Electrode assembly and secondary battery

Abstract

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

Description

[0001] This application is a divisional application of a patent application with an application date of November 15, 2018, an application number of 201880086496.5, and a title of "Electrode Assembly and Secondary Battery". Technical Field

[0002] The present disclosure generally relates to an electrode assembly used in an energy storage device such as a secondary battery. Background Art

[0003] A rocking chair or insertion type secondary battery is a type of energy storage device in which carrier ions such as lithium ions, sodium ions, potassium ions, calcium ions or magnesium ions move between a positive electrode and a negative electrode through an electrolyte. The secondary battery may include a single battery cell, or two or more battery cells that have been electrically coupled to form a battery, and each battery cell includes a positive electrode, a negative electrode, a microporous separator and an electrolyte.

[0004] In a rocking chair battery cell, both the positive electrode and the negative electrode include materials in which carrier ions are inserted and extracted. When the battery discharges, the carrier ions are extracted from the negative electrode and inserted into the positive electrode. When the battery is charged, the reverse process occurs: the carrier ions are extracted from the positive electrode and inserted into the negative electrode.

[0005] One of the ongoing challenges when carrier ions move between electrodes is the fact that the electrodes tend to expand and contract as the battery is repeatedly charged and discharged. The expansion and contraction during cycling tend to cause problems with the reliability and cycle life of the battery because when the electrodes expand, electrical short circuits and battery failures occur. Another problem that may occur is that, for example, a misalignment of the electrodes due to physical or mechanical stress on the battery during manufacturing, use or transportation may lead to battery short circuits and failures.

[0006] Therefore, there is still a need to control the expansion and contraction of the electrodes during battery cycling to improve the reliability and cycle life of the battery. There is also a need to control the electrode alignment and structure, which improves the mechanical stability of the battery without overly increasing the footprint of the battery.

[0007] In addition, there is still a need for a reliable and effective method of manufacturing such a battery. That is, an effective manufacturing method is needed to provide a battery with an electrode assembly that has carefully controlled alignment and in which the expansion of the electrode assembly is controlled during battery cycling. Summary of the Invention

[0008] One aspect of the present disclosure relates to a secondary battery that cycles between a charged state and a discharged state, the secondary battery including a battery housing, an electrode assembly, lithium ions within the battery housing, and a set of electrode restraints, wherein

[0009] (a) The electrode assembly has a transverse axis, a longitudinal axis, and a vertical axis that are perpendicular to each other and correspond to the x-axis, y-axis, and z-axis of a fictional three-dimensional Cartesian coordinate system, a first longitudinal end surface and a second longitudinal end surface that are separated from each other in the longitudinal direction, and a transverse surface that surrounds the longitudinal axis A EA and connects the first longitudinal end surface and the second longitudinal end surface. The transverse surface has opposite first and second regions located on opposite sides of the longitudinal axis and separated in a first direction orthogonal to the longitudinal axis. The electrode assembly has a maximum width W measured in the longitudinal direction EA , a maximum length L defined by the transverse surface and measured in the transverse direction EA , and a maximum height H defined by the transverse surface and measured in the vertical direction EA , where the maximum length L EA and the maximum width W EA have a ratio to the maximum height H EA of at least 2:1

[0010] (b) The electrode assembly includes a series of layers stacked in a stacking direction parallel to the longitudinal axis within the electrode assembly. The stacked series of layers includes a group of negative electrode active material layers, a group of negative electrode current collector layers, a group of separator material layers, a group of positive electrode active material layers, and a group of positive electrode current collector material layers, where

[0011] (i) Each member in the group of negative electrode active material layers has a length L E , a height H E , and a width W E . The length L E corresponds to the Feret diameter of the negative electrode active material layer measured in the transverse direction between the first and second opposite transverse end surfaces of the negative electrode active material layer, and the height H E corresponds to the Feret diameter of the negative electrode active material layer measured in the vertical direction between the first and second opposite vertical end surfaces of the negative electrode active material layer, and the width W E corresponds to the Feret diameter of the negative electrode active material layer measured in the longitudinal direction between the first and second opposite surfaces of the negative electrode active material layer. Wherein, L E has a ratio to H E and W E of at least 5:1;

[0012] (ii) Each member in the group of positive electrode active material layers has a length L C , a height H C , and a width WC , the length L C corresponds to the Feret diameter of the positive electrode active material layer measured in the lateral direction between the first and second opposite lateral end surfaces of the positive electrode active material layer, and the height H C corresponds to the Feret diameter of the positive electrode active material layer measured in the vertical direction between the first and second opposite vertical end surfaces of the positive electrode active material layer, and the width W C corresponds to the Feret diameter of the positive electrode active material layer measured in the longitudinal direction between the first and second opposite surfaces of the positive electrode active material layer, wherein, L C and H C and W C have a ratio of at least 5:1

[0013] (iii) The members of the negative electrode active material layer group include particulate material having at least 60 wt% of negative electrode active material, less than 20 wt% of a conductive additive, and a binder material, and wherein the negative electrode active material includes a silicon-containing material,

[0014] (c) The set of electrode restraining members includes a primary restraining system and a secondary restraining system, wherein

[0015] (i) The primary restraining system includes first and second growth restraining members and at least one primary connecting member, the first and second primary growth restraining members being separated from each other in the longitudinal direction, and the at least one primary connecting member connecting the first and second primary growth restraining members to at least partially restrict the growth of the electrode assembly in the longitudinal direction, and

[0016] (ii) The secondary restraining system includes first and second secondary growth restraining members separated in a second direction and connected by members of the series of stacked layers, wherein the secondary restraining system at least partially restricts the growth of the electrode assembly in the second direction during cycling of the secondary battery, the second direction being orthogonal to the longitudinal direction, and

[0017] (iii) The primary restraining system maintains a pressure on the electrode assembly in the stacking direction, the pressure exceeding the pressure maintained on the electrode assembly in each of two directions that are perpendicular to each other and perpendicular to the stacking direction, and

[0018] (d) The electrode assembly includes a unit elementary group. Each unit element includes a unit element portion of the first member of the electrode current collector layer group, a member of the separator group that is ion-permeable to the carrier ions, a first member of the electrode active material layer group, a unit element portion of the first member of the counter electrode current collector group, and a first member of the counter electrode active material layer group. Wherein, (aa) the first member of the electrode active material layer group is close to the first side of the separator, and the first member of the counter electrode material layer group is close to the opposite second side of the separator; (bb) the separator electrically isolates the first member of the electrode active material layer group from the first member of the counter electrode active material layer group, and during the cycle of the battery between the charged state and the discharged state, the carrier ions are mainly exchanged between the first member of the electrode active material layer group and the first member of the counter electrode active material layer group via the separator of each such unit element; and (cc) within each unit element,

[0019] a. The first vertical end surfaces of the electrode and the counter electrode active material layer are on the same side of the electrode assembly. The median vertical position of the first opposite vertical end surfaces of the electrode active material is along the length L of the electrode active material layer in the X-Z plane E The 2D drawing of the first vertical end surface is shown as figure E VP1 The median vertical position of the first opposite vertical end surfaces of the counter electrode active material layer is along the length L of the counter electrode active material layer in the X-Z plane C The 2D drawing of the first vertical end surface is shown as figure CE VP1 Wherein, for at least 60% of the length L of the first counter electrode active material layer: (i) the absolute value of the separation distance S between figure E C and CE VP1 measured in the vertical direction is 1000μm ≥ |S VP1 | ≥ 5μm; (ii) between the first vertical end surfaces of the electrode and the counter electrode active material layer, the first vertical end surface of the counter electrode active material layer is set inward relative to the first vertical end surface of the electrode active material layer Z1 Z1

[0020] ​​b. The second vertical end surfaces of the electrode and the counter electrode active material layer are located on the same side of the electrode assembly and are respectively opposite to the first vertical end surfaces of the electrode and the counter electrode active material layer. The median vertical position of the second opposite vertical end surface of the electrode active material layer is along the length L of the electrode active material layer in the X-Z plane E The 2D diagram of E depicts the second vertical end surface, Figure E VP2 The median vertical position of the second opposite vertical end surface of the counter electrode active material layer is along the length L of the counter electrode active material layer in the X-Z plane C The 2D diagram of C plots the second vertical end surface, Figure CE VP2 wherein, for the length L of the counter electrode active material layer C of at least 60%: (i) the separation distance S VP2 between Figure E VP2 and CE Z2 measured in the vertical direction has an absolute value of 1000 μm ≥ |S Z2 | ≥ 5 μm, and (ii) between the second vertical end surfaces of the electrode and the counter electrode active material layer, the second vertical end surface of the counter electrode active material layer is set inward relative to the second vertical end surface of the electrode active material layer

[0021] Another aspect of the present disclosure relates to a secondary battery for cycling between a charged state and a discharged state. The secondary battery includes a battery case, an electrode assembly, carrier ions within the battery case, and a set of electrode restraints, wherein

[0022] (a) The electrode assembly has mutually perpendicular lateral, longitudinal, and vertical axes corresponding to the x-axis, y-axis, and z-axis of a fictional three-dimensional Cartesian coordinate system, a first longitudinal end surface and a second longitudinal end surface separated from each other in the longitudinal direction, and a lateral surface surrounding the longitudinal axis A EA of the electrode assembly and connecting the first longitudinal end surface and the second longitudinal end surface. The lateral surface has opposite first and second regions located on opposite sides of the longitudinal axis and separated in a first direction orthogonal to the longitudinal axis. The electrode assembly has a maximum width W EA measured in the longitudinal direction, a maximum length L EA defined by the lateral surface and measured in the lateral direction, and a maximum height H EA defined by the lateral surface and measured in the vertical direction, wherein the maximum length L EA and / or the maximum width W EA is greater than the maximum height HEA ,

[0023] (b) The electrode assembly includes a series of layers stacked in a stacking direction parallel to the longitudinal axis within the electrode assembly, wherein the series of stacked layers includes a group of negative electrode active material layers, a group of negative electrode current collector layers, a separator material layer group, a group of positive electrode active material layers, and a group of positive electrode current collector material layers, where

[0024] (i) Each member in the group of negative electrode active material layers has a length L E , a height H E , and a width W E , where the length L E corresponds to the Feret diameter of the negative electrode active material layer measured in the lateral direction between the first and second opposite lateral end surfaces of the negative electrode active material layer, and the height H E corresponds to the Feret diameter of the negative electrode active material layer measured in the vertical direction between the first and second opposite vertical end surfaces of the negative electrode active material layer, and the width W E corresponds to the Feret diameter of the negative electrode active material layer measured in the longitudinal direction between the first and second opposite surfaces of the negative electrode active material layer, where the ratio of the L E to the H E and the W E is at least 5:1;

[0025] (ii) Each member in the group of positive electrode material layers has a length L C , a height H C , and a width W C , where the length L C corresponds to the Feret diameter of the positive electrode active material layer measured in the lateral direction between the first and second opposite lateral end surfaces of the positive electrode active material layer, and the height H C corresponds to the Feret diameter of the positive electrode active material layer measured in the vertical direction between the first and second opposite vertical end surfaces of the positive electrode active material layer, and the width W C corresponds to the Feret diameter of the positive electrode active material layer measured in the longitudinal direction between the first and second opposite surfaces of the positive electrode active material layer, where the ratio of the L C to the H C and the W C is at least 5:1

[0026] (iii) The members of the group of negative electrode active material layers include particulate material having at least 60 wt% of negative electrode active material, less than 20 wt% of a conductive additive, and a binder material,

[0027] (c) The group of electrode restraint members includes a primary restraint system and a secondary restraint system, wherein

[0028] (i) The primary restraint system includes first and second growth restraint members and at least one primary connecting member, the first and second primary growth restraint members being separated from each other in the longitudinal direction, and the at least one primary connecting member connecting the first and second primary growth restraint members to at least partially restrict growth of the electrode assembly in the longitudinal direction, and

[0029] (ii) The secondary restraint system includes first and second secondary growth restraint members separated in a second direction and connected by members through a series of layers of the stack, wherein the secondary restraint system at least partially restricts growth of the electrode assembly in the second direction during cycling of the secondary battery, the second direction being orthogonal to the longitudinal direction, and

[0030] (iii) The primary restraint system maintains a pressure on the electrode assembly in the stacking direction, the pressure exceeding the pressure maintained on the electrode assembly in each of two directions that are perpendicular to each other and perpendicular to the stacking direction, and

[0031] (d) The series of layers of the stack includes layers having opposite end surfaces spaced apart from each other in the transverse direction, wherein due to elongation and shrinkage of the layers at the opposite end surfaces, a plurality of the opposite end surfaces of the layers exhibit plastic deformation and fracture oriented in the transverse direction.

[0032] Other aspects, features, and embodiments of the present disclosure will be discussed in part in the following description and the drawings and will be in part apparent. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1A is a perspective view of an embodiment of a restraint system for use with an electrode assembly.

[0034] Figure 1B is a schematic view of an embodiment of a three-dimensional electrode assembly for a secondary battery.

[0035] Figure 1C is Figure 1B an insertion cross-sectional view of the electrode assembly of

[0036] Figure 1D is along Figure 1B line E in Figure 1B a cross-sectional view of the electrode assembly of

[0037] Figure 2A is a schematic view of an embodiment of a three-dimensional electrode assembly.

[0038] Figures 2B to 2C It is a schematic diagram of an embodiment of a three-dimensional electrode assembly, showing the anode structure group members in a constrained configuration and an extended configuration.

[0039] Figures 3A to 3H Exemplary embodiments of different shapes and sizes of the electrode assembly are shown.

[0040] Figure 4A Shows along Figure 1A A cross-section of an embodiment of the electrode assembly taken along the line A-A' shown, and further shows the elements of the primary and secondary growth constraint systems.

[0041] Figure 4B Shows along Figure 1A A cross-section of an embodiment of the electrode assembly taken along the line B-B' shown, and further shows the elements of the primary and secondary growth constraint systems.

[0042] Figure 4C Shows along Figure 1A A cross-section of an embodiment of the electrode assembly taken along the line B-B' shown, and further shows the elements of the primary and secondary growth constraint systems.

[0043] Figure 5 Shows along Figure 1A A cross-section of an embodiment of the electrode assembly taken along the line A-A1' shown.

[0044] Figure 6A An embodiment of a top view of a porous secondary growth restraint over the electrode assembly, and an embodiment for adhering the secondary growth restraint to the electrode assembly are shown.

[0045] Figure 6B An embodiment of a top view of a porous secondary growth restraint over the electrode assembly, and another embodiment for adhering the secondary growth restraint to the electrode assembly are shown.

[0046] Figure 7 Shows along Figure 1A A cross-section of an embodiment of the electrode assembly taken along the line A-A' shown, further including a set of electrode restraints, including an embodiment of a primary restraint system and an embodiment of a secondary restraint system.

[0047] Figures 8A to 8B A force schematic diagram according to an embodiment is shown, which shows the forces applied to the electrode assembly by the set of electrode restraints, and the forces applied by the electrode structure during repeated cycling of the battery containing the electrode assembly.

[0048] Figure 9A Shows along Figure 1ACross-section of an embodiment of an electrode assembly taken along line A-A' shown, which further includes a group of electrode restraints, including an embodiment of a primary growth restraint system and an embodiment of a secondary growth restraint system, wherein an electrode backbone is used to assemble the group of electrode restraints.

[0049] Figure 9B Shows a cross-section taken along Figure 1A Cross-section of an embodiment of an electrode assembly taken along line A-A' shown, which further includes a group of electrode restraints, including an embodiment of a primary growth restraint system and an embodiment of a secondary growth restraint system, wherein an electrode current collector is used to assemble the group of electrode restraints.

[0050] Figure 10 Shows an exploded view of an embodiment of an energy storage device or secondary battery utilizing an embodiment of a group of growth restraints.

[0051] Figures 11A to 11C Shows an embodiment for determining the vertical offset and / or separation distance S between the vertical end surfaces of an electrode and a counter electrode active material layer Z1 and S Z2 and an embodiment thereof.

[0052] Figures 12A to 12C Shows an embodiment for determining the lateral offset and / or separation distance S between the lateral end surfaces of an electrode and a counter electrode active material layer X1 and S X2 and an embodiment thereof.

[0053] Figures 13A to 13B Shows an embodiment for determining the height H E 、H C and length L E 、L C and an embodiment thereof according to the Feret diameter of an electrode and / or a counter electrode active material layer.

[0054] Figures 14A to 14H Shows a cross-section in the Z-Y plane of an embodiment of a unit cell having an electrode and a counter electrode active material layer, wherein both have and do not have a vertical offset and / or separation distance.

[0055] Figures 15A to 15F Shows a cross-section in the Y-X plane of an embodiment of a unit cell having an electrode and a counter electrode active material layer, wherein both have and do not have a lateral offset and / or separation distance.

[0056] Figures 16A to 16B Shows an embodiment of an electrode assembly having an electrode and / or a counter electrode bus bar. Figure 16A '-16B' shows Figures 16A - 16B respective cross-sections taken in the X-Y plane.

[0057] Figure 17 An embodiment of a secondary battery having an alternating arrangement of an electrode and a counter electrode structure is shown.

[0058] Figures 18A to 18B A cross-section in the Z-Y plane of an embodiment of an electrode assembly having an auxiliary electrode is shown.

[0059] Figure 19 It is a schematic diagram of images of a negative electrode sub-unit before and after exposing the current collector end after removing the end portion of the negative electrode sub-unit, and shows plastic deformation at a portion of the current collector end due to removing the end portion at the current collector end.

[0060] When considered in conjunction with the accompanying drawings, other aspects, embodiments, and features of the subject matter of the present invention will become apparent from the following detailed description. The drawings are schematic and are not intended to be drawn to scale. For clarity, not every element or component is labeled in every figure, nor is every element or component of every embodiment of the subject matter of the present invention shown, where the illustration is not necessary for one of ordinary skill in the art to understand the subject matter of the present invention. Detailed Description

[0061] Definitions

[0062] As used herein, "a", "an", and "the" (i.e., the singular forms) refer to plural referents unless the context clearly indicates otherwise. For example, in one instance, a reference to "an electrode" includes a single electrode and multiple similar electrodes.

[0063] As used herein, "about" and "approximately" mean the stated value plus or minus 10%, 5%, or 1%. For example, in one instance, about 250 μm will include 225 μm to 275 μm. As a further example, in one instance, about 1000 μm will include 900 μm to 1100 μm. Unless otherwise indicated, all numbers expressing quantities (e.g., measured values, etc.) used in the specification and claims should be understood to be modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations. Each numerical parameter should be construed at least in accordance with the number of reported significant digits and by applying ordinary rounding techniques.

[0064] As used herein, "anode" in the context of a secondary battery refers to the negative electrode in the secondary battery.

[0065] As used herein, "anode active" refers to a material suitable for use as an anode in a secondary battery.

[0066] As used herein, "cathode" in the context of a secondary battery refers to the positive electrode in the secondary battery.

[0067] As used herein, "cathode active" refers to a material suitable for the cathode of a secondary battery.

[0068] As used herein in the context of the state of a secondary battery, "state of charge" refers to the state in which the secondary battery is charged to at least 75% of its rated capacity. For example, the battery can be charged to at least 80% of its rated capacity, at least 90% of its rated capacity, or even at least 95% of its rated capacity, such as 100% of its rated capacity.

[0069] As used herein, "C-rate" refers to a measure of the discharge rate of a secondary battery and is defined as the discharge current divided by the theoretical current draw at which the battery would output its nominal rated capacity in one hour. For example, a C-rate of 1C indicates a discharge current that discharges the battery in 1 hour, 2C indicates a discharge current that discharges the battery in 1 / 2 hour, C / 2 indicates a discharge current that discharges the battery in 2 hours, and so on.

[0070] As used herein in the context of the state of a secondary battery, "state of discharge" refers to the state in which the secondary battery is discharged to less than 25% of its rated capacity. For example, the battery can be discharged to less than 20% of its rated capacity, such as less than 10% of its rated capacity, or even less than 5% of its rated capacity, such as 0% of its rated capacity.

[0071] As used herein in the context of cycling a secondary battery between a state of charge and a state of discharge, "cycle" refers to charging and / or discharging the battery to move the battery in a cycle from a first state (i.e., a state of charge or discharge) to a second state opposite the first state (i.e., if the first state is a state of discharge, then the state is a state of charge; if the first state is a state of charge, then the state is a state of discharge), and then moving the battery back to the first state to complete the cycle. For example, when in a charge cycle, a single cycle between a state of charge and a state of discharge of a secondary battery can include charging the battery from a state of discharge to a state of charge and then discharging it back to a state of discharge to complete the cycle. When in a discharge cycle, a single cycle can also include discharging the battery from a state of charge to a state of discharge and then charging it back to a state of charge to complete the cycle.

[0072] As used herein, the "Feret diameter" as referred to for an electrode assembly, an electrode active material layer, and / or a counter electrode active material layer is defined as the distance between two parallel planes that confine the structure (i.e., the electrode assembly, the electrode active material layer, and / or the counter electrode active material layer), which distance is measured in a direction perpendicular to the two planes. For example, the Feret diameter of an electrode assembly in the longitudinal direction is the distance measured in the longitudinal direction between two parallel planes that confine the electrode assembly, the two parallel planes being perpendicular to the longitudinal direction. As another example, the Feret diameter of an electrode assembly in the transverse direction is the distance measured in the transverse direction between two parallel planes that confine the electrode assembly, the two parallel planes being perpendicular to the transverse direction. As yet another example, the Feret diameter of an electrode assembly in the vertical direction is the distance measured in the vertical direction between two parallel planes that confine the electrode assembly, the two parallel planes being perpendicular to the vertical direction. As yet another example, the Feret diameter of an electrode active material layer in the transverse direction is the distance measured in the transverse direction between two parallel planes that confine the electrode active material layer, the two parallel planes being perpendicular to the transverse direction. As yet another example, the Feret diameter of an electrode active material layer in the vertical direction is the distance measured in the vertical direction between two parallel planes that confine the electrode active material layer, the two parallel planes being perpendicular to the vertical direction. As another example, the Feret diameter of a counter electrode active material layer in the transverse direction is the distance measured in the transverse direction between two parallel planes that confine the counter electrode active material layer, the two parallel planes being perpendicular to the transverse direction. As yet another example, the Feret diameter of a counter electrode active material layer in the vertical direction is the distance measured in the vertical direction between two parallel planes that confine the counter electrode active material layer, the two parallel planes being perpendicular to the vertical direction.

[0073] As used herein, the "longitudinal axis", "transverse axis", and "vertical axis" refer to axes that are perpendicular to each other (i.e., each axis is orthogonal to the others). For example, the "longitudinal axis", "transverse axis", and "vertical axis" as used herein are similar to the Cartesian coordinate system used to define three-dimensional aspects or orientations. Thus, the description of the elements of the subject matter of the present invention herein is not limited to one or more specific axes for describing the three-dimensional orientation of the elements. In other words, when referring to the three-dimensional aspects of the subject matter of the present invention, the axes can be interchangeable.

[0074] As used herein, the "longitudinal direction", "transverse direction", and "vertical direction" refer to directions that are perpendicular to each other (i.e., each direction is orthogonal to the others). For example, the "longitudinal direction", "transverse direction", and "vertical direction" as used herein can generally be parallel to the longitudinal axis, transverse axis, and vertical axis, respectively, of the Cartesian coordinate system used to define three-dimensional aspects or orientations.

[0075] As used herein, "repeated cycling" in the context of cycling between the charged state and the discharged state of a secondary battery refers to more than one cycle from the discharged state to the charged state, or from the charged state to the discharged state. For example, repeated cycling between the charged state and the discharged state may include at least 2 cycles from the discharged state to the charged state, such as charging from the discharged state to the charged state, discharging back to the discharged state, charging again to the charged state, and finally discharging back to the discharged state. As another example, at least 2 repeated cycles between the charged state and the discharged state may include discharging from the charged state to the discharged state, charging back to the charged state, discharging again to the discharged state, and finally charging back to the charged state. As another example, repeated cycling between the charged state and the discharged state may include cycling at least 5 times, or even cycling at least 10 times from the discharged state to the charged state. By way of further example, repeated cycling between the charged state and the discharged state may include cycling from the discharged state to the charged state at least 25, 50, 100, 300, 500, and even 1000 times.

[0076] As used herein, "rated capacity" in the context of a secondary battery refers to the capacity of the secondary battery to output a specified current over a period of time, which is measured under standard temperature conditions (25 °C). For example, the rated capacity can be measured in ampere-hours, either by determining the current output for a specified time or by determining the time for which a current can be output for a specified current and taking the product of the current and the time. For example, for a battery rated at 20 ampere-hours, if the current is specified at 2 amperes for the rating, the battery can be understood to be a battery that will provide that current output for 10 hours. Conversely, if the time is specified at 10 hours for the rating, the battery can be understood to be a battery that will output 2 amperes over a 10-hour period. Specifically, the rated capacity of a secondary battery can be given as the rated capacity at a specified discharge current, such as the C-rate, where the C-rate is a measure of the rate at which the battery is discharged relative to its capacity. For example, a C-rate of 1C indicates a discharge current that discharges the battery in 1 hour, 2C indicates a discharge current that discharges the battery in 1 / 2 hour, C / 2 indicates a discharge current that discharges the battery in 2 hours, and so on. Thus, for example, a battery rated at 20 ampere-hours at a C-rate of 1C will provide a discharge current of 20 amperes for 1 hour, while a battery rated at 20 ampere-hours at a C-rate of 2C will provide a discharge current of 40 amperes for half an hour, and a battery rated at 20 ampere-hours at a C-rate of C / 2 will provide a discharge current of 10 amperes over 2 hours.

[0077] As used herein, "maximum width" (W EA ) in the context of the dimensions of an electrode assembly corresponds to the maximum width of the electrode assembly measured from opposite points on the longitudinal end surfaces of the electrode assembly in the longitudinal direction.

[0078] As used herein, the "maximum length" (L EA ) in the context of the dimensions of the electrode assembly corresponds to the maximum length of the electrode assembly measured from opposite points on the lateral surfaces of the electrode assembly in the lateral direction.

[0079] As used herein, the "maximum height" (H EA ) in the context of the dimensions of the electrode assembly corresponds to the maximum height of the electrode assembly measured from opposite points on the lateral surfaces of the electrode assembly in the lateral direction.

[0080] As used herein, "Centroid" refers to the geometric center of a planar object, which is the arithmetic mean position of all points in the object. In n-dimensional space, the centroid is the average position of all points in the object in all coordinate directions. To describe the centroid of an object herein, for example, the negative electrode sub-unit and the positive electrode sub-unit, as well as the negative electrode active material layer and the positive electrode active material layer, the object can be effectively regarded as a 2-D object, such that the centroid is effectively the same as the center of mass of the object. For example, the centroid of the positive electrode sub-unit or the negative electrode sub-unit, or the centroid of the positive electrode active material layer or the negative electrode active material layer can be effectively the same as its center of mass.

[0081] Detailed Description

[0082] Generally, aspects of the present disclosure are directed to, for example, an energy storage device 100 (such as a secondary battery 102) as shown in Figure 1B and 2A and a method of manufacturing the same, the secondary battery 102 cycling between a charged state and a discharged state. The secondary battery 102 includes a battery case 104, an electrode assembly 106, and carrier ions, and may also include a non-aqueous liquid electrolyte within the battery case. The secondary battery 102 may further include a set of electrode restraints 108 that limit the growth of the electrode assembly 106. The growth of the constrained electrode assembly 106 may be a macroscopic increase in one or more dimensions of the electrode assembly 106.

[0083] Aspects of the present disclosure also provide a reduced offset and / or separation distance of the electrode active material layer and the counter electrode active material layer in the vertical and lateral directions, which can improve the storage capacity of the secondary battery without unduly increasing the risk of short circuit or failure of the secondary battery, as described in detail below. Aspects of the present disclosure may also provide methods of manufacturing a secondary battery and / or manufacturing a high energy density structure and configuration of a secondary battery with a reduced footprint.

[0084] In addition, in some embodiments, aspects of the present disclosure include three-dimensional confinement structures that provide particular advantages when incorporated in an energy storage device 100 such as a battery, capacitor, fuel cell, etc. In one embodiment, the confinement structure has a configuration and / or structure selected to resist at least one of growth, increase, and / or swelling of the electrode assembly 106, which may otherwise occur when the secondary battery 102 cycles repeatedly between a charged state and a discharged state. Specifically, when moving from a discharged state to a charged state, carrier ions (e.g., one or more of lithium, sodium, potassium, calcium, and magnesium) move between the positive and negative electrodes in the battery. Upon reaching the electrode, the carrier ions can then be intercalated or alloyed into the electrode material, thereby increasing the size and volume of the electrode. Conversely, moving from a charged state to a discharged state in turn can result in ion deintercalation or dealloying, causing the electrode to shrink. Such alloying and / or intercalation and dealloying and / or deintercalation can result in significant volume changes of the electrode. In yet another embodiment, the transport of carrier ions away from the electrode can increase the size of the electrode, e.g., by increasing the electrostatic repulsion of the remaining material layer (e.g., employing LCO and some other materials). Other mechanisms that can cause the secondary battery 102 to increase can include, for example, the formation of SEI on the electrode, the decomposition of the electrolyte and other components, and even gas formation. Thus, the repeated swelling and shrinking of the electrode during charging and discharging and other increasing mechanisms can cause strain to be generated in the electrode assembly 106, which can degrade the performance of the secondary battery and ultimately even cause the failure of the secondary battery.

[0085] Reference Figures 2A to 2C , the effects of the repeated swelling and / or shrinking of the electrode assembly 106 according to embodiments of the present disclosure can be described. Figure 2A An embodiment of a three-dimensional electrode assembly 106 is shown, which has a group of electrode structures 110 and a group of counter electrode structures 112 (e.g., an anode structure group and a cathode structure group, respectively). The three-dimensional electrode assembly 106 in this embodiment provides an alternating set of electrode structures 110 and counter electrode structures 112 that are interleaved and, in Figure 2A the embodiment shown, has a longitudinal axis A parallel to the Y axis EA , a transverse axis (not shown) parallel to the X axis, and a vertical axis (not shown) parallel to the Z axis. The X, Y, and Z axes shown here are arbitrary axes, only used to show a set of bases in which the axes are perpendicular to each other in the reference space, and do not limit the structures herein to a specific orientation in any way. During the charging and discharging cycles of the secondary battery 102 having the electrode assembly 106, carrier ions travel between the electrode and the counter electrode structures 110 and 112, e.g., generally in a direction parallel to the Y axis, as Figure 2AAs shown in the embodiments shown, and can be embedded into one or more of the electrode materials of the electrode structure 110 and the counter electrode structure 112 located within the traveling direction. The effect of the host ion embedding and / or alloying into the electrode material can be in Figures 2B to 2C seen in the embodiments shown. Specifically, Figure 2B shows an embodiment of the electrode assembly 106 in which the electrode structure 110 is in a relatively unexpanded state, such as before the secondary battery 106 is repeatedly cycled between a charged state and a discharged state. As a comparison, Figure 2C shows an embodiment of the electrode assembly 106 having the electrode structure 110 after the secondary battery has been repeatedly cycled a predetermined number of times. As shown in this figure, due to the embedding and / or alloying of the host ions into the electrode material or other mechanisms as described above, the size of the electrode structure 110 can increase significantly in the stacking direction (e.g., the Y direction). The size of the electrode structure 110 can also increase significantly in another direction, such as in the Z direction ( Figure 2C not shown). In addition, the increase in the size of the electrode structure 110 can cause deformation of the internal structure of the electrode assembly, such as deformation of the counter electrode structure 112 and the separator 130 in the assembly, to accommodate the expansion of the electrode structure 110. The expansion of the electrode structure 110 can ultimately cause the electrode assembly 106 to bulge and / or warp at its longitudinal ends, as Figure 2C shown in the embodiments shown (and at the top and bottom surfaces in other directions, such as in the Z direction). Therefore, due to the insertion and extraction of the host ions during the charging and discharging processes, the electrode assembly 106 according to one embodiment can exhibit significant expansion and contraction along the longitudinal (Y-axis) and other axes of the assembly 106.

[0086] Therefore, in one embodiment, a primary growth restraint system 151 is provided to mitigate and / or reduce at least one of the growth, expansion, and / or enlargement of the electrode assembly 106 in the longitudinal direction (i.e., in a direction parallel to the Y-axis), such as in, for example, Figure 1AAs shown. For example, the primary growth restraint system 151 may include structures configured to restrain growth by opposing expansion at the longitudinal end surfaces 116, 118 of the electrode assembly 106. In one embodiment, the primary growth restraint system 151 includes first and second primary growth restraint members 154, 156 that are separated from each other in the longitudinal direction and operate with at least one primary connection member 162 that connects the first and second primary growth restraint members 154, 156 together to inhibit growth of the electrode assembly 106. For example, the first and second primary growth restraint members 154, 156 may at least partially cover the first and second longitudinal end surfaces 116, 118 of the electrode assembly 106 and may operate with connection members 162, 164 that interconnect the primary growth restraint members 154, 156 to resist and inhibit any growth in the electrode assembly 106 that occurs during repeated charge and / or discharge cycles. Further discussion of embodiments and operation of the primary growth restraint system 151 is provided in more detail below.

[0087] In addition, repeated cycling of the charge and discharge process of the secondary battery 102 not only induces growth and strain in the longitudinal direction of the electrode assembly 106 (e.g., Figure 2A the Y-axis in ), but as described above can also induce growth and strain in directions orthogonal to the longitudinal direction, such as in the transverse and vertical directions (e.g., the X and Z axes in Figure 2A respectively). In addition, in certain embodiments, including the primary growth restraint system 151 to inhibit growth in one direction can even exacerbate growth and / or increase in one or more other directions. For example, in the case where the primary growth restraint system 151 is provided to inhibit growth of the electrode assembly 106 in the longitudinal direction, the insertion of carrier ions during the charge and discharge cycles and the resulting increase in the electrode structure can induce strain in one or more other directions. Specifically, in one embodiment, the strain resulting from the combination of electrode growth / increase and longitudinal growth restraint can cause the electrode assembly 106 to bend or otherwise fail in the vertical direction (e.g., Figure 2A the Z-axis shown in ), or even in the transverse direction (e.g., Figure 2A the X-axis shown in ).

[0088] Thus, in one embodiment of the present disclosure, the secondary battery 102 includes not only the primary growth restraint system 151, but also at least one secondary growth restraint system 152 that can operate with the primary growth restraint system 151 to inhibit growth of the electrode assembly 106 along multiple axes of the electrode assembly 106. For example, in one embodiment, the secondary growth restraint system 152 can be configured to interlock or otherwise cooperate with the primary growth restraint system 151 such that overall growth of the electrode assembly 106 is inhibited to improve the performance of the secondary battery having the electrode assembly 106 and the primary and secondary growth restraint systems 151 and 152, respectively, and reduce its failure rate. Further discussion of embodiments of the interrelationship between the primary and secondary growth restraint systems 151 and 152, and their operation to inhibit growth of the electrode assembly 106, is provided in more detail below.

[0089] As described above, restraining growth of the electrode assembly 106 means that the overall macroscopic increase in one or more dimensions of the electrode assembly 106 is constrained. That is, the overall growth of the electrode assembly 106 can be constrained such that even though volume changes of one or more electrodes within the electrode assembly 106 may occur at a smaller (e.g., microscopic) scale during charge and discharge cycles, an increase in one or more dimensions of the electrode assembly 106 along the (X, Y, and Z axes) can be controlled. Microscopic changes in electrode volume can be observed via, for example, a scanning electron microscope (SEM). Although the set of electrode restraints 108 is capable of inhibiting some individual electrode growth at the microscopic level, some growth may still occur, although the growth can be at least constrained. Although volume changes of individual electrodes during charge / discharge can be small changes of each individual electrode at the microscopic level, there is still such an additional effect: this additional effect causes a relatively large volume change of the entire electrode assembly 106 at the macroscopic level during cycling between the charged state and the discharged state, which may cause strain in the electrode assembly 106.

[0090] According to one embodiment, the electrode active material used in the electrode structure 110 corresponding to the anode of the electrode assembly 106 includes a material that expands when host ions are inserted into the electrode active material during charging of the secondary battery 102. For example, the electrode active material may include an anode active material that accepts host ions (e.g., by embedding or alloying the host ions in an amount sufficient to cause an increase in the volume of the electrode active material) during charging of the secondary battery. For example, in one embodiment, when the secondary battery 102 is charged from a discharged state to a charged state, the electrode active material may include a material having a capacity to accept more than one mole of host ions per mole of the electrode active material. As another example, the electrode active material may include a material having a capacity to accept 1.5 moles or more of host ions per mole of the electrode active material, such as 2.0 moles or more of host ions per mole of the electrode active material, even 2.5 moles or more of host ions per mole of the electrode active material, for example 3.5 moles or more of host ions per mole of the electrode active material. The host ions accepted by the electrode active material may be at least one of lithium, potassium, sodium, calcium, and magnesium. Examples of electrode active materials that provide such volume change upon expansion include silicon (e.g., SiO), aluminum, tin, zinc, silver, antimony, bismuth, gold, platinum, germanium, palladium, and their alloys and compounds, one or more of which. For example, in one embodiment, the electrode active material may include a silicon-containing material in the form of particles, such as particulate silicon, particulate silicon oxide, and mixtures thereof. In yet another embodiment, the electrode active material may include a material that exhibits a small or even negligible volume change. For example, in one embodiment, the electrode active material may include a carbon-containing material such as graphite. In yet another embodiment, the electrode structure includes a lithium layer that serves as the electrode active material layer.

[0091] Another embodiment of the present disclosure may include an energy storage device 100 including the electrode assembly 106, such as the secondary battery 102 and / or a structure therefor, that does not include a restraint system or is restrained by a restraint system other than the set of electrode restraints 108 described herein.

[0092] Electrode assembly

[0093] Referring again to Figure 1B and Figure 2A , in one embodiment, the electrode assembly 106 includes a group of electrode structures 110, a group of counter electrode structures 112, and an electrical insulating separator 130 that electrically insulates the electrode structures 110 from the counter electrode structures 112. In one example, as Figure 1B shown, the electrode assembly includes a series of stacked layers 800 that include alternately arranged electrode structures 110 and counter electrode structures. Figure 1C is a diagram showing having Figure 1BIllustration of a secondary battery with an electrode assembly 106, and Figure 1D is a secondary battery having Figure 1B a cross-section of the electrode assembly 106. As another example, in an embodiment as shown in Figure 2A the electrode assembly 106 includes an interdigitated electrode assembly 106 having interdigitated electrodes and a counter electrode structure.

[0094] Furthermore, as used herein, for each embodiment of a material or structure described using terms such as "electrode", such as "electrode structure" or "electrode active material", it should be understood that such a structure and / or material may, in certain embodiments, correspond to the structure and / or material of a "negative electrode", such as "negative electrode structure" or "negative electrode active material". Similarly, as used herein, for each embodiment of a material or structure described using terms such as "counter electrode", such as "counter electrode structure" or "counter electrode active material", it should be understood that such a structure and / or material may, in certain embodiments, correspond to the structure and / or material of a "positive electrode", such as "positive electrode structure" or "positive electrode active material". That is, in a suitable case, any embodiment described for an electrode and / or a counter electrode may correspond to the same embodiment in which the electrode and / or the counter electrode are specifically a negative electrode and / or a positive electrode, including their respective corresponding structures and materials, respectively.

[0095] In one embodiment, the electrode structure 110 includes an electrode active material layer 132, an electrode backbone 134 that supports the electrode active material layer 132, and an electrode current collector 136, which may be an ion-permeable current collector to allow ions to pass through, as shown in the embodiment shown in Figure 7 For example, in one embodiment, the electrode structure 110 may include an anode structure having an anode active material layer, an anode backbone, and an anode current collector. In yet another embodiment, as shown in Figure 1B the electrode structure 110 may include an anode structure having an anode current collector 136 and an anode active material layer 132. For example, the anode current collector 136 may include an anode current collector layer disposed between one or more anode active material layers. In yet another embodiment, the electrode structure 110 may include a single-layer material, such as a lithium flake electrode. Similarly, in one embodiment, the counter electrode structure 112 includes a counter electrode active material layer 138, a counter electrode current collector 140, and a counter electrode backbone 141 that supports one or more of the counter electrode current collector 140 and / or the counter electrode active material layer 138, such as in Figure 7as shown in the embodiments shown. For example, in one embodiment, the counter electrode structure 112 may include a cathode structure that includes a cathode active material layer, a cathode current collector, and a cathode backbone. In yet another embodiment, the counter electrode structure 110 may include a cathode structure having a cathode current collector 140 and a cathode active material layer 138, as Figure 1B shown. The electrically insulating microporous separator 130 allows carrier ions to pass through during charging and / or discharging to travel between the electrode structure 110 and the counter electrode structure 112 in the electrode assembly 106. In addition, it should be understood that the electrodes and the counter electrode structures 110 and 112 are not limited respectively to the specific embodiments and structures described herein, and other configurations, structures, and / or materials in addition to those specifically described herein may also be provided to form the electrode structure 110 and the counter electrode structure 112. For example, the electrodes and the counter electrode structures 110, 112 may be provided in such a form that the electrodes and the counter electrode structures are substantially free of any electrode and / or counter electrode backbones 134, 141, as Figure 1B in the case, and / or for example in the case where the regions of the electrodes and / or the counter electrode structures 110, 112 that would otherwise contain the backbones are alternatively made of the electrode active material and / or the counter electrode active material.

[0096] According to Figure 1B and 2A the embodiments shown, the members of the groups 110 and 112 of the electrode and the counter electrode structures are arranged in an alternating order, and the direction of the alternating order corresponds to the stacking direction D. The electrode assembly 106 according to this embodiment further includes a longitudinal axis, a transverse axis, and a vertical axis that are perpendicular to each other, and the longitudinal axis A EA generally corresponds to or is parallel to the stacking direction D of the members of the groups of the electrode and the counter electrode structures. As Figure 2A shown in the embodiments in EA the longitudinal axis A Figure 2A is shown as corresponding to the Y axis, the transverse axis is shown as corresponding to the X axis, and the vertical axis is shown as corresponding to the Z axis. Although various features, including the dimensions and axes of the secondary battery and the electrode assembly, are described herein with reference to Figures 1B to 1D it should be understood that such description also applies to the embodiments depicted in other figures herein, including

[0097] In addition, the electrode assembly 106 has a maximum width W measured in the longitudinal direction (i.e., along the y-axis) EA , a maximum length L defined by the transverse surface and measured in the transverse direction (i.e., along the x-axis) EA , and a maximum height H also defined by the transverse surface and measured in the vertical direction (i.e., along the z-axis) EA . The maximum width W EAcan be understood as corresponding to the maximum width of the electrode assembly 106 measured from opposite points on the longitudinal end surfaces 116, 118 of the electrode assembly 106, where the electrode assembly is widest in the longitudinal direction. For example, referring to Figure 2A the embodiment of the electrode assembly 106 in EA the maximum width W Figure 3H can be understood as simply corresponding to the width of the assembly 106 measured in the longitudinal direction. However, referring to EA the embodiment of the electrode assembly 106 shown in EA it can be seen that the maximum width W Figure 2A corresponds to the width of the electrode assembly measured from two opposite points 300a, 300b at the widest part of the electrode assembly in the longitudinal direction, as opposed to the width measured from opposite points 301a, 301b at a narrower part of the electrode assembly 106. Similarly, the maximum length L EA can be understood as corresponding to the maximum length of the electrode assembly measured from opposite points on the transverse surface 142 of the electrode assembly 106 at the longest part of the electrode assembly in the transverse direction. Referring again to Figure 3H the embodiment in EA the maximum length L EA corresponds to the length of the electrode assembly measured from two opposite points 302a, 302b at the longest part of the electrode assembly in the transverse direction, as opposed to the length measured from opposite points 303a, 303b at a shorter part of the electrode assembly. Along similar lines, the maximum height H Figure 2A can be understood as corresponding to the maximum height of the electrode assembly measured from opposite points on the transverse surface 143 of the electrode assembly at the highest part of the electrode assembly in the vertical direction. That is, in EA the embodiment shown in Figure 3H the maximum height H EA is simply the height of the electrode assembly. Although not specifically shown in EA the embodiment shown in EA if the electrode assembly has different heights at points in one or more of the longitudinal and transverse directions, the maximum height H EA of the electrode assembly EA will be understood as corresponding to the height of the electrode assembly measured from two opposite points at the highest part of the electrode assembly in the vertical direction, as opposed to the height measured from opposite points at a shorter part of the electrode assembly, which is similar to that described for the maximum width W EAIt can vary according to the energy storage device 100 and its intended use. For example, in one embodiment, the electrode assembly 106 can include a maximum length L typical of a conventional secondary battery size EA , a maximum width W EA and a maximum height H EA . As another example, in one embodiment, the electrode assembly 106 can include a maximum length L typical of a thin film battery size EA , a maximum width W EA and a maximum height H EA .

[0098] In some embodiments, the dimensions L EA , W EA and H EA are selected to provide an electrode assembly 106 having a maximum length L along the transverse axis (X-axis) that is longer than the maximum height H along the vertical axis (Z-axis) EA and / or a maximum width W along the longitudinal axis (Y-axis) EA . For example, in the EA embodiment shown, the dimensions L Figure 2A , W EA and H EA are selected to provide an electrode assembly 106 having maximum dimensions along the transverse axis (X-axis) orthogonal to the electrode structure stacking direction D and along the longitudinal axis (Y-axis) coinciding with the electrode structure stacking direction D. That is, the maximum length L EA and / or the maximum width W EA can be greater than the maximum height H EA . For example, in one embodiment, the ratio of the maximum length L EA to the maximum height H EA can be at least 2:1. As another example, in one embodiment, the ratio of the maximum length L EA to the maximum height H EA can be at least 5:1. As another example, in one embodiment, the ratio of the maximum length L EA to the maximum height H EA can be at least 10:1. As another example, in one embodiment, the ratio of the maximum length L EA to the maximum height H EA can be at least 15:1. As another example, in one embodiment, the ratio of the maximum length L EA to the maximum height H EA can be at least 20:1. The ratios of different dimensions can allow for an optimal configuration within the energy storage device to maximize the amount of active material, thereby increasing the energy density. EA

[0099] In some embodiments, the maximum width W can be selected​EA to provide a width of the electrode assembly 106 that is greater than the maximum height H EA For example, in one embodiment, the ratio of the maximum width W EA to the maximum height H EA can be at least 2:1. As another example, in one embodiment, the ratio of the maximum width W EA to the maximum height H EA can be at least 5:1. As another example, in one embodiment, the ratio of the maximum width W EA to the maximum height H EA can be at least 10:1. As another example, in one embodiment, the ratio of the maximum width W EA to the maximum height H EA can be at least 15:1. As another example, in one embodiment, the ratio of the maximum width W EA to the maximum height H EA can be at least 20:1.

[0100] According to one embodiment, the ratio of the maximum width W EA to the maximum length L EA can be selected to be within a predetermined range that provides an optimal configuration. For example, in one embodiment, the ratio of the maximum width W EA to the maximum length L EA can be in the range of 1:5 to 5:1. As another example, in one embodiment, the ratio of the maximum width W EA to the maximum length L EA can be in the range of 1:3 to 3:1. As yet another example, in one embodiment, the ratio of the maximum width W EA to the maximum length L EA can be in the range of 1:2 to 2:1.

[0101] In the embodiments shown in Figure 1B and 2A the electrode assembly 106 has a first longitudinal end surface 116 and an opposite second longitudinal end surface 118, and the second longitudinal end surface 118 is separated from the first longitudinal end surface 116 along the longitudinal axis A EA The electrode assembly 106 further includes a lateral surface 142 that at least partially surrounds the longitudinal axis A EA and connects the first and second longitudinal end surfaces 116, 118. In one embodiment, the maximum width W EA is the dimension measured along the longitudinal axis A EA from the first longitudinal end surface 116 to the second longitudinal end surface 118. Similarly, the maximum length L EAIt may be defined by the transverse surface 142 and, in one embodiment, may be a dimension measured along a transverse axis orthogonal to the longitudinal axis from opposite first and second regions 144 and 146 of the transverse surface 142. In one embodiment, the maximum height H EA may be defined by the transverse surface 142 and may be measured along a vertical axis orthogonal to the longitudinal axis from opposite first and second regions 148, 150 of the transverse surface 142.

[0102] For clarity Figure 2A the illustrated embodiment shows only four electrode structures 110 and four counter - electrode structures 112, and in Figure 1B only a limited number of electrode structures 110 and counter - electrode structures are shown. In one embodiment, the alternating order of the members of the groups 110 and 112 of electrodes and counter - electrodes may each include any number of members of each group, depending on the energy storage device 100 and its intended use, and the alternating order of the members of the groups 110 and 112 of electrodes and counter - electrodes may be staggered, e.g., as Figure 2AAs shown. As another example, in one embodiment, each member of the electrode structure group 110 can be located between two members of the electrode structure group 112, except when the alternating sequence terminates along the stacking direction D. As another example, in one embodiment, each member of the electrode structure group 112 can be located between two members of the electrode structure group 110, except when the alternating sequence terminates along the stacking direction D. As another example, in one embodiment, and more generally, the electrode structure group 110 and the electrode structure group 112 each have N members, each of the N-1 electrode structure members 110 is located between two electrode structure members 112, each of the N-1 electrode structure members 112 is located between two electrode structure members 110, and N is at least 2. As another example, in one embodiment, N is at least 4. As another example, in one embodiment, N is at least 5. As another example, in one embodiment, N is at least 10. As another example, in one embodiment, N is at least 25. As another example, in one embodiment, N is at least 50. As another example, in one embodiment, N is at least 100 or more. In one embodiment, the electrode and / or counter electrode group members extend sufficiently from an imaginary back plate (e.g., a plane substantially coinciding with the surface of the electrode assembly) to have a surface area (ignoring porosity) greater than twice the geometric footprint (i.e., projection) of the member in the back plate. In certain embodiments, the ratio of the surface area of ​​the non-layered (i.e., three-dimensional) electrode and / or counter electrode structure to its geometric footprint in the imaginary back plate can be at least about 5, at least about 10, at least about 50, at least about 100, and / or even at least about 500. However, the ratio is typically between about 2 and about 1000. In one such embodiment, the member of the electrode group is essentially non-layered. As another example, in one such embodiment, the member of the counter electrode group is essentially non-layered. As another example, in one such embodiment, the member of the electrode group and the member of the counter electrode group are essentially non-layered.

[0103] According to one embodiment, the electrode assembly 106 has longitudinal ends 117, 119, and the electrode assembly 106 terminates at the longitudinal ends 117, 119. According to one embodiment, the alternating sequence of electrodes and counter electrode structures 110, 112 in the electrode assembly 106 terminates in a symmetrical manner along the longitudinal direction, for example, the electrode structure 110 terminates at each end 117, 119 of the electrode assembly 106 in the longitudinal direction, or the counter electrode structure 112 terminates at each end 117, 119 of the electrode assembly 106 in the longitudinal direction. In another embodiment, the alternating sequence of electrodes 110 and counter electrode structures 112 can terminate in an asymmetrical manner along the longitudinal direction, for example, the electrode structure 110 terminates at the longitudinal axis A. EA The electrode structure 112 terminates at one end 117 of the longitudinal axis A.EA at the other end 119. According to yet another embodiment, the electrode assembly 106 may be terminated by having, at one or more ends 117, 119 of the electrode assembly 106, one or more sub-structures of the electrode structure 110 and / or the counter electrode structure 112. As an example, according to one embodiment, the alternating sequence of the electrode structure 110 and the counter electrode structure 112 may terminate at one or more sub-structures of the electrode 110 and the counter electrode structure 112, where the sub-structures include the electrode backbone 134, the counter electrode backbone 141, the electrode current collector 136, the counter electrode current collector 140, the electrode active material layer 132, the counter electrode active material layer 138, etc., and may also be terminated by having, for example, structures such as the separator 130, and the structures at each longitudinal end 117, 119 of the electrode assembly 106 may be the same (symmetric) or different (asymmetric). The longitudinal terminals 117, 119 of the electrode assembly 106 may include first and second longitudinal end surfaces 116, 118, and the longitudinal end surfaces 116, 118 contact the first and second primary growth restraint members 154, 156 to restrain the overall growth of the electrode assembly 106.

[0104] According to yet another embodiment, the electrode assembly 106 has first and second transverse ends 145, 147 (see, for example, Figure 1B and 2A ), and the first and second transverse ends 145, 147 may be in contact with one or more electrode and / or counter electrode tabs 190, 192 (see, for example, Figure 10 ), and these tabs may be used to electrically connect the electrode and / or counter electrode structures 110, 112 to a load and / or a voltage source (not shown). For example, the electrode assembly 106 may include an electrode bus 194 (see, for example, Figure 2A ), and each electrode structure 110 may be connected to the electrode bus 194, and the electrode bus 194 collects the current from each member of the group of electrode structures 110. Similarly, the electrode assembly 106 may include a counter electrode bus 196, and each counter electrode structure 112 may be connected to the counter electrode bus 196, and the counter electrode bus 196 collects the current from each member of the group of counter electrode structures 112. The electrode and / or counter electrode buses 194, 196 each have a length measured in the direction D, and this length extends substantially over the entire length of a series of interleaved electrode structures 110, 112. In Figure 10In the illustrated embodiment, the electrode contact piece 190 and / or the counter electrode contact piece 192 include electrode contact piece extensions 191, 193 that are electrically connected to the electrode and / or the counter electrode buses 194, 196 and extend substantially along the entire length of the electrode and / or the counter electrode buses 194, 196. Alternatively, the electrode and / or the counter electrode contact pieces 190, 192 may be directly connected to the electrode and / or the counter electrode buses 194, 196 along the length of the buses 194, 196, such as at their ends or intermediate positions, without the need for contact piece extensions 191, 193. Thus, in one embodiment, the electrode and / or the counter electrode buses 194, 196 may form at least a portion of the terminals 145, 147 of the electrode assembly 106 in the lateral direction and connect the electrode assembly to the contact pieces 190, 192 for electrical connection to a load and / or a voltage source (not shown). Additionally, in yet another embodiment, the electrode assembly 106 includes first and second terminals 149, 153 disposed along the vertical (Z) axis. For example, according to one embodiment, each electrode structure 110 and / or counter electrode structure 112 is provided with top and bottom coatings made of a spacer material, as Figure 2A shown, where the coatings form the terminals 149, 153 of the electrode assembly 106 in the vertical direction. The terminals 149, 153 that may be formed by the coatings of the spacer material may include first and second surface regions 148, 150 of the lateral surface 142 along the vertical axis, which may be arranged to contact the first and second secondary growth constraining members 158, 160 to constrain growth in the vertical direction.

[0105] Typically, the electrode assembly 106 may include planar, coplanar, or non-planar longitudinal end surfaces 116, 118. For example, in one embodiment, the opposing longitudinal end surfaces 116, 118 may be convex. As another example, in one embodiment, the opposing longitudinal end surfaces 116, 118 may be concave. As another example, in one embodiment, the opposing longitudinal end surfaces 116, 118 are substantially planar. In certain embodiments, the electrode assembly 106 may include opposing longitudinal end surfaces 116, 118 that, when projected onto a plane, have any range of two-dimensional shapes. For example, the longitudinal end surfaces 116, 118 may independently have a smooth curved shape (e.g., circular, elliptical, hyperbolic, or parabolic), they may independently include a series of lines and vertices (e.g., a polygon), or they may independently include a smooth curved shape and include one or more lines and vertices. Similarly, the transverse surface 142 of the electrode assembly 106 may be a smooth curved shape (e.g., the electrode assembly 106 may have a circular, elliptical, hyperbolic, or parabolic cross-sectional shape) or the transverse surface 142 may include two or more lines joined at vertices (e.g., the electrode assembly 106 may have a polygonal cross-section). For example, in one embodiment, the electrode assembly 106 has a cylindrical, elliptical cylindrical, parabolic cylindrical, or hyperbolic cylindrical shape. As another example, in one such embodiment, the electrode assembly 106 may have a prismatic shape, with opposing longitudinal end surfaces 116, 118 of the same size and shape and a transverse surface 142 that is a parallelogram (i.e., the surface extending between the opposing longitudinal end surfaces 116 and 118). As another example, in one such embodiment, the electrode assembly 106 has a shape corresponding to a triangular prism, with the electrode assembly 106 having two opposing triangular longitudinal end surfaces 116 and 118 and a transverse surface 142 consisting of three parallelograms (e.g., rectangles) extending between the two longitudinal ends. As another example, in one such embodiment, the electrode assembly 106 has a shape corresponding to a rectangular prism, with the electrode assembly 106 having two opposing rectangular longitudinal end surfaces 116 and 118 and a transverse surface 142 including four parallelogram (e.g., rectangle) faces. As another example, in one such embodiment, the electrode assembly 106 has a shape corresponding to a pentagonal prism, hexagonal prism, etc., where the electrode assembly 106 has two opposing longitudinal end surfaces 116 and 118 that are pentagonal, hexagonal, etc., respectively, and a transverse surface that includes five, six, etc., parallelogram (e.g., rectangle) faces, respectively.

[0106] Now referring to Figures 3A to 3H , several exemplary geometries of the electrode assembly 106 are schematically illustrated. More specifically, in Figure 3AIn [reference], the electrode assembly 106 has a triangular prism shape, having along a longitudinal axis A EA separated opposite first and second longitudinal end surfaces 116, 118, and a transverse surface 142 including three rectangular faces connecting the longitudinal end surfaces 116, 118 and surrounding the longitudinal axis A EA In Figure 3B In [reference], the electrode assembly 106 has a parallelepiped shape, having along a longitudinal axis A EA separated opposite first and second parallelogram longitudinal end surfaces 116, 118, and a transverse surface 142 including four parallelogram faces connecting the two longitudinal end surfaces 116, 118 and surrounding the longitudinal axis A EA In Figure 3C In [reference], the electrode assembly 106 has a rectangular prism shape, having along a longitudinal axis A EA separated opposite first and second rectangular longitudinal end surfaces 116, 118, and a transverse surface 142 including four rectangular faces connecting the two longitudinal end surfaces 116, 118 and surrounding the longitudinal axis A EA In Figure 3D In [reference], the electrode assembly 106 has a pentagonal prism shape, having along a longitudinal axis A EA separated opposite first and second pentagonal longitudinal end surfaces 116, 118, and a transverse surface 142 including five rectangular faces connecting the two longitudinal end surfaces 116, 118 and surrounding the longitudinal axis A EA In Figure 3E In [reference], the electrode assembly 106 has a hexagonal prism shape, having along a longitudinal axis A EA separated opposite first and second hexagonal longitudinal end surfaces 116, 118, and a transverse surface 142 including six rectangular faces connecting the two longitudinal end surfaces 116, 118 and surrounding the longitudinal axis A EA In Figure 3E In [reference], the electrode assembly has a frustum of a square pyramid shape, having along a longitudinal axis A EA separated opposite first and second square end surfaces 116, 118, and a transverse surface 142 including four trapezoidal faces connecting the two longitudinal end surfaces 116, 118 and surrounding the longitudinal axis A EA where the trapezoidal faces taper in size along the longitudinal axis, from a larger size at the first surface 116 to a smaller size at the second surface 118, and the size of the second surface is smaller than the size of the first surface. In Figure 3F In [reference], the electrode assembly has a frustum of a pentagonal pyramid shape, having along a longitudinal axis A EA separated opposite first and second square end surfaces 116, 118, and a transverse surface 142 including four trapezoidal faces connecting the two longitudinal end surfaces 116, 118 and surrounding the longitudinal axis A EAthe transverse surfaces 142 of the five trapezoidal faces, where the trapezoidal faces taper in size along the longitudinal axis from a larger size at the first surface 116 to a smaller size at the second surface 118, and the size of the second surface is smaller than that of the first surface. In Figure 3H , by means of the electrode and counter - electrode structures 110, 112, the electrode assembly 106 has a pyramid shape in the longitudinal direction, and the length of the electrode and counter - electrode structures decreases from a first length towards the middle of the electrode assembly 106 to a second length at the longitudinal ends 117, 119 of the electrode assembly 106 along the longitudinal axis.

[0107] Electrode / counter - electrode separation distance

[0108] In one embodiment, the electrode assembly 106 has an electrode structure 110 and a counter - electrode structure 112, where in adjacent electrode and counter - electrode structures 110, 112, the offset between the electrode active material layer 132 and the counter - electrode material layer 138 in height (vertical direction) and / or length (transverse direction) is selected within a predetermined range. By way of illustration, Figure 14A an embodiment of a cross - section of the electrode assembly 106 is depicted. The electrode assembly 106 includes an electrode active material layer 132 of the electrode structure 110, which is adjacent to a counter - electrode active material layer 138 of the counter - electrode structure 112, and there is a microporous separator 130 therebetween. In the cross - sectional view shown, the height of the electrode active material layer 132 in the z - direction is approximately equal to the height of the counter - electrode active material layer 138 in the z - direction. A structure with electrode active material layer 132 and counter - electrode active material layer 138 having the same height can be beneficial in terms of matching the carrier ion capacity between the layers, thus increasing the storage capacity of the secondary battery 102 with layers of equal height, but such layers of equal height also pose problems. Specifically, for a counter - electrode active material layer 138 having a height overly close to the height of the electrode active material layer 132, carrier ions may be attracted to the vertical end surfaces 500 of the electrode active material layer 132 and / or the exposed portions of the electrode current collector 136 that form part of the electrode structure 110. The result may be precipitation of carrier ions and / or formation of dendrites, which may ultimately lead to performance degradation and / or battery failure. Although the height of the cathode active material layer 138 can be reduced relative to the electrode active material layer 34 to mitigate this problem, excessive inequality in size affects the storage capacity and function of the secondary battery. In addition, even when an offset or separation distance is provided between the layers 138, 132, it may be the case that, for example, during the use or transportation of the secondary battery 106, mechanical shock or collision of the secondary battery having these layers may cause the layers to move and change the alignment of the layers 138, 132, such that any original offset and / or separation distance between the layers becomes negligible or even eliminated.

[0109] Accordingly, aspects of the present disclosure are directed to the discovery that by providing a set of restraints 108 (such as a set of restraints corresponding to any of the embodiments described herein), alignment between the layers 138, 132 in the electrode structure 110 and the counter electrode structure 112 can be maintained even under the physical and mechanical stresses encountered during normal use or transportation of the secondary battery. Thus, a sufficiently small predetermined offset and / or separation distance can be selected to provide good storage capacity of the secondary battery 106 while also reducing the risk of battery short circuit or failure, where the predetermined offset is as small as 5 μm and typically no more than 500 μm.

[0110] Reference Figures 14A - 14H , describes other aspects in accordance with the present disclosure. Specifically, it should be noted that the electrode assembly 106 includes a group of electrode structures 110, a group of electrode current collectors 136, a group of separators 130, a group of counter electrode structures 112, a group of counter electrode current collectors 140, and a group of unit elements 504. As shown in reference Figure 1B and 2A , the components of the electrode and counter electrode structure groups are arranged in an alternating order in the longitudinal direction. Each component of the group of electrode structures 110 includes an electrode current collector 136 and an electrode active material layer 132, and the length L E of the electrode active material layer 132 corresponds to the Feret diameter measured in the transverse direction between the first and second opposite transverse end surfaces 502a, b of the electrode active material layer (e.g., see Figure 15A ). The height H E corresponds to the Feret diameter of the electrode active material layer measured in the vertical direction between the first and second opposite vertical end surfaces 500a, b of the electrode active material layer 132, and this height is measured in the vertical direction between the opposite first and second vertical end surfaces 500a, b of the electrode active material layer (e.g., see Figure 17 ). Each component of the electrode structure 110 further has an electrode active material layer 132, and the width W E of the electrode active material layer 132 corresponds to the Feret diameter of the electrode active material layer 132 measured in the longitudinal direction between the first and second opposite surfaces of the electrode active material layer (e.g., see Figure 14A ). Each component in the group of counter electrode structures also includes a counter electrode current collector 140 and a counter electrode active material layer 138, and the length L C of the counter electrode active material layer 138 corresponds to the Feret diameter of the counter electrode active material measured in the transverse direction between the first and second opposite transverse end surfaces 503a, b of the counter electrode active material layer 138 (e.g., see Figure 15A ), and the height H CThe Feret diameter measured in the vertical direction between the first and second opposite vertical end surfaces 501a, 501b of the counter electrode active material layer 138 (for example, see Figure 17 ). Each member of the counter electrode structure group 112 also has a counter electrode active material layer 138, and the width W of the counter electrode active material layer 138 C corresponds to the Feret diameter of the counter electrode active material layer 138 measured in the longitudinal direction between the first and second opposite surfaces of the electrode active material layer (for example, see Figure 14A ).

[0111] As defined above, the Feret diameter of the electrode active material layer 132 in the transverse direction is the distance measured in the transverse direction between two parallel planes that limit the electrode active material layer in the direction perpendicular to the transverse direction. The Feret diameter of the electrode active material layer 132 in the vertical direction is the distance measured in the vertical direction between two parallel planes that limit the electrode active material layer in the direction perpendicular to the vertical direction. The Feret diameter of the counter electrode active material layer 138 in the transverse direction is the distance measured in the transverse direction between two parallel planes that limit the counter electrode active material layer in the direction perpendicular to the transverse direction. The Feret diameter of the counter electrode active material layer 138 in the vertical direction is the distance measured in the vertical direction between two parallel planes that limit the counter electrode active material layer in the direction perpendicular to the vertical direction. For purposes of explanation, Figure 13A and 13B depict the Feret diameter of the electrode active material layer 132 and / or the counter electrode active material layer 138 determined in a single 2D plane. Specifically, Figure 13A depicts a 2D slice of the electrode active material layer 132 and / or the counter electrode active material layer taken along the Z-Y plane. The distance between two parallel X-Y planes (505a, 505b) that limit the layer in the z direction (vertical direction) corresponds to the height of the layer H in this plane (i.e., H E or H C ). That is, the Feret diameter in the vertical direction can be understood as a measure corresponding to the maximum height of the layer. Although the description in Figure 13A is only for the 2D slice, for purposes of explanation, it can be understood that in 3D space, the Feret diameter in the vertical direction is not limited to a single slice, but is the distance between the X-Y planes 505a, 505b that are separated from each other in the vertical direction and that limit the three-dimensional layer therein. Similarly, Figure 13B depicts a 2D slice of the electrode active material layer 132 and / or the counter electrode active material layer taken along the X-Z plane. The distance between two parallel Z-Y planes (505c, 505d) that limit the layer in the x direction (transverse direction) corresponds to the layer L in the plane (i.e., L E or LC ) length. That is, the Feret diameter in the transverse direction can be understood as a measure corresponding to the maximum length of the layer. Although Figure 13B the description in [reference] is only for 2D slices, for the purpose of explanation, it can be understood that in 3D space, the Feret diameter in the transverse direction is not limited to a single slice, but is the distance between the Z-Y planes 505c and 505d separated from each other in the transverse direction, and the Z-Y planes 505c and 505d limit the three-dimensional layer therein. The Feret diameter of the electrode active material layer and / or the counter electrode active material in the longitudinal direction can be obtained similarly to obtain the width W E of the electrode active material layer 132 and / or the width W C of the counter electrode active material layer 138.

[0112] In one embodiment, as described elsewhere herein, the electrode assembly 106 can be understood to have a transverse axis, a longitudinal axis, and a vertical axis corresponding to the x, y, and z axes of a fictional three-dimensional Cartesian coordinate system that are perpendicular to each other, a first longitudinal end surface and a second longitudinal end surface separated from each other in the longitudinal direction, and a transverse surface that surrounds the longitudinal axis A EA of the electrode assembly and connects the first longitudinal end surface and the second longitudinal end surface, and the transverse surface has opposite first and second regions located on opposite sides of the longitudinal axis and separated in a first direction orthogonal to the longitudinal axis. The electrode assembly has a maximum width W measured in the longitudinal direction EA , a maximum length L defined by the transverse surface and measured in the transverse direction EA , and a maximum height H defined by the transverse surface and measured in the vertical direction EA .

[0113] Referring again to Figures 14A to Figure 14H , it can be seen that each unit element 504 includes a unit element portion of the first electrode current collector 136 of the electrode current collector group, a separator 130 that is ion-permeable to carrier ions (for example, a separator including a porous material), a first electrode active material layer 132 of a member in the electrode group, a unit element portion of the first counter electrode current collector 140 of the counter electrode current collector group, and a first counter electrode active material layer 138 of a member in the counter electrode group. In one embodiment, in the case of continuous and / or adjacent members 504a, 504b, 504c in the unit element group (for example, as Figure 18A shown), at least a part of the electrode current collector 136 and / or the counter electrode current collector can be shared between the units (504a and 504b, and 504b and 504c). For example, referring to Figure 18A, it can be seen that unit elements 504a and 504b share the counter electrode current collector 140, while unit elements 504b and 504c share the electrode current collector 136. In one embodiment, each unit element includes 1 / 2 of the shared current collector, although other structural arrangements may also be provided. According to yet another embodiment, for the current collector that forms part of the terminal unit element at the longitudinal end of the electrode assembly 106, the unit element 504 may include a non-shared current collector and thus includes the entire current collector as part of the element.

[0114] In addition, referring again to Figures 14A to Figure 14H and Figure 18A the unit elements, it can be seen that within each unit element 504, the first electrode active material layer 132a is adjacent to the first side 506a of the separator 130, and the first counter electrode material layer 138a is adjacent to the opposite second side 506b of the separator 130. As shown in the embodiment of Figure 18A , the electrode structure 110 includes both the first electrode active material layer 132a that forms part of the unit element 504a in the longitudinal direction and the second electrode active material layer 132b that forms part of the next adjacent unit element. Similarly, the counter electrode structure 112 includes the first counter electrode active material layer 138a that forms part of the unit element 504a in the longitudinal direction and the second counter electrode active material layer 138b that forms part of the next adjacent unit element 504b. The separator 130 electrically isolates the first electrode active material layer 132a from the first counter electrode active material layer 138a, and during cycling of the battery between the charged and discharged states, carrier ions are exchanged between the first electrode active material layer 132a and the first counter electrode active material layer 138a via the separator 130 of each such unit element 504.

[0115] To further clarify the offset and / or separation distance between the first electrode active material layer 132a and the first counter electrode active material layer 138a in each unit element 504, refer to Figure 11A -C and 12A-C. Specifically, referring to Figure 11A -C, the offset and / or separation distance in the vertical direction is described. As shown in the Figure 11A of this embodiment, the first vertical end surfaces 500a, 501a of the electrode and counter electrode active material layers 132, 138 are on the same side of the electrode assembly 106. In addition, the median vertical position of the first opposite vertical end surface 500a of the electrode active material 132 in the X-Z plane is along the length L of the electrode active material layer E The 2D drawing of the first vertical end surface graph E is shown in VP1 . That is, as referred to in Figure 11CAs shown, for each ZY plane along the transverse direction (X), the median vertical position (z position) of the vertical end surface 500a of the electrode active material layer 132 can be determined such that the median of the z position of this surface as a function of y is obtained at a specific transverse position of the ZY plane (e.g., X 1 、X 2 、X 3 etc.). Figure 11C Generally depicts an example of a line, which shows the median vertical position (z position) of the vertical end surface 500a of a specific ZY plane at a selected x slice (e.g., the slice at X 1 ). (Note that Figure 11C Generally describes the determination of the median vertical position of the vertical end surface (the dashed lines at the top and bottom of the figure), i.e., the determination of the median vertical position of the first vertical end surface 500a and the second vertical end surface 500b of the electrode active material layer 132, and / or the determination of the median vertical position of the first vertical end surface 501a and the second vertical end surface 501b of the counter electrode active material layer 138.) Figure 11B Depicts an embodiment in which a 2D plot of this median vertical position determined along the length L E (i.e., along each x position X E of the length L 1 、X 2 、X 3 etc.) of the electrode active material plots the first vertical end surface plot E VP1 , and the first vertical end surface plot E VP1 corresponds to the median vertical position (z position) plotted as a function of x (e.g., at X 1 、X 2 、X 3 etc.). For example, for x positions corresponding to X 0E at the first transverse end of the electrode active material layer to X LE at the second transverse end of the electrode active material layer, the median vertical position of the vertical end surface 500a of the electrode active material layer 132 can be plotted as a function of x (transverse position), where X LE -X L0 is equivalent to the Feret diameter of the electrode active material layer 132 in the transverse direction (the length L E of the electrode active material layer 132).

[0116] Similarly, in the case of the first opposite end surface 501a of the counter electrode active material layer 138, the median vertical position of the first opposite vertical end surface 501a of the counter electrode active material layer 138 in the X-Z plane along the length L CThe 2D drawing shows the first vertical end surface drawing CE VP1 . Referring again to Figure 11C , it can be understood that for each ZY plane in the transverse direction, the median vertical position (z-position) of the vertical end surface 501a of the counter electrode active material layer 138 can be determined in such a way that, by obtaining the median of the z-position of this surface as a function of y at a specific transverse position (e.g., X 1 , X 2 , X 3 , etc.) in this ZY plane. Figure 11C Generally depicts an example of a line, which shows the median vertical position (z-position) of the vertical end surface 501a of a specific YZ plane at a selected x-slice (e.g., the slice at X 1 ). Figure 11B Depicts an embodiment in which the 2D drawing of the median vertical position determined along the length L C (i.e., along each x-position X C of the length L 1 , X 2 , X 3 ) of the counter electrode active material depicts the first vertical end surface drawing CE VP1 , the first vertical end surface drawing CE VP1 corresponding to the median vertical position (z-position) plotted as a function of x (e.g., at X 1 , X 2 , X 3 , etc.). For example, for x-positions corresponding to X 0c at the first transverse end of the counter electrode active material layer to X Lc at the second transverse end of the counter electrode active material layer, the median vertical position of the vertical end surface 501a of the counter electrode active material layer 138 can be plotted as a function of x (transverse position), where X Lc - X L0 is equivalent to the Feret diameter of the counter electrode active material layer 138 in the transverse direction (the length L C of the counter electrode active material layer 138).

[0117] In addition, the offset and / or separation distance requirements for the vertical spacing between the first vertical surfaces 500a, 501a of the electrode active material layer 132 and the counter electrode active material layer 138: for at least 60% of the length L C of the first counter electrode active material layer: (i) the absolute value of the separation distance S VP1 between the curves E VP1 and CE Z1 measured in the vertical direction is 1000 μm ≥ |S Z1|≥5 μm. Additionally, in one embodiment, it is required that for the length L of the first pair of electrode active material layers C of at least 60%: (ii) between the first vertical end surfaces 500a, 500b of the electrode and the counter electrode active material layers 132, 138, the first vertical end surface of the counter electrode active material layer is disposed inward (e.g., inward along 508) relative to the first vertical end surface of the electrode active material layer. That is, by referring to Figure 11B , it can be seen that for the length L of the first pair of electrode active material layers 138 C of at least 60%, that is, for at least 60% of the position x from X 0C to X LC (60% of the Feret diameter of the counter electrode active material layer in the lateral direction), the absolute value of the separation distance S Z1 is required to be no greater than 1000 μm and no less than 5 μm, and this separation distance S Z1 has an absolute value corresponding to the distance between the curve E VP1 and CE VP1 at any given point along x. Additionally, it can be seen that for the length L of the first pair of electrode active material layers 138 C of at least 60%, that is, for at least 60% of the position x from X 0C to X LC (60% of the Feret diameter of the counter electrode active material layer in the lateral direction), the first vertical end surface of the counter electrode active material layer is disposed inward relative to the first vertical end surface of the electrode active material layer.

[0118] In one embodiment, the absolute value of S Z1 can be ≥5 μm, such as ≥10 μm, ≥15 μm, ≥20 μm, ≥35 μm, ≥45 μm, ≥50 μm, ≥75 μm, ≥100 μm, ≥150 μm, and ≥200 μm. In another embodiment, the absolute value of S Z1 can be ≤1000 microns, such as ≤500 μm, such as ≤475 μm, ≤425 μm, ≤400 μm, ≤375 μm, ≤350 μm, ≤325 μm, ≤300 μm, and ≤250 μm. In one embodiment, the absolute value of S Z1 can follow the relationship: 1000 μm ≥ |S Z1 | ≥ 5 μm, and / or 500 μm ≥ |S Z1 | ≥ 10 μm, and / or 250 μm ≥ |S Z1 | ≥ 20 μm. In yet another embodiment, for the Feret diameter of the width W E of the counter electrode active material layer 132 in the unit element, the absolute value of S Z1 can be within 5 × WE ≥|S Z1 |≥0.05×W E In addition, in one embodiment, |S Z1 Any of the above values ​​and / or relationships may apply to the length L of the first electrode active material layer. C 60% or more, for example, the length L of the first pair of electrode active material layers C At least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, even at least 95% of the total weight of the aqueous solution.

[0119] In addition, for 0C To X LC The first vertical end surface of the electrode active material layer is disposed inwardly relative to the first vertical end surface of the electrode active material layer. That is, the electrode active material layer 132 can be understood as having a length L of the electrode active material layer. C At least 60% of the electrode active material layer 130 has a median vertical position closer to the lateral surface (eg Figure 11C In other words, the electrode active material layer 138 may be understood to have a median vertical position that is further along the inward direction 508 of the electrode assembly 106 than the median vertical position of the electrode active material layer 132 (e.g., Figure 11C , for a given X slice, the position in z in the YZ plane). This vertical offset of the electrode active material layer 132 relative to the counter electrode active material layer 138 can also be related to Figure 11A As seen in the examples, Figure 11A shows that the height of the electrode material layer 132 exceeds the height of the counter electrode active material layer 138, and Figure 11B The curve shows the median vertical position E of the electrode active material layer 132. VP1 The median vertical position CE of the active material layer of the electrode is exceeded in the lateral direction VP1 In one embodiment, for the length L of the first pair of electrode active material layers C 60% or more, for example, the length L of the first pair of electrode active material layers C At least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or even at least 95% of the first vertical end surface of the electrode active material layer is arranged inwardly relative to the first vertical end surface of the electrode active material layer.

[0120] In one embodiment, the separation distance S with respect to the first vertical end surfaces 500a, 501a of the electrode and the counter electrode active material layers 132, 138 z1 For the above relationship, the relationship of the separation distances of the second vertical surfaces 500b, 501b of the electrode and the counter electrode active material layers 132, 138 can also be determined (e.g., as shown Figure 18A ). That is, the second vertical end surfaces 500b and 501b are on the same side of the electrode assembly 106 with respect to each other and are respectively opposite to the first vertical end surfaces 500a, 501a of the electrode and the counter electrode active material layers 132, 138. In addition, similar to the description of the separation distance and / or offset S z1 given above, the median vertical position of the second opposite vertical end surface 500b of the electrode active material 132 in the X-Z plane along the length L E of the electrode active material layer is depicted in a 2D plot in the direction of the second vertical end surface plot E VP2 . That is, as shown in reference Figure 11A -C, for each YZ plane along the transverse direction, the median vertical position (z position) of the second vertical end surface 500b of the electrode active material layer 132 can be determined in such a way that, by obtaining the median of the z positions of the surface as a function of y at a specific transverse position (e.g., X 1 , X 2 , X 3 , etc.) in that YZ plane. Figure 11C Generally depicts an example of a line that shows the median vertical position (z position) of the second vertical end surface 500b of a specific YZ plane at a selected x slice (e.g., the slice at X 1 ). Figure 11B Depicts an embodiment in which a 2D plot of the median vertical position determined along the length L E of the electrode active material (i.e., along each x position X E of the length L 1 , X 2 , X 3 , etc.) plots the second vertical end surface plot E VP2 , and the second vertical end surface plot E VP2 corresponds to the median vertical position (z position) plotted as a function of x (e.g., at X 1 , X 2 , X 3 , etc.). For example, for X 0E corresponding to the first transverse end of the electrode active material layer to X LEFor the x position, the median vertical position of the second vertical end surface 500b of the electrode active material layer 132 can be plotted as a function of x (lateral position), where X LE -X L0 is equivalent to the Feret diameter of the electrode active material layer 132 in the lateral direction (the length L of the electrode active material layer 132 E ).

[0121] Similarly, in the case of the second opposite end surface 501b of the counter electrode active material layer 138, the median vertical position of the second opposite vertical end surface 501b of the counter electrode active material layer 138 is plotted in the X-Z plane along the length L of the counter electrode active material layer 138 C The 2D plot of the second vertical end surface CE VP2 . Referring again to Figures 11A to 11C , it can be understood that for each YZ plane along the lateral direction, the median vertical position (z position) of the second vertical end surface 501b of the counter electrode active material layer 138 can be determined in such a way that the median value of the z position of the surface as a function of y at a specific lateral position (e.g., X 1 , X 2 , X 3 , etc.) in that YZ plane is obtained. Figure 11C Generally depicts an example of a line, which shows the median vertical position (z position) of the second vertical end surface 501b of a specific YZ plane at a selected x slice (e.g., the slice at X 1 ). Figure 11B Depicts an embodiment in which the 2D plot of the median vertical position determined along the length L C (i.e., along each x position X C of the length L 1 , X 2 , X 3 ) of the counter electrode active material depicts the second vertical end surface plot CE VP2 , and the second vertical end surface plot CE VP2 corresponds to the median vertical position (z position) plotted as a function of x (e.g., at X 1 , X 2 , X 3 , etc.). For example, for x positions corresponding to X 0c at the first lateral end of the counter electrode active material layer to X Lc at the second lateral end of the counter electrode active material layer, the median vertical position of the second vertical end surface 501b of the counter electrode active material layer 138 can be plotted as a function of x (lateral position), where X Lc -X L0Equivalent to the Feret diameter of the counter electrode active material layer 138 in the lateral direction (the length L of the counter electrode active material layer 138 C ).

[0122] In addition, the requirements for the offset and / or separation distance of the vertical interval between the second vertical surfaces 500b and 501b of the electrode active material layer 132 and the counter electrode active material layer 138, for the length L of the first counter electrode active material layer C of at least 60%: (i) The separation distance S VP2 between Figure E VP2 and CE Z2 measured in the vertical direction has an absolute value of 1000 μm ≥ |S Z2 | ≥ 5 μm. Additionally, in one embodiment, it is required that for the length L of the first counter electrode active material layer C of at least 60%: (ii) Between the second vertical end surfaces 500b and 501b of the electrode and the counter electrode active material layers 132 and 138, the second vertical end surface of the counter electrode active material layer is set inward relative to the second vertical end surface of the electrode active material layer. That is, by referring to Figure 11B , it can be seen that the absolute value of the separation distance S Z2 is required to be no greater than 1000 μm and no less than 5 μm, which is for at least 60% of the length L of the first counter electrode active material layer 138 C , that is, for at least 60% of the position x from X 0C to X LC (60% of the Feret diameter of the counter electrode active material layer in the lateral direction), the absolute value of this separation distance S Z2 corresponds to the distance between Figure E VP2 and CE VP2 at any given point along x. In addition, it can be seen that for at least 60% of the length L of the first counter electrode active material layer 138 C , that is, for at least 60% of the position x from X 0C to X LC (60% of the Feret diameter of the counter electrode active material layer in the lateral direction), the second vertical end surface of the counter electrode active material layer is set inward relative to the second vertical end surface of the electrode active material layer.

[0123] In one embodiment, the absolute value of S Z2 can be ≥ 5 μm, for example ≥ 10 μm, ≥ 15 μm, ≥ 20 μm, ≥ 35 μm, ≥ 45 μm, ≥ 50 μm, ≥ 75 μm, ≥ 100 μm, ≥ 150 μm, and ≥ 200 μm. In another embodiment, S Z2The absolute value of can be ≤ 1000 microns, such as ≤ 500μm, such as ≤ 475μm, ≤ 425μm, ≤ 400μm, ≤ 375μm, ≤ 350μm, ≤ 325μm, ≤ 300μm, and ≤ 250μm. In one embodiment, S Z2 The absolute value of can follow the relationship: 1000μm ≥ |S Z2 | ≥ 5μm, and / or 500μm ≥ |S Z2 | ≥ 10μm, and / or 250μm ≥ |S Z2 | ≥ 20μm. In yet another embodiment, for the width W E of the counter electrode active material layer 132 in the unit element, the Feret diameter of S Z2 The absolute value of can be in the range of 5×W E ≥ |S Z2 | ≥ 0.05×W E . In addition, in one embodiment, any of the above values and / or relationships of |S Z2 | can apply to more than 60% of the length L C of the first counter electrode active material layer, such as at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or even at least 95% of the length L C of the first counter electrode active material layer. In addition, the values and / or relationships described above for S Z2 can be the same as and / or different from those for S Z1 , and / or can apply to a percentage of the length L Z1 different from that for S C .

[0124] In addition, for at least 60% of the position x from X 0C to X LC (60% of the Feret diameter of the counter electrode active material layer in the lateral direction), the second vertical end surface of the counter electrode active material layer is set inward relative to the second vertical end surface of the electrode active material layer. That is, the electrode active material layer 132 can be understood as having a median vertical position closer to the lateral surface than the counter electrode active material layer 130 for at least 60% of the length L C of the electrode active material layer (as shown in Figure 11C , the position on z in the YZ plane for a specified X slice). In other words, the counter electrode active material layer 138 can be understood as having a median vertical position farther in the inward direction 508 along the electrode assembly 106 than the median vertical position of the electrode active material layer 132 (as shown in Figure 11C , the position on z in the YZ plane for a specified X slice). This vertical offset of the electrode active material layer 132 relative to the counter electrode active material layer 138 can also be with respect toFigure 11A As seen in the examples, Figure 11A shows that the height of the electrode material layer 132 exceeds the height of the counter electrode active material layer 138, and Figure 11B The curve shows the median vertical position E of the electrode active material layer 132. VP2 Below the median vertical position of the active material layer of the counter electrode in the lateral direction CE VP2 In one embodiment, for the length L of the first pair of electrode active material layers C 60% or more, for example, the length L of the first pair of electrode active material layers C At least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or even at least 95% of the second vertical end surface of the electrode active material layer is arranged inwardly relative to the first vertical end surface of the electrode active material layer.

[0125] Additionally, in one embodiment, the electrode assembly 106 further includes a lateral offset and / or separation distance between the lateral ends of the electrode and counter electrode active material layers 132, 138 in each unit cell. Figures 12A to 12C , describes the offset and / or separation distance in the lateral direction. Figure 12A As shown in FIG. 1 , the first lateral end surfaces 502a, 503a of the electrode and counter electrode active material layers 132, 138 are on the same side of the electrode assembly 106 (see also FIG. 1 ). Figures 15A - 15F ). In addition, the median lateral position of the first relative lateral end surface 502a of the electrode active material 132 is in the XZ plane along the height H of the electrode active material layer. E The 2D diagram depicts the first transverse end surface E TP1 That is, as referenced Figure 12A As shown, for each YX plane along the vertical direction, the median lateral position (x position) of the lateral end surface 502a of the electrode active material layer 132 can be determined by obtaining a specific vertical position (e.g., Z position) of the YX plane. 1 , Z 2 , Z 3 The median value of the x position of the surface as a function of y at (e.g., y = y). Figure 12C An example of a line is generally depicted, which shows a selected z-slice (e.g., at Z 1 The median lateral position (x position) of the first lateral end surface 502a at a particular YX plane at a slice at (a). (Note that Figure 12CGenerally describes the determination of the median lateral position of the lateral end surfaces (the dashed lines at the top and bottom of the figure), i.e., the determination of the median lateral position of the first lateral end surface 5002a and the second lateral end surface 5002b of the electrode active material layer 132, and / or the determination of the median lateral position of the first lateral end surface 503a and the second lateral end surface 503b of the counter electrode active material layer 138.) Figure 12B Depicts an embodiment in which along the height H of the electrode active material E (i.e., along the height H E at each z position Z 1 、Z 2 、Z 3 ), a 2D plot of this median lateral position shows the first lateral end surface plot E TP1 , the first lateral end surface plot E TP1 corresponding to the median lateral position (x position) plotted as a function of z (e.g., at Z 1 、Z 2 、Z 3 ). For example, for z positions corresponding to Z 0E at the first vertical end of the electrode active material layer to Z HE at the second vertical end of the electrode active material layer, the median lateral position of the lateral end surface 502a of the electrode active material layer 132 can be plotted as a function of z (vertical position), where Z HE -Z 0E equals the Feret diameter of the electrode active material layer 132 in the vertical direction (the height H E ) of the electrode active material layer 132).

[0126] Similarly, in the case of the first lateral end surface 503a of the counter electrode active material layer 138, the median lateral position of the first opposite lateral end surface 503a of the counter electrode active material layer 138 in the X-Z plane along the height H C of the counter electrode active material layer 138 shows a 2D plot of the first lateral end surface plot CE TP1 . Referring again to Figure 12A -C, it can be understood that for each YX plane in the vertical direction, the median lateral position (x position) of the lateral end surface 503a of the counter electrode active material layer 138 can be determined in this way, i.e., by obtaining the median of the x positions of this surface as a function of y at a specific vertical position (e.g., Z 1 、Z 2 、Z 3 etc.) of this YX plane. Figure 12C Generally depicts an example of a line that shows the median lateral position in a selected z slice (e.g., at Z 1The median lateral position (x-position) of the lateral end surface 503a of a particular YX plane at the slice at Figure 12B depicts an embodiment in which along the height H of the counter electrode active material C (i.e., along the height H C for each z-position Z 1 of Z 2 of Z 3 etc.), the 2D plot of this median lateral position depicts a first lateral end surface plot CE TP1 , the first lateral end surface plot CE TP1 corresponding to the median lateral position (x-position) plotted as a function of z (e.g., at Z 1 of Z 2 of Z 3 etc.). For example, for z-positions corresponding to Z 0c at the first vertical end of the counter electrode active material layer to Z Hc at the second vertical end of the counter electrode active material layer, the median lateral position of the lateral end surface 503a of the counter electrode active material layer 138 can be plotted as a function of z (vertical position), where Z Hc -Z 0c is equivalent to the Feret diameter of the counter electrode active material layer 138 in the vertical direction (the height H of the counter electrode active material layer 138 C ).

[0127] In addition, the offset and / or separation distance requirements of the lateral spacing between the first lateral surfaces 502a, 502b of the electrode active material layer 132 and the counter electrode active material layer 138 are for at least 60% of the height H C of the first counter electrode active material layer: (i) the absolute value of the separation distance S TP1 between the plots E TP1 and CE X1 measured in the vertical direction is 1000 μm ≥ |S X1 | ≥ 5 μm. Additionally, in one embodiment, it is required that for at least 60% of the height H C of the first counter electrode active material layer: (ii) between the first lateral end surfaces 502a, 502b of the electrode and the counter electrode active material layers 132, 138, the first lateral end surface of the counter electrode active material layer is set inward relative to the first lateral end surface of the electrode active material layer. That is, by referring to Figure 12B , it can be seen that for at least 60% of the height H C of the first counter electrode active material layer 138, i.e., for from Z 0C to Z HCThe separation distance S is at least 60% of the position z (60% of the Feret diameter in the vertical direction of the electrode active material layer). X1 The absolute value of is required to be no more than 1000μm and no less than 5μm. X1 The absolute value of corresponds to the curve E at any given point along z TP1 and CE TP1 In addition, it can be seen that for the height H of the first pair of electrode active material layers 138 C At least 60% of 0C to Z HC The position z is at least 60% (60% of the Feret diameter of the electrode active material layer in the vertical direction), and the first lateral end surface of the electrode active material layer is arranged inwardly relative to the first lateral end surface of the electrode active material layer.

[0128] In one embodiment, S X1 The absolute value of may be ≥5 μm, such as ≥10 μm, ≥15 μm, ≥20 μm, ≥35 μm, ≥45 μm, ≥50 μm, ≥75 μm, ≥100 μm, ≥150 μm and ≥200 μm. X1 The absolute value of may be ≤1000 μm, such as ≤500 μm, such as ≤475 μm, ≤425 μm, ≤400 μm, ≤375 μm, ≤350 μm, ≤325 μm, ≤300 μm and ≤250 μm. In one embodiment, S X1 The absolute value of can follow the relationship: 1000μm≥|S X1 |≥5μm, and / or 500μm≥|S X1 |≥10μm, and / or 250μm≥|S X1 |≥20 μm. In another embodiment, for the width W of the counter electrode active material layer 132 in the unit cell, E Feret diameter, S X1 The absolute value can be 5×W E ≥|S X1 |≥0.05×W E In addition, in one embodiment, |S X1 Any of the above values ​​and / or relationships may apply to the height H of the electrode active material layer. C 60% or more, for example, the height H of the electrode active material layer C At least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or even at least 95% of S X1 The values ​​and / or relationships described can be compared with those for S Z1 and / or SZ2 the same and / or different ones of

[0129] In addition, for at least 60% of the position z from Z 0C to Z HC (60% of the Feret diameter of the counter electrode active material layer in the vertical direction), the first lateral end surface of the counter electrode active material layer is arranged inwardly with respect to the first lateral end surface of the electrode active material layer. That is, the electrode active material layer 132 can be understood as having a median lateral position closer to the lateral surface than the counter electrode active material layer 138 for at least 60% of the height H C of the counter electrode active material layer (as shown in Figure 12C , the position on x in the XY plane for a specified Z slice). In other words, the counter electrode active material layer 138 can be understood as having a median lateral position farther in the inward direction 510 along the electrode assembly 106 than the median lateral position of the electrode active material layer 132 (as shown in Figure 12C , the position on x in the XY plane for a specified X slice). This lateral offset of the electrode active material layer 132 with respect to the counter electrode active material layer 138 can also be seen with respect to the embodiment in Figure 12A , Figure 12A shows that the length of the electrode material layer 132 exceeds the length of the counter electrode active material layer 138, and Figure 12B the illustration of TP1 shows that the median lateral position E of the electrode active material layer exceeds the median lateral position CE of the counter electrode active material layer in the vertical direction TP1 . In one embodiment, for more than 60% of the height H C of the first pair of counter electrode active material layers, for example, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or even at least 95% of the height H C of the first pair of counter electrode active material layers, the first lateral end surface of the counter electrode active material layer is arranged inwardly with respect to the first lateral end surface of the electrode active material layer. In addition, the percentage of the height H C along which the counter electrode active material is more inward than the electrode active material may be different at the first lateral end surface compared to the second lateral end surface.

[0130] In one embodiment, for the relationship of the separation distance between the second lateral surfaces 502b, 503b of the electrode and the counter electrode active material layers 132, 138 (for example, as shown in Figures 15A to 15F ), the above-mentioned separation distance S X1The described relationship. That is, the second transverse end surfaces 502b and 503b are on the same side of the electrode assembly 106 with respect to each other and are respectively opposite to the first transverse end surfaces 502a, 503a of the electrode and the counter electrode active material layers 132, 138. In addition, similar to the description given above regarding the separation distance and / or offset S X1 The median transverse position of the second opposite transverse end surface 502b of the electrode active material 132 in the X-Z plane is along the height H of the electrode active material layer E The 2D plot of depicts the second transverse end surface figure E TP2 . That is, as shown in reference Figure 12A -C, for each YX plane in the vertical direction, the median transverse position (x-position) of the second transverse end surface 502b of the electrode active material layer 132 can be determined in such a way that, by obtaining the median of the x-positions of this surface as a function of y at a specific vertical position (e.g., Z 1 , Z 2 , Z 3 , etc.) in that YX plane. Figure 12C Generally depicts an example of a line that shows the median transverse position (x-position) of the second transverse end surface 502b of a specific YX plane at a selected slice (e.g., the slice at Z 1 ). Figure 12B Depicts an embodiment in which the 2D plot of the median transverse position determined along the height H of the electrode active material E (i.e., along each z-position Z E of the height H 1 , Z 2 , Z 3 ) plots the second transverse end surface figure E TP2 , and the second transverse end surface figure E TP2 corresponds to the median transverse position (x-position) plotted as a function of z (e.g., at Z 1 , Z 2 , Z 3 , etc.). For example, for z-positions corresponding to Z 0E at the first vertical end of the electrode active material layer to Z HE at the second vertical end of the electrode active material layer, the median transverse position of the second transverse end surface 502b of the electrode active material layer 132 can be plotted as a function of z (vertical position), where Z HE -Z 0E is equivalent to the Feret diameter of the electrode active material layer 132 in the vertical direction (the height H of the electrode active material layer E ).

[0131] Similarly, in the case of the second opposite lateral end surface 503b of the counter electrode active material layer 138, the median lateral position of the second opposite lateral end surface 503b of the counter electrode active material layer 138 is along the height H of the counter electrode active material layer 138 in the X-Z plane C The 2D plot of the second lateral end surface CE TP2 . Referring again to Figures 12A to 12C , it can be understood that for each YX plane in the vertical direction, the median lateral position (x position) of the second lateral end surface 503b of the counter electrode active material layer 138 can be determined in such a way that, by obtaining the median of the z positions of the surface as a function of y at a specific vertical position (e.g., Z 1 , Z 2 , Z 3 , etc.) in that YX plane. Figure 12C Generally depicts an example of a line that shows the median lateral position (x position) of the second lateral end surface 503b of a specific YX plane at a selected z slice (e.g., the slice at Z 1 ). Figure 12B Depicts an embodiment in which the 2D plot of the median lateral position along the height H C (i.e., along each z position Z C of the height H 1 , Z 2 , Z 3 ) of the counter electrode active material depicts the second lateral end surface plot CE TP2 , and the second lateral end surface plot CE TP2 corresponds to the median lateral position (x position) plotted as a function of z (e.g., at Z 1 , Z 2 , Z 3 , etc.). For example, for the z positions corresponding to Z 0c at the first lateral end of the counter electrode active material layer to Z Hc at the second lateral end of the counter electrode active material layer, the median lateral position of the second lateral end surface 503b of the counter electrode active material layer 138 can be plotted as a function of z (vertical position), where Z Hc -X 0c is equivalent to the Feret diameter of the counter electrode active material layer 138 in the vertical direction (the height H C of the counter electrode active material layer 138).

[0132] In addition, the offset and / or separation distance requirements of the lateral spacing between the electrode active material layer 132 and the second lateral surfaces 502b, 503b of the counter electrode active material layer, for the height H Cat least 60% of: (i) Curve E measured in the vertical direction TP2 and CE TP2 The separation distance S between X2 has an absolute value of 1000 μm ≥ |S X2 | ≥ 5 μm. Additionally, in one embodiment, it is required that for the height H C at least 60% of: (ii) Between the second lateral end surfaces 502b, 503b of the electrode and the counter electrode active material layers 132, 138, the second lateral end surface of the counter electrode active material layer is set inward relative to the second lateral end surface of the electrode active material layer. That is, by referring to Figure 12B , it can be seen that for the height H C at least 60% of the first pair of electrode active material layers 138, that is, from Z 0C to Z HC at least 60% of the position z (60% of the Feret diameter of the counter electrode active material layer in the vertical direction), the absolute value of the separation distance S X2 is required to be no greater than 1000 μm and no less than 5 μm. This separation distance S X2 has an absolute value corresponding to the distance between graph E TP2 and CE TP2 at any given point along z. Furthermore, it can be seen that for the height H C at least 60% of the first pair of electrode active material layers 138, that is, from Z 0C to Z HC at least 60% of the position z (60% of the Feret diameter of the counter electrode active material layer in the vertical direction), the second lateral end surface of the counter electrode active material layer is set inward relative to the second lateral end surface of the electrode active material layer.

[0133] In one embodiment, the absolute value of S X2 can be ≥ 5 μm, such as ≥ 10 μm, ≥ 15 μm, ≥ 20 μm, ≥ 35 μm, ≥ 45 μm, ≥ 50 μm, ≥ 75 μm, ≥ 100 μm, ≥ 150 μm, and ≥ 200 μm. In another embodiment, the absolute value of S X2 can be ≤ 1000 microns, such as ≤ 500 μm, for example ≤ 475 μm, ≤ 425 μm, ≤ 400 μm, ≤ 375 μm, ≤ 350 μm, ≤ 325 μm, ≤ 300 μm, and ≤ 250 μm. In one embodiment, the absolute value of S X2 can follow the relationship: 1000 μm ≥ |S X2 | ≥ 5 μm, and / or 500 μm ≥ |S X2 | ≥ 10 μm, and / or 250 μm ≥ |S X2|≥20 μm. In another embodiment, for the width W of the counter electrode active material layer 132 in the unit element E of the Feret diameter, S X2 the absolute value of can be within 5×W E ≥|S X2 |≥0.05×W E range. In addition, in one embodiment, |S X2 | any of the above values and / or relationships can apply to the height H of the counter electrode active material layer C more than 60%, for example, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or even at least 95% of the height H of the counter electrode active material layer. In addition, the values and / or relationships described above for S C can be the same as and / or different from those for S X2 described, S X1 , S Z1 and / or S Z2 .

[0134] In addition, for at least 60% of the position z from Z 0C to Z HC (60% of the Feret diameter of the counter electrode active material layer in the vertical direction), the second lateral end surface of the counter electrode active material layer is arranged inward relative to the second lateral end surface of the electrode active material layer. That is, the electrode active material layer 132 can be understood as having a median lateral position closer to the lateral surface than the counter electrode active material layer 130 for at least 60% of the height H of the counter electrode active material layer C (as shown in Figure 12C , for a specified Z slice, the position on x in the XY plane). In other words, the counter electrode active material layer 138 can be understood as having a median lateral position farther in the inward direction 510 along the electrode assembly 106 than the median lateral position of the electrode active material layer 132 (as shown in Figure 12C , for a specified X slice, the position on x in the XY plane). This lateral offset of the electrode active material layer 132 relative to the counter electrode active material layer 138 can also be seen in the embodiment of Figure 12A , Figure 12A shows that the length of the electrode material layer 132 exceeds the length of the counter electrode active material layer 138, and Figure 12B the illustration of shows that the median lateral position E TP2 of the electrode active material layer 132 is lower than the median lateral position CE TP2 of the counter electrode active material layer in the vertical direction. In one embodiment, for more than 60% of the height H of the first counter electrode active material layer, for example, the height H of the first counter electrode active material layer C ​C At least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or even at least 95% thereof, the second lateral end surface of the counter electrode active material layer is disposed inwardly with respect to the second lateral end surface of the electrode active material layer. Further, along the height H where the counter electrode active material is more inward than the electrode active material C The percentage thereof may be different at the first lateral end surface compared to the second lateral end surface.

[0135] According to one embodiment, the offset and / or separation distance in the vertical and / or lateral direction can be maintained by providing a set of electrode constraining members 108 that are capable of maintaining and stabilizing the alignment of the electrode active material layer 132 and the counter electrode active material layer 138 in each unit element, and even stabilizing the positions of the electrode structure 110 and the counter electrode structure 112 relative to each other in the electrode assembly 106. In one embodiment, the set of electrode constraining members 108 includes any of those described herein, including any combination or portion thereof. For example, in one embodiment, the set of electrode constraining members 108 includes a primary constraining system 151 that includes first and second primary growth constraining members 154, 156 and at least one primary connecting member 162, the first and second primary growth constraining members 154, 156 being separated from each other in the longitudinal direction, and the at least one primary connecting member 162 connecting the first and second primary growth constraining members 154, 156, wherein the primary constraining system 151 restricts the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20% during 20 consecutive cycles of the secondary battery. In yet another embodiment, the set of electrode constraining members 108 further includes a secondary constraining system 152 that includes first and second secondary growth constraining members 158, 160 that are separated in a second direction and connected by at least one secondary connecting member 166, wherein the secondary constraining system 152 at least partially restricts the growth of the electrode assembly 106 in the second direction when the secondary battery 106 is cycled, the second direction being orthogonal to the longitudinal direction. Other embodiments of the set of electrode constraining members 108 are described below.

[0136] Return Figures 14A to Figure 14H , various different configurations of the unit element 504 with respect to the vertical separation distance and / or offset are described. In the illustrated embodiment, a portion of the set of constraining members 108 is located at at least one vertical end of the layer 132 and can be connected to one or more structures of the unit element 504. For example, the set of electrode constraining members 108 includes first and second secondary growth constraining members 158, 160, and the growth constraining members can be connected to the vertical ends of the structures in the unit element. In as Figure 14AIn the illustrated embodiment, the first and second growth restrictors 158, 160 are attached by an adhesive layer 516 that joins the structure of the unit cell element to the restrictors 158, 160. Figure 1A A cross-sectional view of which shows the upper restrictor 158). In Figure 14A , the vertical ends of the electrode current collector 136, the separator layer 130, and the counter electrode current collector 140 are joined to the first and second growth restrictors 158, 160 by the adhesive layer 516. Thus, as described in further detail below, one or more of the electrode current collector 136, the separator layer 130, and the counter electrode current collector 140 can individually or jointly act as a secondary connection member 166 that connects the first and second growth restrictors to restrict the growth of the electrode assembly 106. Figure 14B Another embodiment is shown in which all of the electrode current collectors 136, the separator layer 130, and the counter electrode current collector 140 of the unit cell element 504 are joined to the first and second secondary growth restrictors 158, 160. Optionally, some of the structure can be joined to the first secondary growth restrictor 158 and some to the second secondary growth restrictor. In as Figure 14C shown in the embodiment, the vertical ends of the electrode current collector 136 and the separator layer 130 are both joined to the first and second secondary growth restrictors 158, 160, while the counter electrode current collector 140 terminates before contacting the first and second growth restrictors in the vertical direction. In as Figures 14D to 14E shown in the embodiment, the vertical ends of the electrode current collector 136 and the counter electrode current collector 140 are joined to the first and second secondary growth restrictors 158, 160, while the separator 130 terminates before contacting the first and second growth restrictors in the vertical direction. In as Figure 14F shown in the embodiment, the vertical end of the electrode current collector 136 is joined to the first and second secondary growth restrictors 158, 160, while the separator 130 and the counter electrode current collector 140 terminate before contacting the first and second growth restrictors in the vertical direction. In as Figures 14G to 14H shown in the embodiment, the vertical end of the counter electrode current collector 140 is joined to the first and second secondary growth restrictors 158, 160, while the separator 130 and the electrode current collector 136 terminate before contacting the first and second growth restrictors in the vertical direction.

[0137] In addition, in one embodiment, the unit cell 504 may include one or more insulator members 514 disposed between one or more of the first and second vertical surfaces of the electrode active material layer 132 and / or the counter electrode active material layer. The insulator member 514 may be electrically insulating to inhibit short circuits between structures in the unit cell 504. The insulator member may also be non-ion permeable, or at least less ion permeable than the separator 130, to prevent carrier ions from passing through. That is, the insulator member 514 may be provided to insulate the vertical surfaces of the electrode and the counter electrode active material layers 132, 138 from plating out, forming dendrites, and / or other electrochemical reactions to which the exposed surfaces may otherwise be susceptible, thereby extending the life of the secondary battery 102 having the unit cell 504 with the insulating member 514. For example, the ion permeability and / or ionic conductance of the insulating member 514 may be less than the ion permeability and / or ionic conductance of the separator 130 disposed in the same unit cell 504. For example, the insulating member 514 may have the same and / or similar permeability and / or conductance to carrier ions as the carrier ion insulating material layer 674 described further below. The insulating member 514 may be made of a variety of different materials, including ceramics, polymers, glass, and combinations and / or composites thereof.

[0138] In Figure 14A the illustrated embodiment, the unit cell 504 does not have the insulating member 514 because the vertical dimensions z of the first vertical end surfaces 500a, 501a of the electrode and the counter electrode active material layers 132, 138 are both close to, and even substantially flush with, the first secondary growth restraint 158. The second vertical end surfaces 500b, 501b may similarly reach the second secondary growth restraint 160 in the opposite vertical direction (not shown). In some embodiments, even if no insulating member 514 is provided on the vertical surfaces of one or more of the electrode and the counter electrode active material layers 132, 138, the unit cell may include a predetermined vertical offset S z1 and S z2 , as described above. Thus, in one aspect, the illustrated embodiment Figure 14A may have the offset S z1 and / or S z2 (not explicitly shown) even if the insulating member 514 is not provided.

[0139] Figure 14B The illustrated embodiment shows a unit cell 504 having a significant offset S z1 between the first vertical end surfaces 500a, 501a of the electrode and the counter electrode active material layers, and / or a significant offset S between the second vertical end surfaces 500a, 501a of the electrode and the counter electrode active material layersz2 (not shown). In this embodiment, the insulating member 514 is disposed between the first vertical end surface 501a of the counter electrode active material layer 138 and the inner surface of the first secondary growth restraint 158, and / or between the second vertical end surface 501b of the counter electrode active material layer 138 and the inner surface of the second secondary growth restraint 160 (not shown). Although not shown in the Figure 14B illustrated 2D Z-Y plane, the insulating member 514 may extend substantially and even entirely over the vertical surfaces of the counter electrode active material layer 138, for example, in the longitudinal direction (y-direction) and the transverse direction (x-direction – into the Figure 14B page), to cover one or more of the vertical surfaces 501a, b. Additionally, in the Figure 14B illustrated embodiment, the insulator member 514 is disposed between the separator 130 at one longitudinal end of the counter electrode active material layer 138 and the counter electrode current collector 140 at the other longitudinal end, and / or is defined by the separator 130 at one longitudinal end of the counter electrode active material layer 138 and the counter electrode current collector 140 at the other longitudinal end.

[0140] Figure 14C The illustrated embodiment also shows the unit cell 504 having a significant offset S between the first vertical end surfaces 500a, 501a of the electrode and the counter electrode active material layer z1 and / or having a significant offset S between the second vertical end surfaces 500b, 501b of the electrode and the counter electrode active material layer z2 (not shown). Also in this embodiment, the insulating member 514 is disposed between the first vertical end surface 500a of the counter electrode active material layer 138 and the inner surface of the first secondary growth restraint 158, and / or between the second vertical end surface 501b of the counter electrode active material layer 138 and the inner surface of the second secondary growth restraint 160 (not shown). Although not shown in the Figure 14C illustrated 2D Z-Y plane, the insulating member 514 may extend substantially and even entirely over the vertical surfaces of the counter electrode active material layer 138, for example, in the longitudinal direction (y-direction) and the transverse direction (x-direction – into the Figure 14C page), to cover one or more of the vertical surfaces 501a, b. Additionally, in the Figure 14CIn the illustrated embodiment, the insulator member 514 is defined by the separator 130 at one longitudinal end of the counter electrode active material layer, but extends on the vertical surface 516a of the counter electrode current collector 140 at the other longitudinal end. That is, the insulating member may extend longitudinally towards an adjacent unit elementary structure (e.g., an adjacent counter electrode active material layer 138 of an adjacent unit elementary structure) and abut the adjacent unit elementary structure. In one embodiment, the insulating member 514 may extend across one or more vertical surfaces 501a, b of the adjacent counter electrode active material layer 138 by crossing the counter electrode current collector 140 that separates the layers 138 in the adjacent unit elements 504a, 504b, and crossing the vertical surfaces of the adjacent counter electrode active material layers 138 in the adjacent elements. That is, the insulating member 514 may extend across one or more vertical surfaces 501a, b of the counter electrode active material layer 138 in the first unit element 504a by crossing the vertical surface of the counter electrode current collector 140 that separates the unit elements 504a, b in the longitudinal direction, and may extend across one or more vertical surfaces 501a, b of the counter electrode active material layer 138 in the second unit element 504b adjacent to the first unit element 504a.

[0141] Figure 14D The illustrated embodiment shows a unit element 504, where the insulating member 514 is disposed between the first vertical end surface 500a of the counter electrode active material layer 138 and the inner surface of the first secondary growth restraint 158 and / or between the second vertical end surface 500b of the counter electrode active material layer 138 and the inner surface of the second secondary growth restraint 160 (not shown), and the insulating member 514 also extends on one or more vertical surfaces 518a, b of the separator 130 to also cover one or more vertical end surfaces 500a, 500b of the electrode active material layer 138. That is, the insulating member 514 is also disposed between the first vertical end surface 500a of the electrode active material layer 132 and the inner surface of the first secondary growth restraint 158, and / or between the second vertical end surface 500b of the electrode active material layer 132 and the inner surface of the second secondary growth restraint 160 (not shown) (and in the space between the first and second secondary growth restraints 158, 160 and the vertical surfaces 518a, b of the separator 130). Although not shown in the illustrated 2D Z-Y plane, the insulating member 514 may extend substantially and even completely on the vertical surfaces of the electrode and counter electrode active material layers 132, 138, e.g., in the longitudinal direction (y direction) and the transverse direction (x direction - into Figure 14D the page), to cover one or more vertical surfaces 500a, b, 501a, b. Further, in Figure 14D the Figure 14DIn the illustrated embodiment, the insulator member 514 is disposed between the electrode current collector 136 at one longitudinal end of the unit cell 504 and the counter electrode current collector 140 at the other longitudinal end, and / or is defined by the electrode current collector 136 at one longitudinal end of the unit cell 504 and the counter electrode current collector 140 at the other longitudinal end.

[0142] Figure 14D The offset S between the first vertical end surfaces 500a, 501a of the electrode and the counter electrode active material layers is not clearly shown in the embodiment shown in V1 , and / or the offset S between the second vertical end surfaces 500a, 501a of the electrode and the counter electrode active material layers V2 , but can also be modified by including one or more of the vertical offsets S as described herein z1 and / or S z2 to modify aspects of the embodiment depicted in Figure 14D . For example, Figure 14E the embodiment shown can include structures that are the same as and / or similar to Figure 14D since the insulating member 514 covers not only one or more of the vertical end surfaces 501a, b of the counter electrode active material layer 138, but also one or more of the vertical end surfaces 500a, b of the electrode active material layer 132. However, Figure 14E a distinct vertical offset and / or separation distance Sz1 is shown between the vertical end surfaces 500a, b of the electrode active material layer 132 and the vertical end surfaces 501a, b of the counter electrode active material layer 138. Thus, as shown in the embodiment, the insulating member 514 includes: a first thickness T1 measured between the inner and outer vertical surfaces of the insulating member 514 on the first and second vertical end surfaces 500a, b of the electrode active material layer 132, and a second thickness T2 measured between the inner and outer vertical surfaces of the insulating member 514 on the first and second vertical end surfaces 501a, b of the counter electrode active material layer 138, the first thickness T1 being less than the second thickness T2. Additionally, although only a single insulating member 514 is shown, it is also possible to provide multiple insulating members 514, such as a first member having a first thickness T1 on the electrode active material layer, and a second insulating member 514 having a second thickness T2 on the counter electrode active material layer 138. Figure 14F The embodiment shown is similar to Figure 14E the embodiment shown, with one or more insulating members 514 having thicknesses T1 and T2 respectively with respect to their arrangement on the vertical end surfaces of the electrode and counter electrode active material layers. However, in this embodiment, the insulating member 514 extends on one or more vertical surfaces 516 of the counter electrode current collector 140 and can even extend to cover surfaces in adjacent unit cells, as referred to above with reference to Figure 14Cdescribed.

[0143] Figure 14G The illustrated embodiment shows a unit cell 504 in which an insulating member 514 is disposed between a first vertical end surface 500a of an electrode active material layer 138 and an inner surface of a first secondary growth restraint 158, and / or between a second vertical end surface 500b of an electrode active material layer 138 and an inner surface of a second secondary growth restraint 160 (not shown), and also extends over one or more vertical surfaces 518a, b of the separator 130 to also cover one or more vertical end surfaces 500a, 500b of the electrode active material layer 138. That is, the insulating member 514 is also disposed between the first vertical end surface 500a of an electrode active material layer 132 and an inner surface of a first secondary growth restraint 158, and / or between the second vertical end surface 500b of an electrode active material layer 132 and an inner surface of a second secondary growth restraint 160 (not shown) (as well as in the space between the first and second secondary growth restraints 158, 160 and the vertical surfaces 518a, b of the separator 130). Although in Figure 14D Not shown in the 2D ZY plane shown, the insulating member 514 may extend substantially and even completely over the vertical surfaces of the electrode and counter electrode active material layers 132, 138, for example in the longitudinal direction (y direction) and the lateral direction (x direction - into Figure 14D ) to cover one or more vertical surfaces 500a, b, 501a, b. In addition, Figure 14G In the illustrated embodiment, the insulator member 514 is defined by the electrode current collector 140 at one longitudinal end of the unit cell 504, but extends in the other longitudinal direction over one or more vertical end surfaces 520 of the electrode current collector 136. For example, similar to the above Figure 14C , the insulating member 514 may extend longitudinally toward and abut an adjacent unit cell structure (e.g., an adjacent electrode active material layer 132 of an adjacent unit cell structure). In one embodiment, the insulating member 514 may extend across one or more vertical surfaces 500a, b of the adjacent electrode active material layer 132 by crossing the electrode current collector 136 separating the layer 138 in the adjacent unit cells 504a, 504b, and across the vertical surfaces of the adjacent electrode active material layer 132 in the adjacent cell. That is, the insulating member 514 may extend across one or more vertical surfaces 500a, b of the electrode active material layer 132 in the first unit cell 504a by crossing the vertical end surfaces 520a, b of the electrode current collector 140 separating the unit cells 504a, b from each other in the longitudinal direction, and may extend across the vertical surfaces 500a, b of the electrode active material layer 132 in the second unit cell 504b adjacent to the first unit cell 504a.

[0144] Figure 14G The embodiments shown do not clearly show the offset S between the first vertical end surfaces 500a, 501a of the electrode and the counter electrode active material layer Z1 , and / or the offset S between the second vertical end surfaces 500a, 501a of the electrode and the counter electrode active material layer Z2 , but can also be modified by including one or more of the vertical offsets S as described herein z1 and / or S z2 . For example, aspects of the embodiments depicted in Figure 14G can be modified. For example, Figure 14H the embodiments shown can include structures that are the same as and / or similar to Figure 14G because the insulating member 514 covers not only one or more vertical end surfaces 501a, b of the counter electrode active material layer 138, but also one or more vertical end surfaces 500a, b of the electrode active material layer 132. However, Figure 14H shows a distinct vertical offset and / or separation distance S between the vertical end surfaces 500a, b of the electrode active material layer 132 and the vertical end surfaces 501a, b of the counter electrode active material layer 138 V1 . Accordingly, in the embodiments shown, the insulating member 514 includes: a first thickness T1 measured between the inner and outer vertical surfaces of the insulating member 514 on the first and second vertical end surfaces 500a, b of the electrode active material layer 132, and a second thickness T2 measured between the inner and outer vertical surfaces of the insulating member 514 on the first and second vertical end surfaces 501a, b of the counter electrode active material layer 138, with the first thickness T1 being less than the second thickness T2. Additionally, although only a single insulating member 514 is shown, it is also possible to provide multiple insulating members 514, such as a first member having a first thickness T1 on the electrode active material layer, and a second insulating member 514 having a second thickness T2 on the counter electrode active material layer 138

[0145] Reference Figures 15A to Figure 15F describes other embodiments of the unit cell 504 with or without the insulating member 514 and / or the lateral offsets S X1 and S X2 . In the embodiments shown in Figure 15A , the electrode active material layers 132 and 138 are shown as not having distinguishable (lateral offsets S X1 and / or S X2 , although the above-mentioned offsets and / or separation distances can be provided along the x-axis, for example, as shown in the embodiments of Figure 15B . As shown by a 2D slice in the Y-X plane, as in Figure 15AThe unit cell element 504 shown includes an electrode current collector 136, an electrode active material layer 132, a separator 130, a counter electrode active material layer 138, and a counter electrode current collector 140. Although Figure 15A the embodiments in Figures 16A - 16B do not include an insulating member 514, it can be seen that the electrode current collector 136 extends beyond the second lateral ends 502b, 503b of the electrode and the counter electrode active material layers 132, 138 and can be connected to an electrode bus bar 600, for example, as Figures 16A - 16B shown. Similarly, the counter electrode current collector 140 extends beyond the first lateral ends 502a, 503a of the electrode and the counter electrode active material layers 132, 138 and can be connected to a counter electrode bus bar 602, for example, as

[0146] Referencing Figure 15B the embodiment shown, a unit cell element configuration is shown having an insulating member 514 extending on at least one of the lateral surfaces 503a, b of the counter electrode active material layer 138. In the embodiment shown, the insulating member 514 is disposed at either lateral end of the counter electrode active material layer 138 and is located between the counter electrode current collector 140 at one longitudinal end of the unit cell element 504 and the separator 130 at the other longitudinal end of the unit cell element and is defined by the counter electrode current collector 140 at one longitudinal end of the unit cell element 504 and the separator 130 at the other longitudinal end of the unit cell element. In the embodiment shown, the insulating member has a lateral extent that matches the length L E of the electrode active material layer 132 and is spaced apart from the electrode active material layer 132 by a separator having the same length as the electrode active material layer in the lateral direction. In one embodiment, the lateral extent of the insulating member 514 in the x direction can be the same as the lateral separation distance and / or offset S X1 , S X2 as Figure 15B shown. Additionally, although not shown in the 2D Y-X plane of Figure 15B shown, the insulating member can similarly extend in the z direction (e.g., along the height H E ) of the counter electrode active material layer 138 and between the opposing vertical end surfaces 501a, b.

[0147] Figure 15CThe illustrated embodiment also shows a unit cell structure having an insulating member 514 extending on at least one of the lateral surfaces 503a, b of the counter electrode active material layer 138. In the illustrated embodiment, the insulating member 514 is disposed at either lateral end of the counter electrode active material layer 138 and has a separator layer 130 at at least one longitudinal end of the unit cell 504. At the other longitudinal end, at least one insulating member is further defined by the counter electrode current collector 140. However, at least one insulating member 514 may also extend on the lateral surfaces 522a, b of the counter electrode current collector 140 at the other longitudinal end of the unit cell 504. That is, the insulating member 514 may extend in the longitudinal direction beyond the lateral end surface of the counter electrode active material layer 138 to cover the counter electrode current collector 140 and may even extend to cover the lateral surface of the counter electrode active layer of an adjacent unit cell. In the embodiment as Figure 15B shown, the insulating member 514 has a lateral extent that matches the length L E of the electrode active material layer 132 and is spaced apart from the electrode active material layer 132 by a separator having the same length as the electrode active material layer 132 in the lateral direction. In one embodiment, the lateral extent of the insulating member 514 in the x direction may be the same as the lateral separation distance and / or offset S X1 、S X2 as shown in Figure 15C . Additionally, although not shown in the 2D Y-X plane as Figure 15C shown, the insulating member may also extend in the z direction, for example, along the height H E of the counter electrode active material layer 138 and extend between the opposing vertical end surfaces 501a, b. Except that the length of the counter electrode current collector 140 extends beyond the lateral surface of the insulating member 514 and the length of the current collector 136 also extends beyond the lateral end surface of the electrode active material layer, Figure 15E the structure of Figure 15C is similar to

[0148] Figure 15D shown. The illustrated embodiment shows a unit cell structure having an insulating member 514 extending on at least one of the lateral surfaces 502a, b, 503a, b of both the electrode active material layer 132 and the counter electrode active material layer 138. In the illustrated embodiment, the insulating member 514 is disposed at either lateral end of the electrode and counter electrode active material layers 132, 138. The insulating member is disposed between the electrode current collector 136 at one longitudinal end and the counter electrode current collector 140 at the other longitudinal end and is defined by the electrode current collector 136 at one longitudinal end and the counter electrode current collector 140 at the other longitudinal end. The insulating member 514 may extend on the lateral end surfaces 524a, b of the separator 130 to extend beyond the lateral surfaces of the electrode and counter electrode layers 132, 138. InFigure 15D In the illustrated embodiment, the insulating member 514 has a lateral extent that matches the length of the electrode current collector 136 at one lateral end and the length of the counter electrode current collector 140 at the other lateral end. In the illustrated embodiment, the electrode and counter electrode active material layers 132, 138 are not shown as having a lateral offset and / or separation distance, although a separation distance and / or offset may also be provided. Additionally, although not shown in the Figure 15D 2D Y-X plane shown, the insulating member may also extend in the z-direction, e.g., along the height H of the counter electrode active material layer 138 E , and extends between the opposing vertical end surfaces 501a, b.

[0149] Figure 15F The illustrated embodiment also shows a unit cell configuration having an insulating member 514 extending on at least one of the lateral surfaces 503a, b of the counter electrode active material layer 138. In the illustrated embodiment, the insulating member 514 is disposed at either lateral end of the counter electrode active material layer 138. The insulating member 514 covers the lateral surfaces of both the electrode and counter electrode active material layers, and is disposed between the electrode current collector 136 at one longitudinal end and the counter electrode current collector 140 at at least one lateral end at the other end, defined by the electrode current collector 136 at one longitudinal end and the counter electrode current collector 140 at at least one lateral end at the other end. In the illustrated embodiment, the insulating member further extends between the lateral surfaces 524a, b of the separator 130, between the electrode and counter electrode active material layers 132, 138, to extend on these surfaces. In the illustrated embodiment, the insulating member 514 has a first lateral thickness T1 extending from the vertical end surface of the electrode active material layer 132, and a second lateral thickness T2 extending from the vertical end surface of the counter electrode active material layer 138, where the second lateral thickness is greater than the first lateral thickness. In one embodiment, the difference between the lateral extent of the second thickness T2 and the first thickness T1 may be equivalent to the lateral offset and / or separation distance S X1 and / or S X2In addition, in the illustrated embodiment, at least one insulating member 514 may also extend on one of the lateral surfaces 522a, b of the counter electrode current collector 138 at one of the longitudinal ends of the unit element 504. That is, the insulating member 514 may extend longitudinally beyond the lateral end surface of the counter electrode active material layer 138 to cover the counter electrode current collector 140, and may even extend to cover the lateral surface of the counter electrode active material layer of an adjacent unit element. On the other hand, the insulating member 514 at the opposite lateral ends of the counter electrode active material layer may be defined by the counter electrode current collector such that the length of the counter electrode current collector in the lateral direction exceeds the lateral thickness of the insulating member 514. At the other longitudinal end, the insulating member 514 is defined by the electrode current collector 136, where the lateral thickness of the insulating member meets the lateral length of the electrode current collector 136 at one lateral end, and the electrode current collector 136 exceeds the lateral thickness of the insulating member at the other lateral end. Additionally, although not shown in the Figure 15C illustrated 2D Y-X plane, the insulating member may also extend in the z direction, for example, along the height H of the counter electrode active material layer 138 E , and extend between the opposite vertical end surfaces 501a, b.

[0150] Furthermore, it should be noted that in order to determine the first and second vertical and / or lateral end surfaces of the electrode active material layer and / or the counter electrode active material layers 132 and 138, only those portions of these layers that contain electrodes and / or counter electrode active materials that can participate in the electrochemical reaction in each unit element 504 are considered to be part of the active material layers 132, 138. That is, if the electrode or counter electrode active material is modified such that it no longer acts as an electrode or counter electrode active material, for example, by covering the active material with an ion insulating material, the portion of the material that has been effectively removed as a participant in the electrochemical unit element is not considered part of the electrode active and / or counter electrode active material layers 132, 138.

[0151] Electrode and counter - electrode busbars

[0152] In one embodiment, the secondary battery 102 includes one or more of an electrode bus bar 600 and a counter electrode bus bar 602 (e.g., as Figure 17 illustrated) to collect current from the electrode current collector 136 and the counter electrode current collector, respectively. As similarly described for the embodiments with the above offset and / or separation distances, the electrode assembly 106 may include an electrode structure group, an electrode current collector group, a separator group, a counter electrode structure group, a counter electrode current collector group, and a unit element group, where the members of the electrode and counter electrode structure groups are arranged in an alternating order in the longitudinal direction. Additionally, each member of the electrode structure group includes an electrode current collector and an electrode active material layer, and the electrode active material layer has a length L E , a height HE and a width W E , the length L E corresponding to the Feret diameter of the electrode active material layer measured in the transverse direction between the first and second opposite transverse end surfaces of the electrode active material layer, and the height H E corresponding to the Feret diameter of the electrode active material layer measured in the vertical direction between the first and second opposite vertical end surfaces of the electrode active material layer, and the width W E corresponding to the Feret diameter of the electrode active material layer measured in the longitudinal direction between the first and second opposite surfaces of the electrode active material layer. Moreover, each member of the counter electrode structure group includes a counter electrode current collector and a counter electrode active material layer, the counter electrode active material layer having a length L C 、height H C 、and a width W C , the length L C corresponding to the Feret diameter of the counter electrode active material layer measured in the transverse direction between the first and second opposite transverse end surfaces of the counter electrode active material layer, and the height H C corresponding to the Feret diameter of the counter electrode active material layer measured in the vertical direction between the first and second opposite vertical end surfaces of the counter electrode active material layer, and the width W C corresponding to the Feret diameter of the counter electrode active material layer measured in the longitudinal direction between the first and second opposite surfaces of the counter electrode active material layer.

[0153] In addition, as described elsewhere herein, in one embodiment, the electrode assembly has mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x-axis, y-axis, and z-axis of a fictional three-dimensional Cartesian coordinate system, a first longitudinal end surface and a second longitudinal end surface separated from each other in the longitudinal direction, and a transverse surface surrounding the longitudinal axis A EA and connecting the first longitudinal end surface and the second longitudinal end surface, the transverse surface having opposite first and second regions located on opposite sides of the longitudinal axis and separated in a first direction orthogonal to the longitudinal axis, the electrode assembly having a maximum width W measured in the longitudinal direction EA , a maximum length L defined by the transverse surface and measured in the transverse direction EA 、and a maximum height H defined by the transverse surface and measured in the vertical direction EA .

[0154] Reference Figure 17 , each member of the electrode structure group 110 includes an electrode current collector 136 to collect current from the electrode active material layer 132, the electrode current collector at least partially along the length L of the electrode active material layer 132 Eextends in the transverse direction, and the electrode current collector includes an electrode current collector end 604 that extends beyond the first transverse end surface 503a of the counter electrode active material layer 138. In addition, each member of the counter electrode structure group 112 includes a counter electrode current collector 140 to collect current from the counter electrode active material layer 138, and the counter electrode current collector 140 extends at least partially along the length L of the counter electrode active material layer 132 C extends in the transverse direction and includes a counter electrode current collector end 606 (e.g., as also shown in Figure 15A ) that extends beyond the second transverse end surface 502b of the electrode active material layer in the transverse direction. In Figure 17 the illustrated embodiment, the electrode and counter electrode current collectors 136, 140 are sandwiched between adjacent electrode active material layers (in the case of the electrode structure 110) or adjacent counter electrode active material layers (in the case of the counter electrode structure 112). However, the current collector can also be a surface current collector that is present on at least a portion of the surface of the separator 130 between the electrode and / or counter electrode active material layers facing the electrode and counter electrode structures 110, 112. In addition, in the embodiment as shown in Figure 17 , the electrode bus bar 600 and the counter electrode bus bar 602 are provided on opposite transverse sides of the electrode assembly 106, where the electrode current collector end 604 is electrically and / or physically connected to the electrode bus bar 600 at one transverse end, and the counter electrode current collector end 606 is electrically and / or physically connected to the counter electrode bus bar 602 at the opposite transverse end.

[0155] Similarly, as described above, each unit element 504 of the electrode assembly includes a unit element portion of the first electrode current collector of the electrode current collector group, a first electrode active material layer of a member of the electrode group, a separator that is ion-permeable to carrier ions, a first counter electrode active material layer of a member of the counter electrode group, and a unit element portion of the first counter electrode current collector of the counter electrode current collector group, where (aa) the first electrode active material layer is adjacent to the first side of the separator, and the first counter electrode material layer is adjacent to the opposite second side of the separator, and (bb) the separator electrically isolates the first electrode active material layer from the first counter electrode active material layer, and during cycling between the charged and discharged states of the battery, carrier ions are mainly exchanged between the first electrode active material layer and the first counter electrode active material layer via the separator of each such unit element.

[0156] Referring to Figure 16A , which shows an embodiment of a bus bar that can be the electrode bus bar 600 or the counter electrode bus bar 602 (depending on whether the electrode current collector or the counter electrode current collector is attached to it). That is, Figure 16AIt can be understood as depicting a structure suitable for the electrode bus bar 600 or the counter electrode bus bar 602. Regarding the electrode bus bar 600, Figure 16A is shown. However, it should be understood that the same structure described herein also applies to the counter electrode bus bar 602, as described herein, even if not specifically shown. The secondary battery may include a single electrode bus bar 600 and a single counter electrode bus bar 602 to be respectively connected to all the electrode current collectors and counter electrode current collectors of the electrode assembly 106, and / or multiple bus bars and / or counter electrode bus bars may be provided. For example, in the case where Figure 16A is understood to show an embodiment of the electrode bus bar 600, it can be seen that the electrode bus bar 600 includes at least one conductive segment 608, which is configured to be electrically connected to the group of electrode current collectors 136 and extends between the first and second longitudinal end surfaces 116, 118 of the electrode assembly 106 in the longitudinal direction (Y direction). The conductive segment 608 includes a first side surface 610 and an opposite second side surface 614. The first side surface 610 has an inner surface 612 facing the first transverse end surface 503a of the counter electrode active material layer 136, and the opposite second side surface 614 has an outer surface 616. In addition, the conductive segment 608 optionally includes a plurality of holes 618 spaced apart in the longitudinal direction. The conductive segment 608 of the electrode bus bar 600 is arranged relative to the electrode current collector end 604 such that the electrode current collector end 604 at least partially extends beyond the thickness of the conductive segment 608 to be electrically connected thereto. The total thickness t of the conductive segment 608 can be measured between the inner surface 612 and the outer surface 616, and the electrode current collector end 608 can extend at least a distance into the thickness of the conductive segment, for example, through the holes 618, and can even completely extend beyond the thickness of the conductive segment (i.e., extend beyond the thickness t measured in the transverse direction). Although the electrode bus bar 600 having a single conductive segment 608 is depicted in Figure 16A , some embodiments may also include multiple conductive segments. Figure 16A ', however, it should be understood that the same structure described herein also applies to the counter electrode bus bar 602, as described herein, even if not specifically shown. The secondary battery may include a single electrode bus bar 600 and a single counter electrode bus bar 602 to be respectively connected to all the electrode current collectors and counter electrode current collectors of the electrode assembly 106, and / or multiple bus bars and / or counter electrode bus bars may be provided. For example, in Figure 16A the case where it is understood to show an embodiment of the electrode bus bar 600, it can be seen that the electrode bus bar 600 includes at least one conductive segment 608, which is configured to be electrically connected to the group of electrode current collectors 136 and extends between the first and second longitudinal end surfaces 116, 118 of the electrode assembly 106 in the longitudinal direction (Y direction). The conductive segment 608 includes a first side surface 610 and an opposite second side surface 614. The first side surface 610 has an inner surface 612 facing the first transverse end surface 503a of the counter electrode active material layer 136, and the opposite second side surface 614 has an outer surface 616. In addition, the conductive segment 608 optionally includes a plurality of holes 618 spaced apart in the longitudinal direction. The conductive segment 608 of the electrode bus bar 600 is arranged relative to the electrode current collector end 604 such that the electrode current collector end 604 at least partially extends beyond the thickness of the conductive segment 608 to be electrically connected thereto. The total thickness t of the conductive segment 608 can be measured between the inner surface 612 and the outer surface 616, and the electrode current collector end 608 can extend at least a distance into the thickness of the conductive segment, for example, through the holes 618, and can even completely extend beyond the thickness of the conductive segment (i.e., extend beyond the thickness t measured in the transverse direction). Although in Figure 16A the electrode bus bar 600 having a single conductive segment 608 is depicted, some embodiments may also include multiple conductive segments.

[0157] In addition, in Figure 16AIn the case where it is understood to show an embodiment of the counter electrode current collector 602, it can be seen that the counter electrode current collector 602 includes at least one conductive segment 608, and the at least one conductive segment 608 is configured to be electrically connected to the counter electrode current collector group 140 and extends between the first and second longitudinal end surfaces 116, 118 of the electrode assembly 106 in the longitudinal direction (y direction). The conductive segment 608 includes a first side surface 610 and an opposite second side surface 614. The first side surface 610 has an inner surface 612 facing the second transverse end surface 502b of the electrode active material layer 136, and the opposite second side surface 614 has an outer surface 616. In addition, the conductive segment 608 optionally includes a plurality of holes 618 spaced apart in the longitudinal direction. The conductive segment 608 of the electrode current collector 600 is arranged relative to the counter electrode current collector end 606 such that the counter electrode current collector end 606 at least partially extends beyond the thickness of the conductive segment 608 to be electrically connected thereto. The total thickness t of the conductive segment 608 can be measured between the inner surface 612 and the outer surface 616, and the counter electrode current collector end 606 can extend at least a distance into the thickness of the conductive segment, for example, through the holes 618, and can even completely extend beyond the thickness of the conductive segment (i.e., extend beyond the thickness t measured in the transverse direction). Although in Figure 16A the counter electrode current collector 602 with a single conductive segment 608 is depicted, some embodiments may also include a plurality of conductive segments.

[0158] In addition, according to one embodiment, the secondary battery 102 having current collectors and counter electrode current collectors 600, 602 further includes a set of electrode restraints, such as any of the restraints described herein. For example, in one embodiment, the set of electrode restraints 108 includes a primary restraint system 151, and the primary restraint system 151 includes first and second primary growth restraints 154, 156 and at least one primary connection member 162. The first and second primary growth restraints 154, 156 are separated from each other in the longitudinal direction, and the at least one primary connection member 162 connects the first and second primary growth restraints 154, 156, wherein the primary restraint system 151 restricts the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20% in 20 consecutive cycles of the secondary battery. In yet another embodiment, the set of electrode restraints 108 further includes a secondary restraint system 152, and the secondary restraint system 152 includes first and second secondary growth restraints 158, 160 separated in a second direction and connected by at least one secondary connection member 166, wherein when the secondary battery 106 is cycled, the secondary restraint system 155 at least partially restricts the growth of the electrode assembly 106 in the second direction, and the second direction is orthogonal to the longitudinal direction. Other embodiments of the set of electrode restraints 108 are described below.

[0159] ReferenceFigure 16A Other embodiments of the electrode bus bar 600 and / or the counter electrode bus bar 602 are described. In one embodiment, as Figure 16A shown, the electrode bus bar 600 includes a conductive segment 608 having a plurality of holes 618 spaced apart in the longitudinal direction, wherein each of the plurality of holes 618 is configured to allow one or more electrode current collector ends 604 to at least partially extend therethrough to electrically connect the one or more electrode current collector ends 604 to the electrode bus bar 600. Similarly, the counter electrode bus bar 602 may include a conductive segment 608 that includes a plurality of holes 618 spaced apart in the longitudinal direction, wherein each of the plurality of holes 618 is configured to allow one or more counter electrode current collector ends 606 to at least partially extend therethrough to electrically connect the one or more counter electrode current collector ends 606 to the counter electrode bus bar 602. Referring to Figure 16A the cross-section of ', it can be seen that on one side of the electrode bus bar, the current collector 136 of the electrode structure 110 extends beyond the first lateral surface 502a of the electrode active material layer 132 and extends through the hole 618 formed in the conductive segment. The electrode current collector end 604 is connected to the outer surface 616 of the electrode bus bar 600. Similarly, although not specifically shown, on the other lateral end where the counter electrode bus bar 602 is located, the electrode current collector 140 of the counter electrode structure 112 extends beyond the second lateral surface 503b of the counter electrode active material layer 138 and extends through the hole 618 formed in the conductive segment. The counter electrode current collector end 606 is connected to the outer surface 616 of the counter electrode bus bar 600.

[0160] Furthermore, although in one embodiment both the electrode bus bar and the counter electrode bus bars 600, 602 may include a plurality of holes 618, in another embodiment, only the electrode bus bar 600 includes holes 618, and in another embodiment, only the counter electrode bus bar 602 includes holes 618. In yet another embodiment, the secondary battery may include both an electrode bus bar and a counter electrode bus bar, while in other embodiments, the secondary battery may include only an electrode bus bar or a counter electrode bus bar and collect current from the remaining current collectors through other mechanisms. In such as Figure 16A and 16A 's embodiment, the holes 618 are shown to be sized to allow the electrode current collector or the counter electrode current collector to pass therethrough. Although in one embodiment the holes are sized and configured to allow only a single current collector to pass through each hole, in another embodiment, the holes may be sized to allow more than one electrode current collector 136 and / or counter electrode current collector 140 to pass therethrough. Furthermore, in such as Figure 16A and 16AIn the illustrated embodiment, the electrode current collector end and / or the counter electrode current collector end extend completely through one or more holes 618, and the ends 604, 606 are bent toward the outer surface 616 of the electrode bus bar and / or the counter electrode bus bar to be attached to the portion 622 of the outer surface electrode bus bar and / or the counter electrode bus bar between the holes 618. The ends 604, 608 may also and / or optionally be connected to other portions of the conductive segment 608, such as portions of the conductive segment located above or below the holes in the vertical direction, and / or to the inner surface 624 of the holes 618 themselves.

[0161] In an embodiment such as Figure 16B and Figure 16B In the illustrated embodiment, the electrode current collector end and / or the counter electrode current collector ends 604, 606 extend completely through one or more holes 618, and the ends are bent toward the outer surface 616 of the electrode bus bar and / or the counter electrode bus bar. However, in this embodiment, at least one or more of the current collector ends extend at least partially into or extend beyond adjacent holes 618 in the longitudinal direction (e.g., extend beyond adjacent holes as shown in Figure 16B to be attached to a separate electrode current collector end and / or a counter electrode current collector end. That is, the ends of the electrode and / or the counter electrode current collector may be attached to each other. In yet another embodiment, also as shown in Figure 16B In the illustrated embodiment, the electrode current collector end and / or the counter electrode current collector end are attached to the portion 622 of the outer surface 616 of the electrode bus bar and / or the counter electrode bus bar between the holes 618 at the first end region 624 and are attached to another separate electrode current collector end and / or a counter electrode current collector end at the second end region 626.

[0162] In one embodiment, the electrode current collector end 604 and / or the counter electrode current collector end 606 are attached to one or more of the following by at least one of adhesive, welding, crimping, brazing, by rivets, mechanical pressure / friction, clamping, and soldering: a portion 622 of the outer surface of the electrode bus bar and / or the counter electrode bus bar, and / or a separate electrode current collector end and / or counter electrode current collector end (such as adjacent current collectors extending through adjacent holes). The ends 604, 604 can also be connected to other portions of the electrode bus bar and / or the counter electrode bus bar via such attachment, such as the inner surface 624 of the hole 618 or other portions of the bus bar. Additionally, according to a preferred embodiment, the number of current collector ends that are attached to each other rather than only to the bus bar can be selected. For example, in one embodiment, in a given group, each of the electrode current collector end and the counter electrode current collector end is respectively attached to a portion 622 of the outer surface 616 of the electrode and / or the counter electrode bus bars 600, 602. In yet another embodiment, at least some of the electrode current collector ends and / or the counter electrode current collector ends are attached to each other (e.g., by extending through a hole and then longitudinally towards or past an adjacent hole to connect to an adjacent current collector extending through the adjacent hole), while at least one of the electrode current collector end and / or the counter electrode current collector end is attached to a portion of the outer surface of the electrode bus bar and / or the counter electrode bus bar (e.g., to provide an electrical connection between the attached bus bar and current collector ends). In yet another embodiment, all of the current collectors in the group can be individually connected to the bus bar without having to be connected to other current collector ends.

[0163] In yet another embodiment, the electrode current collector end and / or the counter electrode current collector end have a surface area (such as a first area 624) attached to the surface (such as the outer surface) of the bus bar and / or the counter electrode bus bar. For example, the electrode current collector end and / or the counter electrode current collector end have a surface area attached to at least one of the outer surface of the electrode bus bar and / or the counter electrode bus bar and the inner surface 624 of the hole 618 of the bus bar and / or the counter electrode bus bar. In one embodiment, one or more ends of the electrode bus bar and / or the counter electrode bus bar can include a surface area attached to the inner surface 612 of the bus bar and / or the counter electrode bus bar. The size of the connecting surface area can be selected according to the type of attachment to be chosen for attaching the end to the electrode and / or the counter electrode bus bar. In one embodiment, for example, as Figure 16A ' and Figure 16BAs shown, the electrode bus bar and / or the counter electrode bus bar include: an insulating material layer 628 on the inner surface 612 near the lateral ends of the electrode and / or the counter electrode, and a conductive material layer (e.g., conductive segment 608) on the outer surface 616 opposite the inner surface. The insulating material layer 628 may include an insulating member 514 disposed between the lateral surfaces of the electrode and / or counter electrode active material layers 132, 138 and the bus bar, as described elsewhere herein, and / or may include a separate insulating material layer 632 along the inner surface of the bus bar to insulate the electrode assembly from the conductive segments of the bus bar.

[0164] In one embodiment, the material and / or physical properties of the electrode and / or counter electrode current collectors 136, 140 can be selected to provide good electrical contact with the bus bar while also imparting good structural stability to the electrode assembly. For example, in one embodiment, the electrode current collector end 604 and / or the counter electrode current collector end 606 (and optionally, at least a portion and even all of the electrode and / or counter electrode current collectors) include the same material as the material from which the electrode bus bar and / or the counter electrode bus bar are made. For example, in the case where the bus bar and / or the counter electrode bus bar include aluminum, the electrode and / or the counter electrode current collectors may also include aluminum. In one embodiment, the electrode current collector end and / or the counter electrode current collector end include any one selected from aluminum, copper, stainless steel, nickel, nickel alloy, carbon, and their combinations / alloys. Additionally, in one embodiment, the electrode current collector end and / or the counter electrode current collector end include a material having a conductivity relatively close to the conductivity of the material of the electrode bus bar and / or the counter electrode bus bar, and / or the electrode and / or the counter electrode current collectors may include the same material as the electrode and / or the counter electrode bus bar.

[0165] In yet another embodiment, the ends of the electrode current collector and / or the counter electrode current collector extend through the holes 618 of the electrode bus bar and / or the counter electrode bus bar and bend backward toward the outer surface 616 of the electrode bus bar and / or the counter electrode bus bar to be attached thereto, and wherein the end region 624 that bends to be attached to the outer surface is substantially flat, such as Figure 16A and 16A as shown.

[0166] In one embodiment, the electrode current collector and / or the counter electrode current collectors 136, 140 extend along the length L of the electrode material layer E and / or the length L of the counter electrode material layer C in the lateral direction by at least 50%, where L E and L C are defined as above. For example, in one embodiment, the electrode current collector and / or the counter electrode current collectors extend along the length L of the electrode material layer E and / or the length L of the counter electrode material layer Cextends by at least 60%. In another embodiment, the electrode current collector and / or the counter electrode current collector extend along the length L of the electrode material layer and / or the length L of the counter electrode material layer in the lateral direction E and / or the length L of the counter electrode material layer C extends by at least 70%. In yet another embodiment, the electrode current collector and / or the counter electrode current collector extend along the length L of the electrode material layer and / or the length L of the counter electrode material layer in the lateral direction E and / or the length L of the counter electrode material layer C extends by at least 80%. In another embodiment, the electrode current collector and / or the counter electrode current collector extend along the length L of the electrode material layer and / or the length L of the counter electrode material layer in the lateral direction E and / or the length L of the counter electrode material layer C extends by at least 90%.

[0167] In addition, in one embodiment, the electrode current collector and / or the counter electrode current collector extend along the height H of the electrode material layer and / or the height H of the counter electrode material layer in the vertical direction E and / or the height H of the counter electrode material layer C extends by at least 50%, where H is defined as above. For example, in one embodiment, the electrode current collector and / or the counter electrode current collector extend along the height H of the electrode material layer and / or the height H of the counter electrode material layer in the vertical direction E and H C as defined above. For example, in one embodiment, the electrode current collector and / or the counter electrode current collector extend along the height H of the electrode material layer and / or the height H of the counter electrode material layer in the vertical direction E and / or the height H of the counter electrode material layer C extends by at least 60%. In another embodiment, the electrode current collector and / or the counter electrode current collector extend along the height H of the electrode material layer and / or the height H of the counter electrode material layer in the vertical direction E and / or the height H of the counter electrode material layer C extends by at least 70%. In yet another embodiment, the electrode current collector and / or the counter electrode current collector extend along the height H of the electrode material layer and / or the height H of the counter electrode material layer in the vertical direction E and / or the height H of the counter electrode material layer C extends by at least 80%. In another embodiment, the electrode current collector and / or the counter electrode current collector extend along the height H of the electrode material layer and / or the height H of the counter electrode material layer in the vertical direction E and / or the height H of the counter electrode material layer C extends by at least 90%.

[0168] According to an aspect of yet another embodiment, referring to Figure 18A and Figure 18B, the electrode assembly 106 includes at least one of a vertical electrode current collector end 640 and a vertical counter - electrode current collector end 642 that extend over one or more of the first and second vertical surfaces 500a, b, 501a, b of the adjacent electrode active material layer 132 and / or counter - electrode active material layer 138. In one embodiment, the vertical current collector ends 640, 642 may also be at least partially coated with a host - ion insulating material, as described in further detail below, to reduce the likelihood of short - circuiting and / or precipitation of host ions on the exposed vertical current collector ends.

[0169] According to one embodiment, for at least one of the members of the electrode group and the members of the counter - electrode group, (I) each member of the electrode structure group 110 includes an electrode current collector 136 to collect current from the electrode active material layer 132, and the electrode current collector 136 extends at least partially along the height H of the electrode active material layer 132 in the vertical direction E and includes at least one of the following: (a) a first vertical electrode current collector end 640a that extends over the first vertical end surface 500a of the electrode active material layer 132, and (b) a second vertical electrode current collector end 640b that extends over the second vertical end surface 500b of the electrode active material layer 132, and / or (II) each member of the counter - electrode structure group 112 includes a counter - electrode current collector 140 to collect current from the counter - electrode active material layer 138, and the counter - electrode current collector 140 extends at least partially along the height H of the counter - electrode active material layer 138 in the vertical direction C and includes at least one of the following: (a) a first vertical counter - electrode current collector end 642a that extends vertically over the first vertical end surface 501a of the counter - electrode active material layer 138, and (b) a second vertical electrode current collector end 640b that extends over the second vertical end surface 501b of the electrode active material layer 138. Referring to Figure 18A the embodiment shown, it can be seen that the vertical ends 640a, b, 642a, b of the electrode current collector 136 and the counter - electrode current collector 140 extend over the first and second vertical end surfaces of the electrode active and counter - electrode active material layers 132, 138.

[0170] Electrode restraint

[0171] In one embodiment, a set of electrode restraints 108 is provided that restrain the overall macroscopic growth of the electrode assembly 106, such as for example Figure 1AAs shown. This set of electrode restraints 108 can restrain the growth of the electrode assembly 106 along one or more dimensions, for example to reduce the enlargement and deformation of the electrode assembly 106, thereby improving the reliability and cycle life of the energy storage device 100 having this set of electrode restraints 108. As described above, without being limited to any particular theory, it is considered that carrier ions traveling between the electrode structure 110 and the counter electrode structure 112 during charging and / or discharging of the secondary battery 102 can be inserted into the electrode active material, thereby causing the electrode active material and / or the electrode structure 110 to expand. This expansion of the electrode structure 110 can cause the electrode and / or the electrode assembly 106 to deform and enlarge, thereby compromising the structural integrity of the electrode assembly 106 and / or increasing the likelihood of electrical short circuits or other failures. In one example, during cycling of the energy storage device 100, excessive enlargement and / or expansion and contraction of the electrode active material layer 132 can cause fragments of the electrode active material to detach from and / or delaminate from the electrode active material layer 132, thereby compromising the efficiency and cycle life of the energy storage device 100. In yet another example, excessive enlargement and / or expansion and contraction of the electrode active material layer 132 can cause the electrode active material to break the electrically insulating microporous separator 130, thereby causing an electrical short circuit and other failures in the electrode assembly 106. Therefore, this set of electrode restraints 108 inhibits this otherwise possible enlargement or growth that may occur during cycling between the charged state and the discharged state, thereby improving the reliability, efficiency, and / or cycle life of the energy storage device 100.

[0172] According to one embodiment, this set of electrode restraints 108 includes a primary growth restraint system 151 to restrain the growth and / or enlargement of the electrode assembly 106 along a longitudinal axis (e.g., Figure 1A the Y axis in ). In another embodiment, this set of electrode restraints 108 may include a secondary growth restraint system 152 that restrains growth along a vertical axis (e.g., Figure 1A the Z axis in ). In yet another embodiment, this set of electrode restraints 108 may include a tertiary growth restraint system 155 that restrains growth along a transverse axis (e.g., Figure 4CGrowth along the X-axis) of. In one embodiment, the set of electrode restraints 108 respectively includes primary growth and secondary growth restraint systems 151, 152, and even a tertiary growth restraint system 155, which cooperate to simultaneously restrain growth in one or more directions, such as along the longitudinal and vertical axes (e.g., the Y-axis and Z-axis), and even simultaneously along all longitudinal, vertical, and transverse axes (e.g., the Y, Z, and X axes). For example, the primary growth restraint system 151 can restrain growth that would otherwise occur along the stacking direction D of the electrode assembly 106 during the cycle between the charged state and the discharged state, while the secondary growth restraint system 152 can restrain the increase and growth that would occur along the vertical axis to prevent the electrode assembly 106 from bending or otherwise deforming in the vertical direction. As another example, in one embodiment, the secondary growth restraint system 152 can reduce the increase and / or expansion along the vertical axis that would otherwise be exacerbated by the restriction of growth imposed by the primary growth restraint system 151. The tertiary growth restraint system 155 can also optionally reduce the increase and / or expansion along the transverse axis that may occur during the cycle. That is, according to one embodiment, the primary growth restraint system 151, the secondary growth restraint system 152, and the optional tertiary growth restraint system 155 can operate together to cooperatively restrain the multi-dimensional growth of the electrode assembly 106.

[0173] See Figures 4A to 4B , which shows an embodiment of a set of electrode restraints 108 having a primary growth restraint system 151 and a secondary growth restraint system 152 for the electrode assembly 106. Figure 4A Shows a cross-section taken along the longitudinal axis (Y-axis) of Figure 1A the electrode assembly 106 therein, such that the resulting 2-D cross-section is shown through the vertical axis (Z-axis) and the longitudinal axis (Y-axis). Figure 4B Shows a cross-section taken along the transverse axis (X-axis) of Figure 1A the electrode assembly 106 therein, such that the resulting 2-D cross-section is shown through the vertical axis (Z-axis) and the transverse axis (X-axis). As Figure 4AAs shown, the primary growth restraint system 151 can generally include a first and a second primary growth restraint members 154, 156, which are separated from each other along the longitudinal direction (Y-axis). For example, in one embodiment, the first and second primary growth restraint members 154, 156 respectively include a first primary growth restraint member 154 that at least partially or even completely covers the first longitudinal end surface 116 of the electrode assembly 106, and a second primary growth restraint member 156 that at least partially or even completely covers the second longitudinal end surface 118 of the electrode assembly 106. In another version, one or more of the first and second primary growth restraint members 154, 156 can be inside the longitudinal ends 117, 119 of the electrode assembly 106, for example when one or more of the primary growth restraint members include the internal structure of the electrode assembly 106. The primary growth restraint system 151 can further include at least one primary connection member 162 that connects the first and second primary growth restraint members 154, 156 and can have a main axis parallel to the longitudinal direction. For example, the primary growth restraint system 151 can respectively include a first and a second primary connection members 162, 164, which are separated from each other along an axis orthogonal to the longitudinal axis, for example as shown in this embodiment, separated from each other along the vertical axis (Z-axis). The first and second primary connection members 162, 164 can be respectively used to connect the first and second primary growth restraint members 154, 156 to each other respectively, and respectively keep the first and second primary growth restraint members 154, 156 in tension with each other to restrain growth along the longitudinal axis of the electrode assembly 106.

[0174] According to one embodiment, the set of electrode restraints 108 including the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction (i.e., the electrode stack direction D) such that during 20 consecutive cycles of the secondary battery between a charged state and a discharged state, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 30 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 50 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 80 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 100 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 200 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 300 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 500 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 800 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 1000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20%.As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20% during 2000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20% during 3000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20% during 5000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20% during 8000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 20% during 10000 consecutive cycles of the secondary battery.

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

[0176] In yet another embodiment, the set of electrode restraints 108 including the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 5 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 10 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 20 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 30 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 50 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 80 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 100 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 200 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 300 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 500 consecutive cycles of the secondary battery between the charged state and the discharged state, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%.As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 800 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 1000 consecutive cycles of the secondary battery between the charged state and the discharged state, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 2000 consecutive cycles of the secondary battery between the charged state and the discharged state, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 3000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 5000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 8000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%. In one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 10000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 5%.

[0177] In yet another embodiment, the set of electrode restraints 108 including the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during each cycle of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 5 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 10 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 20 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 30 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 50 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 80 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 100 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 200 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1%. As another example, in one embodiment, the primary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the longitudinal direction such that during 300 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1%.As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1% during 500 consecutive cycles of the secondary battery between the charged state and the discharged state. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1% during 800 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1% during 1000 consecutive cycles of the secondary battery between the charged state and the discharged state. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1% during 2000 consecutive cycles of the secondary battery between the charged state and the discharged state. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1% during 3000 consecutive cycles of the secondary battery. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1% during 5000 consecutive cycles of the secondary battery between the charged state and the discharged state. As another example, in one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1% during 8000 consecutive cycles of the secondary battery. In one embodiment, the primary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in the longitudinal direction such that any increase in the Feret diameter of the electrode assembly in the longitudinal direction is less than 1% during 10000 consecutive cycles of the secondary battery.

[0178] The charged state means that the secondary battery 102 is charged to at least 75% of its rated capacity, such as at least 80% of its rated capacity, even at least 90% of its rated capacity, such as at least 95% of its rated capacity, and even 100% of its rated capacity. The discharged state means that the secondary battery is discharged to less than 25% of its rated capacity, such as less than 20% of its rated capacity, even less than 10%, such as less than 5%, and even 0% of its rated capacity. In addition, it should be noted that the actual capacity of the secondary battery 102 may vary over time and the number of cycles the battery has experienced. That is, although the secondary battery 102 may initially exhibit an actual measured capacity close to its rated capacity, the actual capacity of the battery will decrease over time, and when the actual capacity measured during the process from the charged state to the discharged state drops below 80% of the rated capacity, the secondary battery 102 is considered to be at the end of its life.

[0179] In Figure 4A and 4B it is further shown that the set of electrode restraint members 108 may further include a secondary growth restraint system 152, which generally may include first and second secondary growth restraint members 158, 160 that are separated from each other along a second direction orthogonal to the longitudinal direction (e.g., along the vertical axis (Z-axis) in the illustrated embodiment). For example, in one embodiment, the first secondary growth restraint member 158 extends at least partially across a first region 148 of the lateral surface 142 of the electrode assembly 106, and the second secondary growth restraint member 160 extends at least partially across a second region 150 of the lateral surface 142 of the electrode assembly 106 that is opposite the first region 148. In another version, one or more of the first and second secondary growth restraint members 154, 156 may be within the lateral surface 142 of the electrode assembly 106, such as when one or more of the secondary growth restraint members include internal structures of the electrode assembly 106. In one embodiment, the first and second secondary growth restraint members 158, 160 are respectively connected by at least one secondary connection member 166, which may have a major axis parallel to the second direction, such as a vertical axis. The secondary connection member 166 can be used to connect and keep the first and second secondary growth restraint members 158, 160 in tension with each other to inhibit the growth of the electrode assembly 106 in a direction orthogonal to the longitudinal direction, such as inhibiting growth in the vertical direction (e.g., along the Z-axis). In Figure 4A the illustrated embodiment, at least one secondary connection member 166 may correspond to at least one of the first and second primary growth restraint members 154, 156. However, the secondary connection member 166 is not limited thereto and may alternatively and / or additionally include other structures and / or configurations.

[0180] According to one embodiment, the set of restraints including the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a second direction (e.g., the vertical direction (Z-axis)) orthogonal to the longitudinal direction such that, during 20 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 30 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 50 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 80 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 100 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 200 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 300 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 500 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 800 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 1000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%.As another example, in one embodiment, the secondary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 2000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 3000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 5000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 8000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 10000 consecutive cycles of the secondary battery between the charged state and the discharged state, any increase in the Feret diameter of the electrode assembly in the second direction is less than 20%.

[0181] In an embodiment, the set of restraining members including the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a second direction such that, during 10 consecutive cycles of the secondary battery between a charged state and a discharged state, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 20 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 30 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 50 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 80 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 100 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 200 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 300 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 500 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that, during 800 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%.As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a second direction such that, during 1000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a second direction such that, during 2000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a second direction such that, during 3000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a second direction such that, during 5000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a second direction such that, during 8000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a second direction such that, during 10000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 10%.

[0182] In an embodiment, the set of restraining members including the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that any increase in the Feret diameter of the electrode assembly in the second direction is less than 5% during 5 consecutive cycles of the secondary battery between the charged state and the discharged state. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that any increase in the Feret diameter of the electrode assembly in the second direction is less than 5% during 10 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that any increase in the Feret diameter of the electrode assembly in the second direction is less than 5% during 20 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that any increase in the Feret diameter of the electrode assembly in the second direction is less than 5% during 30 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that any increase in the Feret diameter of the electrode assembly in the second direction is less than 5% during 50 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that any increase in the Feret diameter of the electrode assembly in the second direction is less than 5% during 80 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that any increase in the Feret diameter of the electrode assembly in the second direction is less than 5% during 100 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that any increase in the Feret diameter of the electrode assembly in the second direction is less than 5% during 200 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that any increase in the Feret diameter of the electrode assembly in the second direction is less than 5% during 300 consecutive cycles of the secondary battery. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that any increase in the Feret diameter of the electrode assembly in the second direction is less than 5% during 500 consecutive cycles of the secondary battery.As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a second direction such that, during 800 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 5%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a second direction such that, during 1000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 5%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a second direction such that, during 2000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 5%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a second direction such that, during 3000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 5%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a second direction such that, during 5000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 5%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a second direction such that, during 8000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 5%. As another example, in one embodiment, the secondary growth restraint system 151 is capable of restraining the growth of the electrode assembly 106 in a second direction such that, during 10000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 5%.

[0183] In an embodiment, the set of restraint members including the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during each cycle of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 5 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 10 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 20 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 30 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 50 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 80 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 100 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 200 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 300 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the second direction such that during 500 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%.As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in a second direction such that, during 800 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in a second direction such that, during 1000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in a second direction such that, during 2000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in a second direction such that, during 3000 consecutive cycles of the secondary battery between a charged state and a discharged state, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in a second direction such that, during 5000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth constraint system 152 is capable of constraining the growth of the electrode assembly 106 in a second direction such that, during 8000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%. As another example, in one embodiment, the secondary growth constraint system 151 is capable of constraining the growth of the electrode assembly 106 in a second direction such that, during 10000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the second direction is less than 1%.

[0184] Figure 4C An embodiment of a set of electrode restraints 108 is shown that further includes a tertiary growth constraint system 155 to constrain the growth of the electrode assembly in a third direction (e.g., a lateral (X) direction) perpendicular to the longitudinal direction and the second direction. The tertiary growth constraint system 155 may be provided in addition to the primary and secondary growth constraint systems 151, 152 to constrain the overall growth of the electrode assembly 106 in three dimensions, and / or the tertiary growth constraint system 155 may be provided in combination with one of the primary or secondary growth constraint systems 151, 152 to constrain the overall growth of the electrode assembly 106 in two dimensions. Figure 4C Shows a cross-section taken along the lateral axis (X-axis) of Figure 1A the electrode assembly 106 in, such that the resulting 2D cross-section is shown through the vertical axis (Z-axis) and the lateral axis (X-axis). AsFigure 4C As shown, the three - stage growth restraint system 155 generally may include first and second three - stage growth restraint members 157, 159, which are separated from each other along a third direction (e.g., a lateral direction (X - axis)). For example, in one embodiment, the first three - stage growth restraint member 157 extends at least partially across a first region 144 of the lateral surface 142 of the electrode assembly 106, and the second three - stage growth restraint member 159 extends at least partially across a second region 146 of the lateral surface 142 of the electrode assembly 106 that is opposite the first region 144 in the lateral direction. In another version, one or more of the first and second three - stage growth restraint members 157, 159 may be inside the lateral surface 142 of the electrode assembly 106, such as when one or more of the three - stage growth restraint members include internal structures of the electrode assembly 106. In one embodiment, the first and second three - stage growth restraint members 157, 159 are respectively connected by at least one three - stage connection member 165, which may have a main axis parallel to the third direction. The three - stage connection member 165 can be used to connect and keep the first and second three - stage growth restraint members 157, 159 taut with respect to each other to inhibit the growth of the electrode assembly 106 along a direction orthogonal to the longitudinal direction, such as inhibiting growth in the lateral direction (e.g., along the X - axis). In Figure 4C In the embodiment shown, the at least one three - stage connection member 165 may correspond to at least one of the first and second two - stage growth restraint members 158, 160. However, the three - stage connection member 165 is not limited thereto and may alternatively and / or additionally include other structures and / or configurations. For example, in one embodiment, the at least one three - stage connection member 165 may correspond to at least one of the first and second primary growth restraint members 154, 156 (not shown).

[0185] According to one embodiment, the set of restraints having the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction (e.g., the lateral direction (X-axis)) orthogonal to the longitudinal direction such that, during 20 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that, during 30 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that, during 50 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that, during 80 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that, during 100 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that, during 200 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that, during 300 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that, during 500 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that, during 800 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that, during 1000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%.As another example, in one embodiment, the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that during 2000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%. As another example, in one embodiment, the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that during 3000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%. As another example, in one embodiment, the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that during 5000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%. As another example, in one embodiment, the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that during 8000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%. As another example, in one embodiment, the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that during 10000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 20%.

[0186] In one embodiment, the set of restraints having the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that, during 10 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%. As another example, in one embodiment, the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that, during 20 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%. As another example, in one embodiment, the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that, during 30 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%. As another example, in one embodiment, the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that, during 50 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%. As another example, in one embodiment, the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that, during 80 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%. As another example, in one embodiment, the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that, during 100 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%. As another example, in one embodiment, the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that, during 200 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%. As another example, in one embodiment, the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that, during 300 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%. As another example, in one embodiment, the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that, during 500 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%. As another example, in one embodiment, the three - stage growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a third direction such that, during 800 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%.As another example, in one embodiment, the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that during 1000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%. As another example, in one embodiment, the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that during 2000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%. As another example, in one embodiment, the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that during 3000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%. As another example, in one embodiment, the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that during 5000 consecutive cycles of the secondary battery between the charged state and the discharged state, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%. As another example, in one embodiment, the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that during 8000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%. As another example, in one embodiment, the three - stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that during 10000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 10%.

[0187] In one embodiment, the set of restraints having the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 5 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 10 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 20 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 30 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 50 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 80 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 100 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 200 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 300 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three - stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 500 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%.As another example, in one embodiment, the three-stage growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in a third direction such that during 800 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that during 1000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that during 2000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that during 3000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that during 5000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that during 8000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three-stage growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in a third direction such that during 10000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%.

[0188] In one embodiment, the set of restraints having the three-stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during each cycle of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the three-stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 5 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the three-stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 10 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the three-stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 20 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the three-stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 30 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the three-stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 50 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 5%. As another example, in one embodiment, the three-stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 80 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the three-stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 100 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the three-stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 200 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the three-stage growth restraint system 155 can restrain the growth of the electrode assembly 106 in the third direction such that, during 300 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%.As another example, in one embodiment, the tertiary growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that during 500 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the tertiary growth restraint system 152 is capable of restraining the growth of the electrode assembly 106 in the third direction such that during 800 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the tertiary growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that during 1000 consecutive cycles of the secondary battery between a charged state and a discharged state, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the tertiary growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that during 2000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the tertiary growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that during 3000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the tertiary growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that during 5000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the tertiary growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that during 8000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%. As another example, in one embodiment, the tertiary growth restraint system 155 is capable of restraining the growth of the electrode assembly 106 in the third direction such that during 10000 consecutive cycles of the secondary battery, any increase in the Feret diameter of the electrode assembly in the third direction is less than 1%.

[0189] According to one embodiment, the primary and secondary growth restraint systems 151, 152 and the optional tertiary growth restraint system 155 are configured to operate in cooperation such that multiple parts of the primary growth restraint system 151 cooperate to act as part of the secondary growth restraint system 152, and / or multiple parts of the secondary growth restraint system 152 cooperate to act as part of the primary growth restraint system 151, and multiple parts of either the primary and / or secondary restraint systems 151, 152 can also cooperate to act as part of the tertiary growth restraint system, and vice versa. For example, in Figure 4A and 4BIn the illustrated embodiment, the first and second primary connection members 162, 164 of the primary growth restraint system 151 can respectively serve as at least a part or even the entire structure of the first and second secondary growth restraint members 158, 160, and the first and second secondary growth restraint members 158, 160 restrain growth in a second direction orthogonal to the longitudinal direction. In yet another embodiment, as described above, one or more of the first and second primary growth restraint members 154, 156 can respectively serve as one or more secondary connection members 166 to connect the first and second secondary growth restraint members 158, 160, respectively. Conversely, at least a part of the first and second secondary growth restraint members 158, 160 can respectively serve as the first and second primary connection members 162, 164 of the primary growth restraint system 151, and in one embodiment, at least one secondary connection member 166 of the secondary growth restraint system 152 can respectively serve as one or more of the first and second primary growth restraint members 154, 156. In yet another embodiment, at least a part of the first and second primary connection members 162, 164 of the primary growth restraint system 151 and / or at least one secondary connection member 166 of the secondary growth restraint system 152 can respectively serve as at least a part or even the entire structure of the first and second tertiary growth restraint members 157, 159, and the first and second tertiary growth restraint members 157, 159 restrain growth in a transverse direction orthogonal to the longitudinal direction. In yet another embodiment, one or more of the first and second primary growth restraint members 154, 156 and / or the first and second secondary growth restraint members 158, 160 can respectively serve as one or more tertiary connection members 165 to connect the first and second tertiary growth restraint members 157, 159, respectively. Conversely, at least a part of the first and second tertiary growth restraint members 157, 159 can respectively serve as the first and second primary connection members 162, 164 of the primary growth restraint system 151, and / or in one embodiment, at least one secondary connection member 166 of the secondary growth restraint system 152 and at least one tertiary connection member 165 of the tertiary growth restraint system 155 can respectively serve as one or more of the first and second primary growth restraint members 154, 156, and / or one or more of the first and second secondary growth restraint members 158, 160. Alternatively and / or additionally, the primary and / or secondary and / or tertiary growth restraint members can include other structures that cooperate to restrain the growth of the electrode assembly 106. Thus, the primary and secondary growth restraint systems 151, 152 and the optional tertiary growth restraint system 155 can share components and / or structures that impose constraints on the growth of the electrode assembly 106.

[0190] In one embodiment, the set of electrode restraints 108 may include structures such as primary and secondary growth restraints, and primary and secondary connection members, which are structures located external and / or internal to the cell housing 104, or may be part of the cell housing 104 itself. For example, the set of electrode restraints 108 may include a combination of structures that includes the cell housing 104 and other structural components. In one such embodiment, the cell housing 104 may be a component of the primary growth restraint system 151 and / or the secondary growth restraint system 152; in other words, in one embodiment, the cell housing 104, alone or in combination with one or more other structures (inside and / or outside the cell housing 104, such as the primary growth restraint system 151 and / or the secondary growth restraint system 152), restrains the growth of the electrode assembly 106 in the electrode stacking direction D and / or in a second direction orthogonal to the stacking direction D. For example, one or more of the primary growth restraints 154, 156 and the secondary growth restraints 158, 160 may include structures located inside the electrode assembly. In another embodiment, the primary growth restraint system 151 and / or the secondary growth restraint system 152 do not include the cell housing 104, but instead, one or more discrete structures (located inside and / or outside the cell housing 104) other than the cell housing 104 restrain the growth of the electrode assembly 106 in the electrode stacking direction D and / or in a second direction orthogonal to the stacking direction D. In another embodiment, the primary and secondary growth restraint systems, and optionally also a tertiary growth restraint system, are within a cell housing, which may be a sealed cell housing, such as an airtight sealed cell housing. During repeated cycling of the energy storage device 100 or secondary battery having the electrode assembly 106, the set of electrode restraints 108 may restrain the electrode assembly 106 with a pressure greater than the pressure exerted by the growth and / or expansion of the electrode assembly 106.

[0191] In an exemplary embodiment, the primary growth restraint system 151 includes one or more discrete structures located within the battery housing 104 that restrain the growth of the electrode structure 110 in the stacking direction D by applying a pressure that exceeds the pressure generated by the electrode structure 110 in the stacking direction D during repeated cycling of the secondary battery 102 having the electrode structure 110 as part of the electrode assembly 106. In another exemplary embodiment, the primary growth restraint system 151 includes one or more discrete structures located within the battery housing 104 that restrain the growth of the counter electrode structure 112 in the stacking direction D by applying a pressure that exceeds the pressure generated by the counter electrode structure 112 in the stacking direction D during repeated cycling of the secondary battery 102 having the counter electrode structure 112 as part of the electrode assembly 106. The secondary growth restraint system 152 can similarly include one or more discrete structures located within the battery housing 104 that restrain the growth of at least one of the electrode structure 110 and the counter electrode structure 112 in a second direction (e.g., along the vertical axis (Z-axis)) orthogonal to the stacking direction D by applying a pressure that exceeds the pressure generated by the electrode or counter electrode structure 110, 112 in the second direction during repeated cycling of the secondary battery 102 having the electrode or counter electrode structures 110, 112.

[0192] In yet another embodiment, the first and second primary growth restraint members 154, 156 of the primary growth restraint system 151 restrain the growth of the electrode assembly 106 by applying pressure on the first and second longitudinal end surfaces 116, 118 of the electrode assembly 106 (i.e., in the longitudinal direction), the pressure exceeding the pressure that the first and second primary growth restraint members 154, 156 would apply on other surfaces of the electrode assembly 106 in a direction orthogonal to the longitudinal direction (e.g., the first and second regions of the lateral surface 142 of the electrode assembly 106 that are opposite along the lateral axis and / or the vertical axis). That is, the first and second primary growth restraint members 154, 156 can apply pressure in the longitudinal direction (Y-axis) that exceeds the pressure generated thereby in the directions orthogonal thereto (e.g., the lateral (X-axis) direction and the vertical (Z-axis) direction). For example, in one such embodiment, the primary growth restraint system 151 restrains the growth of the electrode assembly 106 by the pressure on the first and second longitudinal end surfaces 116, 118 (i.e., in the stacking direction D), the pressure exceeding the pressure maintained by the primary growth restraint system 151 on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the stacking direction D by at least 2 times. As another example, in one such embodiment, the primary growth restraint system 151 restrains the growth of the electrode assembly 106 by the pressure on the first and second longitudinal end surfaces 116, 118 (i.e., in the stacking direction D), the pressure exceeding the pressure maintained by the primary growth restraint system 151 on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the stacking direction D by at least 3 times. As another example, in one such embodiment, the primary growth restraint system 151 restrains the growth of the electrode assembly 106 by the pressure on the first and second longitudinal end surfaces 116, 118 (i.e., in the stacking direction D), the pressure exceeding the pressure maintained on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the stacking direction D by at least 4 times.

[0193] Similarly, in one embodiment, the first and second secondary growth restraint members 158, 160 of the primary growth restraint system 151 restrain the growth of the electrode assembly 106 by applying pressure on first and second opposite regions of the lateral surface 142 of the electrode assembly 106 in a second direction orthogonal to the longitudinal direction (e.g., first and second opposite surface regions along the vertical axes 148, 150 (i.e., in the vertical direction)), the pressure exceeding the pressure that the first and second secondary growth restraint members 158, 160 will respectively apply on other surfaces of the electrode assembly 106 in a direction orthogonal to the second direction. That is, the first and second secondary growth restraint members 158, 160 can respectively apply pressure in the vertical direction (Z-axis), the pressure exceeding the pressure generated thereby in the directions orthogonal thereto (e.g., the lateral (X-axis) direction and the longitudinal (Y-axis) direction). For example, in one such embodiment, the secondary growth restraint system 152 restrains the growth of the electrode assembly 106 by the pressure on the first and second opposite surface regions 148, 150 (i.e., in the vertical direction), the pressure exceeding the pressure maintained by the secondary growth restraint system 152 on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the vertical direction by at least 2 times. As another example, in one such embodiment, the secondary growth restraint system 152 restrains the growth of the electrode assembly 106 by the pressure on the first and second opposite surface regions 148, 150 (i.e., in the vertical direction), the pressure exceeding the pressure maintained by the secondary growth restraint system 152 on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the vertical direction by at least 3 times. As another example, in one such embodiment, the secondary growth restraint system 152 restrains the growth of the electrode assembly 106 by the pressure on the first and second opposite surface regions 148, 150 (i.e., in the vertical direction), the pressure exceeding the pressure maintained on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the vertical direction by at least 4 times.

[0194] In yet another embodiment, the first and second tertiary growth restraint members 157, 159 of the tertiary growth restraint system 155 restrain the growth of the electrode assembly 106 by applying pressure in a direction orthogonal to both the longitudinal direction and the second direction on first and second opposing regions of the lateral surface 142 of the electrode assembly 106 (e.g., first and second opposing surface regions along the lateral axes 161, 163 (i.e., in the lateral direction), respectively), the pressure being greater than the pressure that the tertiary growth restraint system 155 will apply to other surfaces of the electrode assembly 106 in a direction orthogonal to the lateral direction. That is, the first and second tertiary growth restraint members 157, 159 can apply pressure in the lateral direction (X-axis), the pressure being greater than the pressure generated thereby in the directions orthogonal thereto (e.g., the vertical (Z-axis) direction and the longitudinal (Y-axis) direction). For example, in one such embodiment, the tertiary growth restraint system 155 restrains the growth of the electrode assembly 106 by pressure on first and second opposing surface regions 144, 146 (i.e., in the lateral direction), the pressure being at least 2 times greater than the pressure maintained by the tertiary growth restraint system 155 on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the lateral direction. As another example, in one such embodiment, the tertiary growth restraint system 155 restrains the growth of the electrode assembly 106 by pressure on first and second opposing surface regions 144, 146 (i.e., in the lateral direction), the pressure being at least 3 times greater than the pressure maintained by the tertiary growth restraint system 155 on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the lateral direction. As another example, in one such embodiment, the tertiary growth restraint system 155 restrains the growth of the electrode assembly 106 by pressure on first and second opposing surface regions 144, 146 (i.e., in the lateral direction), the pressure being at least 4 times greater than the pressure maintained on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the lateral direction.

[0195] In one embodiment, the set of electrode constraining members 108 (which may include a primary growth constraining system 151, a secondary growth constraining system 152, and an optional tertiary growth constraining system 155) is configured to apply pressure to the electrode assembly 106 along two or three dimensions of the electrode assembly 106 (e.g., along the longitudinal direction and the perpendicular direction, and optionally along the transverse direction), wherein the pressure applied by the set of electrode constraining members 108 along the longitudinal direction is greater than any pressure applied by the set of electrode constraining members 108 in any one of the directions orthogonal to the longitudinal direction (e.g., the Z and X directions). That is, when the pressures applied by the primary, secondary, and optional tertiary growth constraining systems 151, 152, 155 that make up the set of electrode constraining members 108 are added together, the pressure applied to the electrode assembly 106 along the longitudinal axis exceeds the pressure applied to the electrode assembly 106 in the direction orthogonal to the longitudinal axis. For example, in one such embodiment, the set of electrode constraining members 108 applies pressure on the first and second longitudinal end surfaces 116, 118 (i.e., in the stacking direction D), and this pressure exceeds the pressure maintained by the set of electrode constraining members 108 on the electrode assembly 106 in at least one or even both of the two directions perpendicular to the stacking direction D by at least 2 times. As another example, in one such embodiment, the set of el...

Claims

1. A battery, the battery comprising a battery housing, an electrode assembly, lithium ions within the battery housing, and a set of electrode constraining members, wherein (a) the electrode assembly includes a series of layers stacked in a stacking direction, wherein, the series of stacked layers includes a group of negative electrode active material layers, a group of negative electrode current collector layers, a group of separator material layers, a group of positive electrode active material layers, and a group of positive electrode current collector material layers, wherein (b) the set of electrode constraining members includes a primary constraining system and a secondary constraining system, wherein (i) the primary constraining system includes a first primary growth constraining member and a second primary growth constraining member and at least one primary connecting member, the first primary growth constraining member and the second primary growth constraining member are separated from each other in the stacking direction, and the at least one primary connecting member connects the first primary growth constraining member and the second primary growth constraining member to at least partially restrict growth of the electrode assembly in the stacking direction, and (ii) the secondary constraining system includes a first secondary growth constraining member and a second secondary growth constraining member separated in a second direction and connected by a member passing through the series of layers, wherein the secondary constraining system at least partially restricts growth of the electrode assembly in the second direction during battery cycling, the second direction being orthogonal to the stacking direction, and (iii) the primary constraining system maintains a pressure on the electrode assembly in the stacking direction, the pressure exceeding the pressure maintained on the electrode assembly in each of two directions mutually perpendicular to the stacking direction.

2. The battery according to claim 1, wherein, the group of positive electrode active material layers includes a silicon composite material having an allotrope of elemental carbon, a silicon mixture having an allotrope of elemental carbon, silicon oxide, porous silicon, or an intermetallic silicon alloy.

3. The battery according to claim 1, wherein, the battery is configured such that a plurality of carrier ions pass through a solid electrolyte.

4. The battery according to claim 1, wherein, The electrode assembly has a transverse axis, a longitudinal axis, and a vertical axis that are perpendicular to each other and correspond to the x-axis, y-axis, and z-axis of a fictional three-dimensional Cartesian coordinate system, a first longitudinal end surface and a second longitudinal end surface that are separated from each other in the longitudinal direction, and a transverse surface that surrounds the longitudinal axis A EA and connects the first longitudinal end surface and the second longitudinal end surface. The transverse surface has opposite first and second regions located on opposite sides of the longitudinal axis and separated in a first direction orthogonal to the longitudinal axis. The electrode assembly has a maximum width W measured in the longitudinal direction EA , a maximum length L defined by the transverse surface and measured in the transverse direction EA , and a maximum height H defined by the transverse surface and measured in the vertical direction EA , wherein the maximum length L EA and the maximum width W EA each are greater than the maximum height H EA .

5. The battery according to claim 4, wherein, a member of the group of negative electrode current collector layers or a member of the group of positive electrode current collector layers includes opposite end surfaces having a surface area exhibiting plastic deformation and fracture oriented in a lateral direction due to elongation and shrinkage at the opposite end surfaces.

6. The battery according to claim 4, wherein, the first primary growth constraining member and the second primary growth constraining member respectively cover the first longitudinal end face and the second longitudinal end face.

7. The battery according to claim 1, wherein, (i) The component of the negative electrode active material layer group has a length L E , a height H E , and a width W E , where the length L E corresponds to the Feret diameter of the component of the negative electrode active material layer group measured in the lateral direction between the first lateral end surface and the second lateral end surface of the component of the negative electrode active material layer group, and the height H E corresponds to the Feret diameter of the component of the negative electrode active material layer group measured in the vertical direction between the first vertical end surface and the second vertical end surface of the component of the negative electrode active material layer group, and the width W E corresponds to the Feret diameter of the component of the negative electrode active material layer group measured in the longitudinal direction between the first surface and the second surface of the component of the negative electrode active material layer group, wherein the L E and each of the H E and the W E has a ratio of at least 5:1; (ii) The component of the positive electrode active material layer group has a length L C , a height H C , and a width W C , where the length L C corresponds to the Feret diameter of the component of the positive electrode active material layer group measured in the lateral direction between the first lateral end surface and the second lateral end surface of the component of the positive electrode active material layer group, and the height H C corresponds to the Feret diameter of the component of the positive electrode active material layer group measured in the vertical direction between the first vertical end surface and the second vertical end surface of the component of the positive electrode active material layer group, and the width W C corresponds to the Feret diameter of the component of the positive electrode active material layer group measured between the first longitudinal surface and the second longitudinal surface of the component of the positive electrode active material layer group, wherein the L C and the H C and the W C each have a ratio of at least 5:

1.

8. The battery according to claim 1, wherein, the first secondary growth constraining member and the second secondary growth constraining member are connected to each other via a member of the group of negative electrode current collector layers.

9. The battery according to claim 1, wherein, the first secondary growth constraining member and the second secondary growth constraining member are connected to each other via a member of the group of positive electrode current collector layers.

10. The battery according to claim 1, wherein, The electrode assembly includes a unit elementary group, wherein each unit element includes a unit element portion of a first member of the negative current collector layer group, a member of a separator material layer group that is ion-permeable to a plurality of carrier ions, a first member of the negative active material layer group, a unit element portion of a first member of the positive current collector layer group, and a first member of the positive active material layer group, wherein, (aa) the first member of the negative active material layer group is adjacent to a first side of the member of the separator material layer group, and the first member of the positive active material layer group is adjacent to an opposite second side of the member of the separator material layer group, and (bb) the member of the separator material layer group electrically isolates the first member of the negative active material layer group from the first member of the positive active material layer group, and during the cycle of the battery between the charged state and the discharged state, the plurality of carrier ions are mainly exchanged between the first member of the negative active material layer group and the first member of the positive active material layer group via the member of the separator material layer group of each such unit element.

11. The battery according to claim 1, wherein, (A) the member of the negative current collector layer group includes copper or stainless steel and / or (B) the member of the positive current collector layer group includes aluminum.

12. The battery according to claim 1, wherein, the member of the negative active material layer group includes lithium.

13. The battery according to claim 1, wherein, the battery housing is hermetically sealed, and the set of electrode restraints is within the battery housing.

14. The battery according to claim 1, wherein, (I) the member of the negative current collector layer group has longitudinally opposite ends operatively coupled to a conductive bus, and / or (II) the member of the positive current collector layer group has longitudinally opposite ends operatively coupled to a conductive bus.

15. The battery according to claim 1, wherein, the member of the negative active material layer group includes particulate material that includes (a) at least 60 wt% of a negative active material and (b) a binder material.

16. The battery according to claim 1, wherein, the first restraint system and / or the second restraint system is configured to anisotropically inhibit the growth of the electrode assembly.

17. The battery according to claim 1, wherein, the secondary restraint system is configured to maintain a pressure greater than the ambient pressure of the environment external to the battery.

18. The battery according to claim 1, wherein, the secondary restraint system is configured to maintain a pressure greater than 1000 pounds per square inch (PSI).

19. A method related to the battery according to any one of claims 1 to 18, the method comprising: (A) manufacturing the battery, (b) providing the battery and using the battery for its intended purpose, or (c) any combination of (A) and (b).

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