speed (VSS), coolant temperature (ECT), accelerator pedal position (PPS), ignition switch position (IGN), ambient air temperature (e.g., ambient air temperature sensor 33), transmission gear, gear ratio or mode, transmission oil temperature (TOT), transmission input and output speeds, speed reduction or shift mode (MDE), battery temperature, voltage, current or state of charge (SOC).

[0020] The control logic or functions performed by the controller 32 can be represented by a flowchart or similar diagram in one or more of the accompanying drawings. These drawings provide representative control strategies and / or logic that can be implemented using one or more processing strategies (such as event-driven, interrupt-driven, multi-tasking, multi-threading, etc.). Thus, the various steps or functions shown can be performed in the order shown, in parallel, or omitted in some cases. Although not always explicitly shown, it will be recognized by those of ordinary skill in the art that one or more of the steps or functions shown can be repeatedly performed according to the specific processing strategy used. Similarly, the order of processing is not necessarily required to achieve the features and advantages described herein, but is provided for ease of illustration and description. The control logic can be implemented primarily in software executed by a microprocessor-based vehicle and / or powertrain controller (such as controller 32). Of course, depending on the specific application, the control logic can be implemented in software, hardware, or a combination of software and hardware in one or more controllers. When implemented in software, the control logic can be provided in one or more computer-readable storage devices or media, which store data representing codes or instructions executed by a computer to control a vehicle or a vehicle subsystem. The computer-readable storage device or medium may include one or more of several known physical devices that use electrical, magnetic, and / or optical storage to hold executable instructions and associated calibration information, operating variables, and the like.

[0021] The driver of the vehicle uses an accelerator pedal 34 to provide the desired torque, power or drive command for propelling the vehicle to the powertrain 12 (or more specifically, the M / G 14). Typically, depressing and releasing the accelerator pedal 34 generates an accelerator pedal position signal, which can be interpreted by the controller 32 as a need for increased power or reduced power, respectively. The driver of the vehicle also uses a brake pedal 36 to provide a desired braking torque for decelerating the vehicle. Typically, depressing and releasing the brake pedal 36 generates a brake pedal position signal, which can be interpreted by the controller 32 as a need to reduce the vehicle speed. Based on inputs from the accelerator pedal 34 and the brake pedal 36, the controller 32 commands torque and / or power to the M / G 14 and the friction brake 38. The controller 32 also controls the timing of shifting in the transmission 16.

[0022] The M / G 14 can function as a motor and provide driving force for the powertrain 12. To drive the vehicle with the M / G 14, the traction battery 22 transmits stored electrical energy to the power electronics 24, which may include, for example, inverter and rectifier circuits, via the wiring 40. The inverter circuit of the power electronics 24 can convert the DC voltage from the battery 22 into an AC voltage to be used by the M / G 14. The rectifier circuit of the power electronics 24 can convert the AC voltage from the M / G 14 into a DC voltage to be stored by the battery 22. The controller 32 commands the power electronics 24 to convert the voltage from the battery 22 into an AC voltage provided to the M / G 14 to provide positive or negative torque to the input shaft 18.

[0023] The M / G 14 may also function as a generator and convert kinetic energy from the powertrain 12 into electrical energy for storage in the battery 22. More specifically, the M / G 14 may function as a generator during regenerative braking events, in which torque and rotational (or kinetic) energy from the rotating wheels 28 are transferred back through the transmission 16 and converted into electrical energy for storage in the battery 22.

[0024] It should be understood that the vehicle configurations described herein are exemplary only and are not intended to be limiting. Other electric vehicle or hybrid electric vehicle configurations should be interpreted as disclosed herein. Other electric or hybrid vehicle configurations may include, but are not limited to, series hybrid vehicles, parallel hybrid vehicles, series-parallel hybrid vehicles, plug-in hybrid electric vehicles (PHEVs), fuel cell hybrid vehicles, battery-operated electric vehicles (BEVs), or any other vehicle configuration known to those of ordinary skill in the art.

[0025] In a hybrid configuration including an internal combustion engine such as a gasoline, diesel or natural gas powered engine or a fuel cell, the controller 32 may be configured to control various parameters of such an internal combustion engine. Representative examples of internal combustion engine parameters, systems and / or components that may be directly or indirectly actuated using control logic and / or algorithms executed by the controller 32 include fuel injection timing, rate and duration, throttle position, spark plug firing timing (for spark ignition engines), intake / exhaust valve timing and duration, etc. Sensors that transmit inputs from such an internal combustion engine to the controller 32 via an I / O interface may be used to indicate turbocharger boost pressure, crankshaft position (PIP), engine speed (RPM), intake manifold pressure (MAP), throttle position (TP), exhaust oxygen (EGO) or other exhaust constituent concentrations or presence, intake air flow (MAF), etc.

[0026] It should be understood that Figure 1 The schematic diagrams shown in are representative only and are not intended to be limiting. Other configurations are contemplated without departing from the scope of the present disclosure. For example, the vehicle powertrain 12 may be configured to deliver power and torque to one or both of the front wheels, rather than the rear wheels 28 shown.

[0027] Solid-state batteries (SSBs) have been considered as an alternative for electric and hybrid vehicles because they employ relatively stable solid electrolytes. However, SSBs are generally limited in charging rate due to the slower diffusion of lithium (Li) ions in the solid electrolyte when compared to liquid electrolytes.

[0028] Previous methods using SSBs were limited to patterned electrodes (i.e., cathodes and anodes) having grooves in a three-dimensional rectangular shape with sharp edges. Although such methods can achieve fast charging by reducing the Li ion diffusion path when compared to a flat interface, the mechanical stability of the structure may be limited and potential lithium plating may occur. Lithium plating may cause interface problems, short circuits, and / or thermal runaway. First, a high voltage of typically more than 100 MPa is applied to each SSB component and the entire battery cell during the manufacturing process, which may include calendering, lamination, and battery cell assembly to densify the solid electrode so as to achieve better contact to enhance the ionic conductivity between multiple solid components. Moreover, SSBs are typically operated under stacking pressure to ensure interfacial contact between two different solid components. Even if the stacking pressure is less than the pressure during manufacturing, the stacking pressure during repeated cycles may affect mechanical stability and battery performance over a period of time. Therefore, the patterned structure should be mechanically strong enough to withstand high pressure and maintain its structure. Secondly, the uniform current density distribution is disturbed by the pattern. In addition to the original patterned structure, many sharp edges may be additionally formed at the interface if fractured under high voltage during fabrication. The current density will be localized at each edge of the rectangular pattern and at each edge of the potential cracks. The local current density will cause local lithium precipitation, causing problems. In summary, mechanically stable patterned structures in SSBs should be developed to achieve fast charging capabilities and increased stability.

[0029] Three-dimensional dome-shaped patterned electrodes for SSBs will exhibit better mechanical strength and fast charging capabilities compared to typical rectangular patterns. First, this design has a mechanically stable interface, which is critical during the SSB manufacturing process which is at high voltage. For example, this design will dissipate the pressure applied during the SSB manufacturing process, thereby eliminating mechanical issues in the structure and eliminating the formation of sharp edges caused by mechanical issues. In addition, this design achieves fast charging by utilizing a large interface area and fast charge / ion transfer without the need for locally high current density. The current density distribution in this design will be more uniform without the significant localization of current density which is known to be the root cause of lithium plating. This design was studied using physics-based modeling and compared to rectangular-shaped patterns to demonstrate better mechanical strength and more uniform current density distribution (see Figures 3 to 6 ).

[0030] refer to Figure 2, the battery 22 is shown in further detail. The battery 22 includes a cathode 42 and an anode 44. The cathode 42 and the anode 44 can each be formed as a plate. The cathode 42 can refer to a negatively charged electrode, while the anode 44 can refer to a positively charged electrode. The cathode 42 defines a first array or first group of notches 46. The anode 44 defines a second array or second group of notches 48. The notches from each of the first group of notches 46 and the second group of notches 48 can be circular, dome-shaped, or partially elliptical. More specifically, when viewed from one side of the battery 22 (e.g., as shown in FIG. 2 ), the notches are shaped like a circle, a dome, or a partially elliptical shape. Figure 2 ), the partial elliptical shape of the first set of notches 46 and the second set of notches 48 may appear as a partial ellipse (e.g., a half-ellipse) and when viewed from the top or bottom of the battery 22 (e.g., when viewed along the direction shown in FIG. Figure 2 When viewed in the direction 50 or the direction 53 shown, it can appear as a whole ellipse or a circle.

[0031] The first set of notches 46 is positioned opposite and facing the second set of notches 48. An electrolyte 52 is disposed between the cathode 42 and the anode 44. The electrolyte 52 may be a solid electrolyte. The electrolyte 52 has a protruding area 54 extending outwardly from a first opposing surface 56 and a second opposing surface 58 of the electrolyte 52. The protruding area 54 may also be circular, dome-shaped, or partially elliptical.

[0032] Each protruding region 54 within the first subset of protruding regions 60 extends into one of the recesses in the first set of recesses 46 and contacts the cathode 42 within the one recess. The first subset of protruding regions 60 may more specifically refer to a group of protruding regions 54 extending from the first surface 56 of the electrolyte 52. More specifically, each recess within the first set of recesses 46 may be completely filled or occupied by one of the protruding regions 54 in the first subset of protruding regions 60. In other words, each protruding region 54 within the first subset of protruding regions 60 occupies the entire corresponding recess (e.g., one of the recesses within the first set of recesses 46).

[0033] Each protruding region 54 within the second subset of protruding regions 62 extends into one of the recesses in the second set of recesses 48 and contacts the anode 44 within the one recess. The second subset of protruding regions 62 may more specifically refer to a group of protruding regions 54 extending from the second surface 58 of the electrolyte 52. More specifically, each recess within the second set of recesses 48 may be completely filled or occupied by one of the protruding regions 54 in the second subset of protruding regions 62. In other words, each protruding region 54 within the second subset of protruding regions 62 occupies the entire corresponding recess (e.g., one of the recesses within the second set of recesses 48).

[0034] The first set of recesses 46, the second set of recesses 48, and the protruding areas 54 are shown arranged as Figure 2 However, it should be understood that the first set of recesses 46, the second set of recesses 48 and the protruding area 54 can be arranged as Figure 2 Extends from left to right and becomes Figure 2 A two-dimensional array of images. In addition, Figure 2 The number of notches in the first set of notches 46, the number of notches in the second set of notches 48, and the number of protruding areas 54 are for illustration purposes only. The first set of notches 46, the second set of notches 48, and the protruding areas 54 may include any number of notches and protruding areas arranged in an array.

[0035] Cell 22 also includes a cathode current collector 64 disposed on an opposite side of cathode 42 relative to electrolyte 52 and an anode current collector 65 disposed on an opposite side of anode 44 relative to electrolyte 52 .

[0036] Each protruding area 54 and each notch (e.g., notches within the first group of notches 46 and / or the second group of notches 48) have a first dimension 66 (e.g., width) and a second dimension 68 (e.g., height). The ratio of the first dimension 66 to the second dimension 68 can be in a range between 1 and 10. Each protruding area 54 and each notch (e.g., notches within the first group of notches 46 and / or the second group of notches 48) are spaced apart from each other by a third dimension 70 (e.g., spatial distance). The ratio of the first dimension 66 to the third dimension 70 can be in a range between 0.1 and 10. Each protruding area 54 in the first subset of protruding areas 60 forms an aligned pair with one of the protruding areas 54 in the second subset of protruding areas 62. More specifically, the vertices 72 of the protruding areas 54 within each aligned pair can be aligned along the direction 50, the direction 53, or vertically.

[0037] The protruding regions 54 within each alignment pair extend outwardly from the central region 74 of the electrolyte 52 in opposite directions (e.g., the first direction 50 and the second direction 53). The cathode 42 has a fourth dimension 76 (e.g., height) and the central region 74 has a fifth dimension 78 (e.g., height). The ratio of the fourth dimension 76 to the fifth dimension 78 can be in the range of 1 to 20. The anode 44 has a sixth dimension 80 (e.g., height). The ratio of the sixth dimension 80 to the fifth dimension 78 can be in the range of 1 to 20. The cathode current collector 64 has a seventh dimension 82 (e.g., height). The ratio of the fourth dimension 76 to the seventh dimension 82 can be in the range of 0.1 to 20. The anode current collector 65 has an eighth dimension 84 (e.g., height). The ratio of the eighth dimension 84 to the sixth dimension 80 can be in the range of 0.1 to 20.

[0038] Physics-based modeling is used to study the dome-shaped structure of a single "cell" or section 100 of a solid-state battery design (e.g., battery 22) described herein. Section 100 includes at least a portion of cathode 42, anode 44, solid electrolyte 52, cathode current collector 64, and anode current collector 65. This design is compared to a single "cell" or section 102 of a solid-state battery having a rectangular shape pattern to demonstrate an increase in mechanical strength and a more uniform current density distribution. Section 102 of a solid-state battery includes at least a portion of cathode 142, anode 144, solid electrolyte 152, cathode current collector 164, and anode current collector 165.

[0039] Physics-based modeling of thin-film SSBs was performed using COMSOL 6.1. Periodic boundary conditions were applied to reduce computational overhead. For stress analysis, a pressure of 100 MPa was applied to the anode current collector in the normal direction (e.g., direction 50 or direction 53). The deformation, pressure distribution, and first principal stress of the cell structure were analyzed. For current density distribution analysis, constant current constant voltage (CC-CV) charging was applied at a C rate of 1C, and the current density distribution was analyzed at the beginning of charging and at 50% lithiation of the cathode.

[0040] Figure 3 Contour plots depicting the distribution of hydrostatic pressure in different areas of battery cells 100, 102 are shown. In the dome-shaped pattern (i.e., battery cell 100), the pressure is more evenly distributed. Specifically, in the dome-shaped design (i.e., battery cell 100), the maximum and minimum pressures applied are 98MPa and 36MPa, respectively, while in the conventional design (i.e., battery cell 102), they are 154MPa and 27MPa. Compared with the conventional design, the maximum pressure is about 36% smaller and the pressure change is about 51% smaller in the dome-shaped design. Moreover, the change in hydrostatic pressure at the two vertices of the rectangular pattern is sudden (about 80MPa), which may cause mechanical problems. In contrast, there is no such significant pressure change in the new design, indicating a mechanically stable interface under high pressure.

[0041] Figure 4The first principal stress distribution in different areas of the battery cells 100 and 102 is shown. The first principal stress is used as a measure to identify the location of possible mechanical problems. The maximum compressive and tensile first principal stresses in the new design (i.e., battery cell 100) are about 16MPa and about 54MPa, while in the conventional design (i.e., battery cell 102), they are about 45MPa and about 71MPa. Compared with the conventional design (i.e., battery cell 102), the change in the first principal stress in the dome-shaped design (i.e., battery cell 100) is about 40% smaller. In the new dome-shaped design (i.e., battery cell 100), no significant change in the first principal stress is observed, while the edges of the conventional design (i.e., battery cell 102) are under greater tensile and compressive stresses. Therefore, in the conventional design (i.e., battery cell 102), mechanical problems may occur at the interface. In the case where the mechanical structure of the conventional design (i.e., battery cell 102) undergoes some changes due to stress, the SSB can still operate if there is an available ion path. However, changes in the mechanical structure can lead to higher impedance, resulting in reduced battery performance. Therefore, the dome-shaped structure is more mechanically reliable by dissipating the first principal stress.

[0042] Figure 5 and Figure 6 The electrode current density distribution near the interface between the solid electrolyte and the patterned electrode in the dome-shaped design (ie, cell 100) is shown compared to the conventional design (ie, cell 102). The scale depicts the magnitude of the electrode current density [A / m 2 ], and the arrows indicate the direction and magnitude of the electrode current density vector. The size of the arrow is proportional to the magnitude of the vector. Figure 5 At the beginning of CC charging as depicted in FIG, in the dome-shaped design (i.e., cell 100), the maximum current density and the minimum current density are 50 A / m 2 and 26A / m 2 , while in the conventional design (i.e., battery cell 102), the maximum current density and the minimum current density are 78A / m 2 and 22A / m 2 Compared to the conventional design (ie, cell 102 ), in the dome-shaped design (ie, cell 100 ), the maximum current density is about 36% smaller and the variation is about 57% smaller.

[0043] exist Figure 6 At 50% lithiation in the cathode during CC charging depicted in FIG, the maximum and minimum current densities in the dome-shaped design (i.e., cell 100) are 51 A / m 2 and 10A / m 2 , whereas in the conventional design (i.e., battery cell 102), the maximum current density and the minimum current density are 62 A / m 2 and 7A / m 2. The maximum current density is still about 18% smaller and the variation is about 25% smaller in the dome-shaped design (i.e., cell 100) than in the conventional design (i.e., cell 102). At both charge states (i.e., at the beginning of CC charging and at 50% lithiation in the cathode during CC charging), the current density is more evenly distributed in the dome-shaped design (i.e., cell 100), as shown by the smaller variation relative to the conventional design (i.e., cell 102). The conventional design (i.e., cell 102) shows local current density at the edges of sharp edges, which will cause lithium plating and ultimately cause cell degradation. The dome-shaped structure (i.e., cell 100) eliminates the local current density, which reduces or eliminates lithium plating.

[0044] The dome-shaped pattern (i.e., cell 100) has a mechanically stable interface, which is critical during the SSB manufacturing process at high pressure. The pattern evenly dissipates and distributes the applied pressure. The dome-shaped pattern (i.e., cell 100) also enables fast charging by utilizing a large interface area and fast charge / ion transfer without the need for locally high current density. Highly localized current density is known to be the root cause of lithium plating.

[0045] It should be understood that the first, second, third, fourth, etc. labels for any components, states or conditions described herein can be rearranged in the claims so that they are arranged in chronological order with respect to the claims. In addition, it should be understood that if one or more specific components, states or conditions are claimed, any components, states or conditions described herein without a numerical designation can be given a first, second, third, fourth, etc. designation in the claims.

[0046] The words used in the specification are descriptive rather than restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of the present disclosure. As previously mentioned, the features of the various embodiments may be combined to form additional embodiments that may not be explicitly described or shown. Although various embodiments may have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, it should be recognized by those of ordinary skill in the art that one or more features or characteristics may be compromised to achieve the desired overall system properties, depending on the specific application and implementation. To this end, embodiments that are described as being less desirable than other embodiments or prior art implementations with respect to one or more characteristics are within the scope of the present disclosure and may be desirable for a particular application.

[0047] According to the present invention, a battery is provided, the battery having: a cathode plate, the cathode plate defining a first dome-shaped recess array; an anode plate, the anode plate defining a second dome-shaped recess array, wherein the first dome-shaped recess array is positioned opposite to and facing the second dome-shaped recess array; and an electrolyte, the electrolyte (i) being disposed between the cathode plate and the anode plate and (ii) having dome-shaped protruding areas extending outwardly therefrom, wherein (a) each dome-shaped protruding area in a first subset of the dome-shaped protruding areas extends into one of the dome-shaped recesses in the first dome-shaped recess array and contacts the cathode within the one dome-shaped recess, and (b) each dome-shaped protruding area in a second subset of the dome-shaped protruding areas extends into one of the dome-shaped recesses in the second dome-shaped recess array and contacts the anode within the one dome-shaped recess.

[0048] According to an embodiment, the electrolyte is a solid-state electrolyte.

[0049] According to an embodiment, (i) each dome-shaped protruding area has a width and a height, and (ii) a ratio of the width to the height is in a range between 1 and 10.

[0050] According to an embodiment, (i) each of the dome-shaped protruding regions has a width, (ii) adjacent dome-shaped protruding regions are spaced a distance from each other, and (iii) a ratio of the width to the distance is in a range between 0.1 and 10.

[0051] According to an embodiment, each of said dome-shaped protruding areas occupies the entire corresponding dome-shaped recess.

[0052] According to an embodiment, (i) each of the dome-shaped protruding regions in the first subset of dome-shaped protruding regions forms an aligned pair with one of the dome-shaped protruding regions in the second subset of dome-shaped protruding regions, and (ii) the dome-shaped protruding regions within each pair extend outwardly in opposite directions from a central region of the electrolyte.

[0053] According to an embodiment, (i) the cathode has a first height, (ii) the central region has a second height, and (iii) a ratio of the first height to the second height is in a range between 1 and 20.

[0054] According to an embodiment, (i) the anode has a first height, (ii) the central region has a second height, and (iii) a ratio of the first height to the second height is in a range between 1 and 20.

[0055] According to the present invention, a battery is provided, the battery having: a cathode, the cathode defining a first set of notches; an anode, the anode defining a second set of notches, wherein (i) the notches in the first set of notches and the second set of notches are partially elliptical, and (ii) the first set of notches are positioned opposite to and facing the second set of notches; and an electrolyte, the electrolyte (i) being disposed between the cathode and the anode and (ii) having a protruding area extending outwardly from a first opposing surface and a second opposing surface, wherein (a) each of the protruding areas extending from the first opposing surface further extends into one of the notches in the first set of notches and contacts the cathode within the one notch, and (b) each of the protruding areas extending from the second opposing surface further extends into one of the notches in the second set of notches and contacts the anode within the one notch.

[0056] According to an embodiment, the electrolyte is a solid-state electrolyte.

[0057] According to an embodiment, (i) each notch in the first and second sets of notches has a width and a height, and (ii) a ratio of the width to the height is in a range between 1 and 10.

[0058] According to an embodiment, (i) each notch in the first group of notches and the second group of notches has a width, (ii) adjacent notches within the first group of notches and the second group of notches are spaced apart from each other by a certain distance, and (iii) a ratio of the width to the distance is in a range between 0.1 and 10.

[0059] According to an embodiment, each of said protruding areas occupies the entire corresponding recess.

[0060] According to an embodiment, (i) each of the protruding regions extending from the first opposing surface forms an aligned pair with one of the protruding regions extending from the second opposing surface, and (ii) the protruding regions within each pair extend outwardly in opposite directions from a central region of the electrolyte.

[0061] According to an embodiment, (i) the cathode has a first height, (ii) the central region has a second height, and (iii) a ratio of the first height to the second height is in a range between 1 and 20.

[0062] According to an embodiment, (i) the anode has a first height, (ii) the central region has a second height, and (iii) a ratio of the first height to the second height is in a range between 1 and 20.

[0063] According to the present invention, a battery is provided, the battery having: a positive electrode, the positive electrode defining a first group of notches; a negative electrode, the negative electrode defining a second group of notches, wherein the first group of notches is positioned opposite to and facing the second group of notches; and a solid electrolyte, the solid electrolyte being arranged between the positive electrode and the negative electrode, thereby defining a circular protruding area extending outward from the first surface and the second surface and into the first group of notches and the second group of notches.

[0064] According to an embodiment, each of the notches in the first and second groups of notches has a width and a height, and a ratio of the width to the height is in a range between 1 and 10.

[0065] According to an embodiment, each of the notches in the first group of notches and the second group of notches has a width, adjacent notches within the first group of notches and the second group of notches are spaced a distance from each other, and a ratio of the width to the distance is in a range between 0.1 and 10.

[0066] According to an embodiment, each of the protruding regions extending from the first surface forms an aligned pair with one of the protruding regions extending from the second surface, and the protruding regions within each pair extend outwardly in opposite directions from a central region of the electrolyte.

Claims

1. A battery, comprising: a cathode plate defining a first array of dome-shaped recesses; an anode plate defining a second array of dome-shaped recesses, wherein the first array of dome-shaped recesses is positioned opposite and facing the second array of dome-shaped recesses; as well as An electrolyte (i) is disposed between the cathode plate and the anode plate and (ii) has a dome-shaped protruding area extending outwardly therefrom, wherein (a) each dome-shaped protruding area in a first subset of the dome-shaped protruding areas extends into one of the dome-shaped recesses in the first dome-shaped recess array and contacts the cathode within the one dome-shaped recess, and (b) each dome-shaped protruding area in a second subset of the dome-shaped protruding areas extends into one of the dome-shaped recesses in the second dome-shaped recess array and contacts the anode within the one dome-shaped recess.

2. The battery of claim 1, wherein the electrolyte is a solid electrolyte.

3. The battery of claim 1, wherein (i) each dome-shaped protruding region has a width and a height, and (ii) a ratio of the width to the height is in a range between 1 and 10.

4. The battery of claim 1, wherein (i) each of the dome-shaped protruding regions has a width, (ii) adjacent dome-shaped protruding regions are spaced a distance apart from each other, and (iii) a ratio of the width to the distance is in a range between 0.1 and 10.

5. The battery of claim 1, wherein each of the dome-shaped protruding areas occupies the entirety of a corresponding dome-shaped recess.

6. The battery of claim 1 , wherein (i) each of the dome-shaped protruding regions in the first subset of dome-shaped protruding regions forms an aligned pair with one of the dome-shaped protruding regions in the second subset of dome-shaped protruding regions, and (ii) the dome-shaped protruding regions within each pair extend outwardly in opposite directions from a central region of the electrolyte.

7. The battery of claim 6, wherein (i) the cathode has a first height, (ii) the central region has a second height, and (iii) a ratio of the first height to the second height is in a range between 1 and 20.

8. The battery of claim 6, wherein (i) the anode has a first height, (ii) the central region has a second height, and (iii) a ratio of the first height to the second height is in a range between 1 and 20.

9. A battery, comprising: a cathode defining a first set of notches; an anode defining a second set of notches, wherein (i) the notches in the first set of notches and the second set of notches are partially elliptical, and (ii) the first set of notches are positioned opposite and facing the second set of notches; as well as An electrolyte (i) disposed between the cathode and the anode and (ii) having a protruding region extending outwardly from a first opposing surface and a second opposing surface, wherein (a) each of the protruding regions extending from the first opposing surface further extends into one of the recesses in the first set of recesses and contacts the cathode within the one recess, and (b) each of the protruding regions extending from the second opposing surface further extends into one of the recesses in the second set of recesses and contacts the anode within the one recess.

10. The battery of claim 9, wherein (i) each notch in the first and second sets of notches has a width and a height, and (ii) a ratio of the width to the height is in a range between 1 and 10.

11. The battery of claim 9, wherein (i) each notch in the first group of notches and the second group of notches has a width, (ii) adjacent notches in the first group of notches and the second group of notches are spaced a distance from each other, and (iii) a ratio of the width to the distance is in a range between 0.1 and 10.

12. The battery of claim 9, wherein (i) each of the protruding regions extending from the first opposing surface forms an aligned pair with one of the protruding regions extending from the second opposing surface, and (ii) the protruding regions within each pair extend outwardly in opposite directions from a central region of the electrolyte.

13. A battery, comprising: a positive electrode defining a first set of notches; a negative electrode defining a second set of notches, wherein the first set of notches is positioned opposite and facing the second set of notches; as well as A solid electrolyte, which (i) is arranged between the positive electrode and the negative electrode and (ii) has circular protruding areas extending outward from a first surface and a second surface, wherein (a) each circular protruding area extending from the first surface further extends into one of the recesses in the first group of recesses, and (b) each protruding area extending from the second surface further extends into one of the recesses in the second group of recesses.

14. The battery of claim 13, wherein (i) each of the notches in the first and second sets of notches has a width and a height, and (ii) a ratio of the width to the height is in a range between 1 and 10.

15. A battery as described in claim 13, wherein (i) each of the notches in the first group of notches and the second group of notches has a width, (ii) adjacent notches within the first group of notches and the second group of notches are spaced a distance from each other, and (iii) a ratio of the width to the distance is in a range between 0.1 and 10.

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