Rechargeable solid-state battery module and battery pack

Abstract

The present application provides a module having at least two electrochemical stack assemblies (ESAs), each ESA individually comprising one or more electrochemical cells in each case, each electrochemical cell includes a solid state electrolyte, a frame surrounding the one or more electrochemical cells, and a laminated pouch surrounding the frame and the one or more electrochemical cells. Methods of making and using the same are also described.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority and benefit to U.S. Provisional Patent Application No. 63 / 492,629, filed March 28, 2023, the entire contents of which are incorporated herein by reference for all purposes. Technical Field

[0003] This application relates to modules, battery packs, and related housings for rechargeable batteries, particularly solid-state lithium batteries. Background Technology

[0004] Solid-state lithium batteries offer numerous advantages over traditional lithium batteries that rely solely on liquid electrolytes. However, the inherently lower deformability of solid-state lithium batteries compared to liquids makes their packaging more challenging.

[0005] One of the challenges in encapsulating lithium metal anode solid-state lithium batteries is that the batteries expand and contract during charge-discharge cycles. A packaging technology is needed that can accommodate this expansion and contraction without adversely affecting battery performance. Invention Overview

[0007] In one embodiment, this application describes a module comprising at least two electrochemical stack assemblies (ESAs), each ESA individually comprising in each case: one or more electrochemical cells, each of the electrochemical cells comprising a solid electrolyte; a frame surrounding the one or more electrochemical cells; and a laminated bag surrounding the frame and the one or more electrochemical cells.

[0008] In another embodiment, this application describes a method for determining the state of charge (SOC), comprising: measuring the thickness of the laminated bag in the module described in this application, the thickness being proportional to the SOC; and then determining the SOC based on the measured thickness.

[0009] In another embodiment, this application describes a method for pumping coolant, comprising: providing the module described in this application, having a compressible cooling bag or bladder disposed between laminated bags, the cooling bag or bladder comprising coolant and connected to a cooling system; causing the laminated bags to expand and contract by charging and discharging an electrochemical cell; utilizing the mechanical force generated by one or more laminated bags expanding due to lithium metal plating at the anode during charging and contracting due to the stripping of lithium metal during discharging. The expansion and contraction pump the coolant.

[0010] In another embodiment, this application describes a method for cooling the module described in this application, comprising: absorbing heat from the ESA through the edge of the laminated bag. This is referred to as edge cooling of the laminated bag.

[0011] In another embodiment, this application describes a method for cooling the module described in this application, comprising: absorbing heat from the electrochemical cell through the sides (commonly referred to as the face or main surface) of the laminated bag. This is referred to as face cooling of the laminated bag. Attached Figure Description

[0012] Figure 1 A laminated bag according to one embodiment is shown.

[0013] Figures 2 to 5 This is an exploded view of the laminated bag according to different embodiments.

[0014] Figure 6 and Figure 7 These are schematic diagrams of modules according to different embodiments. Invention Details

[0016] definition

[0017] In this application, the term "about" when used to define a numerical value, such as about 15% by weight (%w / w), refers to the defined value and values ​​within ±10% of that value. For example, about 15%w / w includes 15%w / w, as well as 13.5%w / w, 14%w / w, 14.5%w / w, 15.5%w / w, 16%w / w, or 16.5%w / w. For example, "about 75°C" includes 75°C, as well as 67°C, 68°C, 69°C, 70°C, 71°C, 72°C, 73°C, 74°C, 75°C, 76°C, 77°C, 78°C, 79°C, 80°C, 81°C, 82°C, or 83°C.

[0018] In this application, "a group selected from..." means a single member of the group, multiple members of the group, or a combination of members of the group. For example, the members of a group selected from A, B, and C may include only A, only B, or only C, as well as A and B, A and C, B and C, and A, B, and C.

[0019] In this application, unless otherwise stated, the term "electrochemical cell" or "cell" refers to a single battery comprising a positive electrode and a negative electrode that are ionically connected to each other via an electrolyte. In some embodiments, a battery or module may comprise multiple positive electrodes and / or multiple negative electrodes enclosed in a container or otherwise stacked together (e.g., an electrochemical cell stack). An electrochemical cell stack or "electrochemical stack" may be referred to as a multilayer battery. A symmetrical battery may be a battery having two lithium metal anodes separated by a solid electrolyte.

[0020] In this application, "module" and "battery module" refer to a unit housing one or more electrochemical cells, which may, but does not necessarily, include the following elements: (i) mechanical structural components (e.g., external module housing / structure, means for spacing and securing the cells, battery pressure distributor, battery expansion compensation device); (ii) thermal management components (e.g., cell thermal contacts / interfaces, ventilation, cooling channels, and thermal barriers, all of which are at least partially located within the module housing); (iii) high-voltage components (e.g., busbars, cables, couplers, electrical insulation, and terminals, all of which are at least partially enclosed by the module housing); and (iv) electronic hardware components for battery monitoring and identification (e.g., battery monitoring electronics, electrical connectors, wireless or wired communication devices, RFID, thermocouples, current sensors, and voltage sensors). An electrochemical stack may include multiple of the above-described units arranged in an electrically connected manner (e.g., series or parallel electrical connection). In some embodiments, when an electrochemical stack includes multiple units, these units may be layered, laminated together, or otherwise adhered to each other in a columnar structure. In some embodiments, when the electrochemical stack comprises multiple units, these units may be layered, laminated together, or otherwise adhered to each other in an array. In some embodiments, when the electrochemical stack comprises multiple units, the stack may be arranged such that two or more negative electrodes share a single negative electrode current collector. That is, two or more negative electrodes are connected to the same negative electrode current collector. Alternatively, in some embodiments, when the electrochemical stack comprises multiple units, the stack may be arranged such that two or more positive electrodes share a single positive electrode current collector. That is, two or more positive electrodes are connected to the same positive electrode current collector. Adhesives or other bonding materials may be provided between the layers in the stack, as appropriate or necessary. Optionally or additionally, when batteries are combined together to form a stack, one battery may simply be stacked on top of another, or one or more batteries may be adhered to one or two adjacent batteries.

[0021] An electrochemical stack assembly refers to multiple electrochemical cells connected together.

[0022] In this application, the term "positive electrode" refers to an electrode in a secondary battery that receives positive ions (e.g., Li) during battery discharge. + ) conduct, flow, or move to this electrode. In this application, the term "negative electrode" refers to an electrode in a secondary battery that receives positive ions (e.g., Li) during battery discharge. +Lithium ions flow out or move out of this electrode. In a battery containing a lithium metal electrode and an electrode containing a conversion chemistry, intercalation chemistry, or a combination of conversion / intercalation chemistry (i.e., cathode active material), the electrode with the conversion chemistry, intercalation chemistry, or combination of conversion / intercalation chemistry is called the positive electrode. In some applications, the cathode is used instead of the positive electrode, and the anode is used instead of the negative electrode. When a lithium secondary battery is charged, lithium ions flow out or move out of the positive electrode (e.g., nickel fluoride (NiF)). x Lithium ions move from the negative electrode (e.g., lithium metal) to the positive electrode (where x is 0 to 2.5). When a lithium-ion secondary battery discharges, lithium ions move from the negative electrode to the positive electrode.

[0023] In this application, the term "positive electrode terminal" refers to an electrical connection to a positive electrode. A positive electrode terminal may also be referred to as a positive electrode current collector.

[0024] In this application, the term "negative electrode terminal" refers to an electrical connection to a negative electrode. A negative electrode terminal may also be referred to as a negative electrode current collector.

[0025] In this application, the term "cathode active material" refers to a material capable of reversibly intercalating or reacting with lithium ions. Examples include LiMPO4 (M = Fe, Ni, Co, Mn); Li x Ti y O2, where x is 0 to 8, y is 1 to 12, and z is 1 to 24; LiMn 2a Ni a O4, where a is 0 to 2; nickel cobalt aluminum oxide; LiNi x Mn y Co2O2, where x+y+z=1, and 0≤x≤1, 0≤y≤1, 0≤z≤1; and LiNi x Co y Al z O2, where x + y + z = 1, and 0 ≤ x ≤ 1, 0 ≤ y ≤ 1, 0 ≤ z ≤ 1. In these formulas, x, y, and z are chosen to make the chemical formula electrically neutral.

[0026] In this application, the terms "solid electrolyte membrane" and "solid membrane" are used interchangeably, referring to a membrane that is carbon-free and capable of conducting ions (e.g., Li). +However, it is a material that cannot conduct electrons. A solid electrolyte separator is a solid material suitable for electrically separating the positive and negative electrodes of a lithium-ion secondary battery while providing a conduction path for lithium ions. Examples of solid electrolytes include oxide electrolytes and sulfide electrolytes, as defined below. Non-limiting examples of sulfide electrolytes can be found in U.S. Patent No. 9,172,114, issued October 27, 2015, and U.S. Patent Application Publication No. 2017-0162901A1, published June 8, 2017. Non-limiting examples of oxide electrolytes can be found in U.S. Patent Application Publication No. 2015-0200420A1, issued July 16, 2015, and granted October 31, 2017, as U.S. Patent No. 9,806,372. In some embodiments, the solid electrolyte also includes a polymer, referred to as a composite electrolyte. Examples of composite electrolytes can be found in U.S. Patent No. 10,374,254, issued August 6, 2019. The entire contents of the U.S. patents and U.S. patent applications just mentioned are incorporated herein by reference for all purposes.

[0027] In this application, the term "diaphragm" is "Li + "Ion-conducting membrane" is an abbreviation unless otherwise explicitly stated.

[0028] In this application, the terms "side," "edge," "edge surface," or "minor surface" are used interchangeably to refer to the side or edge of an electrochemical cell stack, frame, or prismatic-frame-in-pouch. For example, a prismatic-frame-in-pouch has a "side edge" that is perpendicular to the "bottom edge" of the prismatic-frame-in-pouch.

[0029] In this application, the terms "face" or "major surface" are used interchangeably to refer to the primary surface of an electrochemical cell stack, frame, or pouch-like prismatic frame, as opposed to "edge" or "edgesurface" or "minor surface," the latter having a surface area much smaller than the primary surface. In some cases, depending on the orientation of the electrochemical stack, the primary surface can be either a top primary surface or a bottom primary surface. "Top surface" or "top major surface" is generally contrasted with "bottom surface" or "bottom major surface."

[0030] In this application, the term "thickness" or "film thickness" refers to the median distance or measured distance between the top and bottom principal surfaces of a layer or film. In this application, the top and bottom principal surfaces refer to the surfaces of the layer or film having the largest geometrical surface area. As a non-limiting example in this application, a layer with dimensions of 64 x 79 mm and a thickness of 1 μm to 100 μm is described by the distance measured between the top and bottom principal surfaces, each of which has dimensions of 64 x 79 mm.

[0031] In this application, when modifying a solid electrolyte, “thin” means a thickness dimension of less than 200 μm, sometimes less than 100 μm, in some cases between 0.1 and 60 μm, and in other cases between about 10 nm and about 100 μm; in other cases the thickness is about 1 μm, 10 μm or 50 μm.

[0032] In this application, the term "laminated frame" refers to the flexibility of the laminate that surrounds and encapsulates the frame, but without significant space between the laminate and the frame where the laminate is not in contact with the frame. In some embodiments, the laminate is in close contact with the frame, particularly when the bag is under vacuum or the internal pressure is sufficiently lower than the external pressure or ambient atmospheric pressure.

[0033] In some embodiments of this application, the frame-laminated assembly includes at least one electrochemical cell, which in turn includes at least one positive electrode terminal and at least one negative electrode terminal; at least one electrochemical stack including a solid electrolyte; the electrochemical cell having a top primary surface, a bottom primary surface and four secondary surfaces; a lamination bag; and a frame housed within the lamination bag and surrounding the at least one electrochemical stack; wherein: the frame does not contact the four secondary surfaces; and the lamination bag contacts the top primary surface and the bottom primary surface.

[0034] In this application, the term "pre-formed shape of laminated bag" refers to the shape formed on the laminate. In some instances, the laminate is made from a flat sheet placed in a pneumatic press. The flat sheet is transformed into a pre-formed shape using molds and cavities. This includes debossing the flat sheet to lift a portion of the laminate upwards and away from the laminate surface, and embossing it to push a portion of the laminate downwards and away from the laminate surface. In some embodiments, debossing and embossing are used in combination to form the laminate. By forming in the laminate, the laminate does not need to deform much (if any) relative to the top or bottom main surface of the electrochemical stack. When vacuumed, because the atmospheric pressure outside the laminate is higher than the pressure inside the laminate, the atmosphere pushes the sealed laminate onto the frame and battery stack, giving it the shape of the frame and battery stack. In some embodiments, the laminate is formed into the shape of an electrochemical stack at 0% state of charge. Because the laminate is pre-stressed during its manufacturing process, there is no stress concentration on the electrochemical stack when the laminate is stretched on the frame. When the laminate is stretched on the frame, a draft angle occurs. This draft angle provides some space between the laminate and the electrochemical stack, allowing the laminate to contact only the top or bottom primary surfaces of the electrochemical stack. When a vacuum is applied to the sealed laminate, the draft angle collapses towards the frame, but not towards the secondary surfaces of the electrochemical stack. After vacuuming the sealed laminate, the pre-formed portion of the laminate will take on the shape of the frame.

[0035] In this application, the term "lithium-filled garnet" refers to an oxide having a crystal structure associated with that of garnet. This application is incorporated herein by reference in its entirety to U.S. Patent Application Publication No. US2015 / 0099190 (published April 9, 2015), for all purposes. That application describes a lithium-filled garnet solid electrolyte for use in solid-state lithium rechargeable batteries.

[0036] Unless otherwise stated, lithium-filled garnets include those having the formula Li A La B M' C M” D Zr E O F Li A La B M' C M” D Ta E O F Or Li A La B M' C M” D Nb E O Fcompounds, where 4 < A < 8.5, 1.5 < B < 4, 0 ≤ C ≤ 2, 0 ≤ D ≤ 2, 0 ≤ E ≤ 2, 10 < F < 13, M' and M” are each independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb or Ta in each case, or the formula Li a La b Zr C Al d Me” e O f compounds, where 5 < a < 7.7, 2 < b < 4, 0 ≤ c ≤ 2.5, 0 ≤ d ≤ 2, 0 ≤ e ≤ 2, 10 < f < 13, Me” is a metal selected from Nb, Ta, V, W, Mo, Ga or Sb, as described in this application.

[0037] The lithium - filled garnet can also be of the formula Li A La B M' C M” D Zr E O F 、Li A La B M' C M” D Ta E O F or Li A La B M' C M” D Nb E O F The compositions shown, where 4 < A < 8.5, 1.5 < B < 4, 0 ≤ C ≤ 2, 0 ≤ D ≤ 2, 0 ≤ E < 3, 10 < F < 13, and M' and M” are each independently selected from Ga, Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb or Ta in each case, or the formula Li a La b Zr c Al d Me” e O f The compositions shown, where 5 < a < 8.5, 2 < b < 4, 0 < c ≤ 2.5, 0 ≤ d < 2, 0 ≤ e < 2, 10 < f < 13, Me” is a metal selected from Ga, Nb, Ta, V, W, Mo or Sb, as further described in U.S. Patent Application Publication No. U.S. 2015 / 0099190. In this application, the lithium - filled garnets and garnets generally include, but are not limited to, Li 7.0 La3(Zr t1 +Nb t2 +Ta t3 )O 12+0.35Al 12 O3, where (t1+t2+t3=2) makes the La:(Zr / Nb / Ta) ratio 3:2. Additionally, the garnet used in this application includes, but is not limited to, Li. x La3Zr2O F+yAl₂O₃, where x ranges from 5.5 to 9 and y ranges from 0.05 to 1. In these embodiments, the subscripts x, y, and F are chosen such that garnet is charge neutral. In some embodiments, x is 7 and y is 1.0. In some embodiments, x is 5 and y is 1.0. In some embodiments, x is 6 and y is 1.0. In some embodiments, x is 8 and y is 1.0. In some embodiments, x is 9 and y is 1.0. In some embodiments, x is 7 and y is 0.35. In some embodiments, x is 5 and y is 0.35. In some embodiments, x is 6 and y is 0.35. In some embodiments, x is 8 and y is 0.35. In some embodiments, x is 9 and y is 0.35. In some embodiments, x is 7 and y is 0.7. In some embodiments, x is 5 and y is 0.7. In some embodiments, x is 6 and y is 0.7. In some embodiments, x is 8 and y is 0.7. In some embodiments, x is 9 and y is 0.7. In some embodiments, x is 7 and y is 0.75. In some embodiments, x is 5 and y is 0.75. In some embodiments, x is 6 and y is 0.75. In some embodiments, x is 8 and y is 0.75. In some embodiments, x is 9 and y is 0.75. In some embodiments, x is 7 and y is 0.8. In some embodiments, x is 5 and y is 0.8. In some embodiments, x is 6 and y is 0.8. In some embodiments, x is 8 and y is 0.8. In some embodiments, x is 9 and y is 0.8. In some embodiments, x is 7 and y is 0.5. In some embodiments, x is 5 and y is 0.5. In some embodiments, x is 6 and y is 0.5. In some embodiments, x is 8 and y is 0.5. In some embodiments, x is 9 and y is 0.5. In some embodiments, x is 7 and y is 0.4. In some embodiments, x is 5 and y is 0.4. In some embodiments, x is 6 and y is 0.4. In some embodiments, x is 8 and y is 0.4. In some embodiments, x is 9 and y is 0.4. In some embodiments, x is 7 and y is 0.3. In some embodiments, x is 5 and y is 0.3. In some embodiments, x is 6 and y is 0.3. In some embodiments, x is 8 and y is 0.3. In some embodiments, x is 9 and y is 0.3. In some embodiments, x is 7 and y is 0.22. In some embodiments, x is 5 and y is 0.22. In some embodiments, x is 6 and y is 0.22. In some embodiments, x is 8 and y is 0.22. In some embodiments, x is 9 and y is 0.22. Additionally, the garnet used in this application includes, but is not limited to, Li. x La3Zr2O 12+yAl2O3. In one embodiment, the lithium-filled garnet of this application has Li7Li3Zr2O 12 The composition. In another embodiment, the lithium-filled garnet of this application has Li7Li3Zr2O. 12 • The composition of Al2O3. In yet another embodiment, the lithium-filled garnet of this application has Li7Li3Zr2O 12 • Composition of 0.22Al2O3. In yet another embodiment, the Li-filled garnet of this application has Li7Li3Zr2O 12 • Composition of 0.35Al2O3. In some other embodiments, the Li-filled garnet of this application has Li7Li3Zr2O 12 The composition is 0.5Al2O3. In another embodiment, the Li-filled garnet of this application has Li7Li3Zr2O 12 The composition of 0.75Al2O3.

[0038] In this application, garnet does not include YAG-garnet (i.e., yttrium aluminum garnet or, for example, Y3Al5O). 12 In this application, garnet does not include silicate-based garnets, such as pyrope, almandine, spessartine, grossular, galvanic, or cinnamonite, tsavorite, uvarovite, and andradite, as well as solid solutions of pyrope-almandine-spessartine and uvarovite-grossular-andradite. Garnet in this application does not include island silicates having the general formula X3Y2(SiO4)3, where X is Ca, Mg, Fe, and / or Mn, and Y is Al, Fe, and / or Cr.

[0039] In this application, "close-packed" refers to a stacking arrangement that minimizes the gaps between stacked items. Close-packed pouch battery modules are a stacking arrangement that minimizes the gaps between pouch batteries.

[0040] In this application, "dimensional stability" refers to the ability of laminated bags to provide structural support for the module along a preferred dimension. For example, if laminated bags are stacked vertically and adjacent to each other, providing mechanical support for the bags in the same direction of vertical alignment of the stack, then the laminated bags are providing dimensional stability for the module. This is merely a non-limiting example. Dimensional stability may include structural support in more than one dimension, but at least one dimension.

[0041] In this application, "fast charge" refers to charging the battery at a rate of 4C or higher.

[0042] In this application, "state of charge" (SOC) refers to the degree to which a given battery cell is charged or discharged relative to its charging capacity. For example, when a battery cell has half of its total rechargeable capacity, the SOC of the battery is 50%. The percentage (%) given is relative to the available capacity of the battery at its maximum charging voltage. For example, a battery rated at 100 kWh with an SOC of 50% has 50 kWh.

[0043] In this application, "State of Health" (SOH) is an indicator of the degree of battery degradation. More specifically, SOH measures the remaining capacity of a battery relative to its original capacity. SOH is expressed as a percentage of usable capacity relative to the battery's rated capacity or nameplate capacity. For example, after some use, a battery rated at 100 kWh will no longer be able to retain 100 kWh of charge. For instance, if a battery was originally rated to charge and discharge 100 kWh of energy but now can only charge and discharge 90 kWh of energy, then the battery's SOH is 90%.

[0044] According to the aforementioned definitions of SOC and SOH, if a 100kWh battery has 90% SOH and is charged to 50% capacity, then the battery has 45kWh.

[0045] Module

[0046] In one embodiment, this application describes a module comprising at least two electrochemical stack assemblies (ESAs), each ESA individually comprising, in each case: one or more electrochemical cells, each electrochemical cell including a solid electrolyte; a frame surrounding the one or more electrochemical cells; and a laminated bag surrounding the frame and the one or more electrochemical cells. In addition to the description herein, examples of laminated bag assemblies surrounding a frame are illustrated in International PCT Patent Application No. PCT / US22 / 44883, filed September 27, 2022, the entire contents of which are incorporated herein by reference for all purposes.

[0047] In some embodiments, including any of the foregoing embodiments, the module includes an alignment portion that engages with one or more edges of the laminated bag. For example Figure 1 As shown, when the laminated bag 240 is mounted onto the module, its edges 242 are aligned using an alignment block 250; the alignment block includes a slit 252 to receive one of the edges 242, 244, 246, and 248 of the laminated bag 240. In some embodiments, the edge 242 inserted into the slit 252 of the alignment block 250 is a side edge of the laminated bag 240. In some embodiments, the edge 242 inserted into the slit 252 of the alignment block 250 is a bottom edge of the laminated bag 240.

[0048] In one embodiment, such as Figure 1As shown, at least one side of the assembled laminated bag, such as the side opposite the electrode, remains unrolled, allowing it to be inserted into the slotted metal piece 250 for alignment or heat dissipation. In one embodiment, as... Figure 1 As shown, the sides of the assembled bag can be inserted between the flat metal pieces on the base to facilitate heat dissipation or bag alignment.

[0049] An implementation of the frame upper laminate, for example Figure 2 As shown. In Figure 2 In the assembly 2000, from top to bottom, a top laminate portion 2010 is arranged above an upper frame portion 2020. An electrochemical stack 2030 is mounted between the upper frame portion 2020 and the lower frame portion 2040. The upper frame portion 2020 and the lower frame portion 2040 are connected to each other to form a frame surrounding the electrochemical stack 2030. This frame surrounds but does not contact the secondary surfaces of the electrochemical stack 2030. A bottom laminate portion 2050 is arranged below the lower frame portion 2040. The top laminate portion 2010 and the bottom laminate portion 2050 form a laminated bag (sometimes referred to in this application as a pre-formed laminated bag) surrounding the assembled frame and the electrochemical stack 2030 therein. The top laminate portion 2010 and the bottom laminate portion 2050 are sealed together, surrounding the assembled frame and the electrochemical stack 2030 therein.

[0050] The electrochemical stack 2030 also has cathode and anode terminals (positive and negative electrodes or tabs) 2060 respectively connected to the electrochemical stack 2030. The cathode and anode extend through the frame and can contact the frame. In some embodiments, the terminals 2060 extend through the laminated bag. In some embodiments, the terminals 2060 extend through the laminated bag and form part of a seal. The sealing portion around each terminal 2060 is a separate seal, for example, in the event of a safety event that may require venting of the laminated bag. In this case, one or both seals around the respective terminal 2060 are set to an open state to allow venting, rather than opening the entire seal around the bag opening.

[0051] exist Figure 3In the assembly 2100, from top to bottom, a top laminate portion 2110 is arranged above an upper frame portion 2120. An electrochemical stack 2130a is mounted inside the upper frame portion 2120, which is located above (and fixed to) a lower frame portion 2140 in one embodiment. The lower frame portion 2140 has a solid portion or surface 2140a to which the electrochemical stack 2130a is bonded or otherwise attached. The lower frame portion 2140 has edges 2141-2144 extending downward from the solid portion or surface 2140a to accommodate the electrochemical stack 2130b. In one embodiment, the lower frame portion 2140 and its edges 2141-2144 form a tray-like structure, which may be referred to elsewhere in this application as a tray.

[0052] The upper frame portion 2120 and the lower frame portion 2140 are connected to each other to form a frame surrounding the electrochemical stack 2130a. This frame surrounds but does not contact the secondary surface of the electrochemical stack 2130a. Another electrochemical stack 2130b is disposed below the surface 2140a and is attached to the surface 2140a by adhesive or other means. This frame surrounds but does not contact the secondary surface of the electrochemical stack 2130b. In one embodiment, the electrochemical stack 2130b is mounted within the edges 2141-2144 of the lower frame portion 2140 such that the edges 2141-2144 of the lower frame portion 2140 surround but do not contact the edge of the electrochemical stack 2130b. A bottom laminate portion 2150 is disposed below the lower frame portion 2140. The top laminate portion 2110 and the bottom laminate portion 2150 form a laminated bag surrounding the assembled frame and the electrochemical stacks 2130a and 2130b therein. The top laminate 2110 and the bottom laminate 2150 are sealed together around the assembled frame and the electrochemical stacks 2130a and 2130b therein.

[0053] The electrochemical stack 2130a also has terminals (positive and negative electrodes or tabs) 2160, which are respectively connected to the individual cell cathode terminals 2131a and 2132a of the electrochemical stack 2130a, and the individual cell cathode terminals 2131b and 2132b of the electrochemical stack 2130b. These individual cell cathode terminals 2131a and 2131b and anode terminals 2132a and 2132b extend through the frame and may contact the frame. In some embodiments, terminals 2160 extend through the laminated bag. In some embodiments, terminals 2160 (but not terminals 2131a and 2132b) extend through the laminated bag and form part of a seal.

[0054] In some embodiments, including any of the foregoing embodiments, the frame is a structural support member of the module. In some embodiments, the structural support member is an aircraft wing strut. In other embodiments, the structural support member is a motorcycle body. In other embodiments, the structural support member is a car body. In other embodiments, the structural support member is a honeycomb structure component. In some embodiments, the ESA described in this application can be used in consumer electronics products, such as mobile devices, tablets, laptops, computers, wearable devices; electric vehicles; and electric motorcycles.

[0055] Figure 4 This is a detailed exploded view of the ESA, showing a laminated bag assembly 400 with a pouch-like prism frame, including electrochemical cells 430, 435, 470, and 480 as described in embodiments of this application. According to embodiments, the module may have one or more laminated bag assemblies 400. Each ESA may contain multiple electrochemical cells. In different embodiments, an adhesive layer (not shown) exists between adjacent electrochemical cells to facilitate alignment of the electrochemical cells with each other. In different embodiments, the electrochemical cells are assembled without an adhesive layer, and alignment is maintained by pressure from the remainder of the laminated bag assembly 400, such as vacuuming inside the bag and contacting the top and bottom of the frame and the upper and lower laminated portions of the electrochemical stack assembly within the bag.

[0056] Looking further Figure 4 The laminated preforms 405 and 495 constitute the upper and lower portions of the laminated bag assembly 400. A spacer block 420 (which, according to one embodiment, may be foam or other compressible material) is located below the laminated preform 405. A spacer block 490 (which, according to one embodiment, may also be foam or other compressible material) is located above the laminated preform 450. Figure 4 In this embodiment, electrochemical cells 430, 435, 470, and 480 are located between spacers 420 and 490. In one embodiment, a frame 450 surrounds spacers 420 and 490 and electrochemical cells 430, 435, 470, and 480 on three sides. On a fourth side of the frame 450, a top end 440 and a bottom end 445 are combined to enclose terminals 460 and 465. According to embodiments, as will be understood by those skilled in the art, one or both of terminals 460 and 465 may be made of aluminum, copper, nickel-plated copper, or other suitable terminal materials.

[0057] In one embodiment, elements 430, 435, 470, and 480 may themselves be ESAs, with the aforementioned adhesive layer between adjacent ESAs. In this manner, although... Figure 4The laminated bag assembly 400 shown has four ESAs within its frame 450, but those skilled in the art will understand that more than four ESAs may be present. According to embodiments, multiple sets of four ESAs may be present; five ESAs or multiple sets of five ESAs may be present; six ESAs or multiple sets of six ESAs may be present; seven ESAs or multiple sets of seven ESAs may be present; eight ESAs or multiple sets of eight ESAs may be present; nine ESAs or multiple sets of nine ESAs may be present; or ten ESAs or multiple sets of ten ESAs may be present. In some embodiments, the laminated bag assembly 400 has approximately 100, approximately 200, approximately 300, approximately 400, approximately 500, approximately 600, approximately 700, approximately 800, approximately 900, or up to approximately 1000 ESAs.

[0058] In some embodiments, including any of the foregoing embodiments, the module includes a plurality of laminated bag assemblies 400. In some embodiments, the module achieves the aforementioned number of ESAs by including a plurality of laminated bag assemblies 400.

[0059] In some embodiments, the frame may include a central wall or a central plate, as will be described below. Figure 5 As shown in discussion 545. In some embodiments, the frame does not include a central wall or central plate, such as Figure 4 The frame 450 is shown in the diagram.

[0060] Figure 5 A detailed exploded view of a laminated bag assembly 500 according to an embodiment is shown. Figure 5 In this configuration, laminated preforms 510 and 570 form the upper and lower portions of the laminated bag assembly 500. An electrochemical cell stack 520 (including one or more electrochemical cells) is located below the laminated preform 510. According to embodiments, the module may have one or more laminated bag assemblies 500. In various embodiments, an adhesive layer (not shown) exists between adjacent electrochemical cells or electrochemical stacks to facilitate alignment of the electrochemical cells or stacks with each other. In various embodiments, the electrochemical cells or stacks may be assembled without an adhesive layer, maintaining alignment of the electrochemical cells or stacks with pressure on the remainder of the laminated bag assembly 500—including vacuuming inside the bag and contacting the top and bottom of the frame and the upper and lower laminated portions of the electrochemical stack assembly. In one embodiment, the electrochemical stack 520 itself may be an ESA, with the aforementioned adhesive layer between adjacent ESAs.

[0061] Looking further Figure 5A cooling plate or center plate 540 is located above the laminated preform 570. One end of plate 540 is open. Terminals 550 and 560 are located above the open end of plate 540; the terminals extend outside the preforms when the edges of the two preforms 510 and 570 are sealed. An end piece 530 is located above the terminals 550 and 560 and closes the opening of plate 540 at the end where the terminals 550 and 560 are located. According to embodiments, as will be understood by those skilled in the art, one or both of terminals 550 and 560 may be made of aluminum, copper, nickel-plated copper, or other suitable terminal materials.

[0062] In some embodiments of this application, the frame-laminated assembly includes at least two electrochemical cells. In some embodiments of this application, the frame-laminated assembly includes at least 2, 4, 6, 8, 10, 20, 30, 40, 50, 60, 70, 80, 90, or more electrochemical cells. In some embodiments of this application, the frame-laminated assembly includes a stack of electrochemical cells. In some embodiments of this application, the frame-laminated assembly includes a stack of electrochemical cells arranged vertically or adjacent to each other.

[0063] In some embodiments, including any of the foregoing embodiments, the thickness of one of the at least two ESAs in the module is greater than the thickness of the other.

[0064] In some embodiments, including any of the foregoing embodiments, the thickness of one of the at least two ESAs in the module is at least twice the thickness of the other.

[0065] In some embodiments, including any of the foregoing embodiments, the laminated bags are tightly stacked.

[0066] In some embodiments, including any of the foregoing embodiments, the laminated bag provides dimensional stability to the module.

[0067] In some embodiments, including any of the foregoing embodiments, the module is a prismatic design with a smooth outer surface or main surface.

[0068] In some embodiments, including any of the foregoing embodiments, the stacking of the laminated bags minimizes the natural harmonic bending pattern.

[0069] In some embodiments, including any of the foregoing embodiments, the laminated bags are stacked vertically.

[0070] In some embodiments, including any of the foregoing embodiments, the module is the maximum length that minimizes the natural harmonic bending mode.

[0071] In some embodiments, including any of the foregoing examples, the module includes a compliant cooling plate between adjacent laminated bags. In some embodiments, the compliant cooling plate is metallic. In some embodiments, the compliant cooling plate acts as a central wall between adjacent laminated bags. Figure 6 A module with a flexible cooling plate 620 between adjacent laminated bags 600 is shown. Each laminated bag 600 includes two or more ESAs 610. In some embodiments, the laminated bags 600 may be as follows: Figure 4 The illustrated bagged prismatic frame. According to an embodiment, one module contains two laminated bags, such as... Figure 6 As shown; or there may be more than two laminated bags. When there are more than two laminated bags, there may be one or more flexible cooling plates 620, or there may be no flexible cooling plates.

[0072] In some embodiments, including any of the foregoing embodiments, the module includes a compressible cooling bag or bladder containing coolant, disposed between adjacent laminated bags. Figure 7 A module is shown with compressible cooling bags or bladders 720 between adjacent laminated bags 700. Each laminated bag 700 contains two or more ESAs 710. As described above, the compressible cooling bags or bladders are connected to a cooling system. According to an embodiment, the module has two laminated bags, such as... Figure 7 As shown; or there may be more than two laminated bags. When there are more than two laminated bags, there may be one or more compressible cooling bags or bladders 720, or there may be no compressible cooling bags or bladders.

[0073] In some embodiments, including any of the foregoing embodiments, one or more pipes extend through the cooling plate 620 to deliver coolant for further cooling. A cooling system is connected to the ends of the one or more pipes.

[0074] In some embodiments, including any of the foregoing examples, each ESA of the module contains approximately 20-100 solid electrolytes. In some embodiments, including any of the foregoing examples, each ESA of the module contains approximately 60 solid electrolytes. In some embodiments, including any of the foregoing examples, each ESA of the module contains approximately 80 solid electrolytes. In some embodiments, including any of the foregoing examples, each ESA of the module contains approximately 100 solid electrolytes.

[0075] In some embodiments, including any of the foregoing embodiments, the battery pack contains approximately 100,000 solid electrolytes.

[0076] In some embodiments, including any of the foregoing embodiments, the module has a capacity of approximately 100 kWh.

[0077] In some embodiments, including any of the foregoing embodiments, the module contains approximately 1000 ESAs.

[0078] In some embodiments, including any of the foregoing embodiments, the laminated bag is pressurized to 300 Pa or other pressures sufficiently different from the external pressure of the laminated bag to bring the upper and lower portions of the laminated bag into contact with the internal components.

[0079] In some embodiments, including any of the foregoing examples, the laminated bag is not subjected to any external pressure. In some embodiments, including any of the foregoing examples, the laminated bag is subjected to atmospheric pressure only.

[0080] In some embodiments, including any of the foregoing embodiments, the electrodes or tabs are configured to vent during a safety incident.

[0081] In some embodiments, including any of the foregoing embodiments, a seal is provided around the tab or electrode to allow for venting in the event of a safety incident.

[0082] In some embodiments, including any of the foregoing embodiments, the module includes a laminated bag laid flat relative to the ground.

[0083] In some embodiments, including any of the foregoing embodiments, the module includes laminated bags sized and / or oriented to be attached to a skateboard (e.g., in a skateboard battery pack design). In terms of orientation, the bags may be stacked vertically or arranged horizontally, for example, along the bottom surface of the skateboard.

[0084] In some embodiments, including any of the foregoing examples, the module includes a laminated bag sized and / or oriented for placement within a car body or motorcycle body. In some embodiments, including any of the foregoing examples, the module includes a laminated bag sized and / or oriented for placement within the aforementioned consumer electronics product.

[0085] In some embodiments, including any of the foregoing embodiments, the module includes at least two laminated bags of different sizes.

[0086] Laminated bag assembly

[0087] In addition to the foregoing description, a non-limiting embodiment of the laminated bag assembly is described below. Those skilled in the art will understand that other assembly methods are also possible.

[0088] A laminated bag assembly protects a prismatic battery cell with a peripheral (mechanical) frame. The prismatic battery cell is located in a battery stack that is vacuum-sealed and placed inside a laminated bag. Electrical terminals protrude from the laminated bag. The resulting bagged prismatic frame protects the prismatic battery cell.

[0089] In some embodiments, a battery cell including a solid cathode is packaged in the electrochemical stack disclosed in this application. In some embodiments, a battery cell including a cathode (which includes a solid cathode electrolyte) is packaged in the electrochemical stack disclosed in this application.

[0090] In some embodiments, an electrochemical stack is provided, comprising a series of electrochemical cells arranged in series. In some other embodiments, an electrochemical stack is provided, comprising a series of electrochemical cells arranged in parallel.

[0091] In some embodiments, including any of the foregoing examples, the electrochemical cell includes a lithium metal negative electrode. In some embodiments, including any of the foregoing examples, the electrochemical cell includes a solid electrolyte.

[0092] In some embodiments, including any of the foregoing embodiments, the electrochemical cell includes a solid electrolyte membrane containing lithium-filled garnet.

[0093] In some embodiments, including any of the foregoing embodiments, the positive and negative electrode terminals are connected to an electrochemical stack.

[0094] The electrochemical stack is bonded to an adhesive plate, which is also part of the frame, using a pressure-sensitive adhesive.

[0095] In some embodiments, the top or bottom major surface of the electrochemical stack is attached to the surface of the frame using a pressure-sensitive adhesive (PSA) material. The PSA secures the stack to the frame surface via the top or bottom major surface, preventing it from moving within the frame during charging and discharging. The PSA prevents secondary surfaces of the electrochemical stack from contacting the frame. In some embodiments, the top major surface is bonded to the frame at the center wall. In some embodiments, the bottom major surface is bonded to the frame at the center wall. In some embodiments, there is no center wall. In this case, the stacks are adhered to each other using PSA.

[0096] In an embodiment with two frame members, the other half of the frame is connected to and attached to the aforementioned half of the frame.

[0097] In some embodiments, including any of the foregoing examples, the laminate is processed into a molded shape. In some embodiments, the shape matches the shape of the electrochemical stack. In some embodiments, including any of the foregoing examples, the laminate has multiple layers. In some embodiments, the laminate has five layers. In some embodiments, the multiple layers include polyester (PET) layers adjacent to oriented nylon (ONy) layers. The ONy layer is adjacent to an aluminum layer. The aluminum layer is adjacent to a non-adhesive, sealant, chemically bonded polyphthalamide (PPa) layer. The PPa layer is adjacent to a polypropylene (PP) layer. In some embodiments, the order of these layers may vary. In some embodiments, there are more than five layers, some or all of which are one or more of the five materials described above. In some embodiments, including any of the foregoing examples, there may be fewer than five layers, some or all of which are one or more of the five materials described above.

[0098] In some embodiments, including any of the foregoing embodiments, the polymer material on both sides of the aluminum comprises one or more of polypropylene (PP), polyphthalamide (PPa), polyethylene terephthalate (PET), and oriented nylon (ONy).

[0099] The laminate is made from a flat sheet placed in a pneumatic press. A mold and cavity are used to transform the flat sheet into a pre-formed shape. This involves debossing the flat sheet to lift a portion of the laminate upwards and away from the laminate surface, and embossing it to push a portion of the laminate downwards and away from the laminate surface. Debossing and embossing can be combined to shape the laminate. By shaping within the laminate, the laminate does not need to deform much (if any) relative to either of the main surfaces of the electrochemical stack when a vacuum is applied. The laminate is pre-stressed during its manufacturing process, so there is no stress concentration on the electrochemical stack when the laminate is stretched on the frame. A draft angle occurs when the laminate is stretched on the frame. This draft angle provides some space between the laminate and the electrochemical stack, allowing the laminate to contact only one or two main surfaces of the electrochemical stack.

[0100] In some embodiments, including any of the foregoing embodiments, a pneumatic press with a forming mold and a cavity is used.

[0101] The laminated parts of the laminated bag are sealed together. This adhesive seal can be made by heat sealing. In some heat sealing methods, two laminated bag sheets are pressed together with two hot metal rods until the polymer layers on each laminate melt and bond (e.g., weld) the two sheets together.

[0102] A vacuum is applied to the sealed laminate, causing the draft angle to collapse and rest against the frame, but not against the secondary surfaces of the electrochemical stack. After the vacuum is applied to the sealed laminate, the preformed portion of the laminate will take on the shape of the frame.

[0103] Battery pack

[0104] This application describes a battery pack including at least one module described in this application. These modules may be arranged vertically or adjacent to each other.

[0105] method

[0106] In one embodiment, this application describes a method for determining the state of charge (SOC), comprising: measuring the thickness of a laminated bag in the module described in this application, the thickness being proportional to the SOC; and determining the SOC based on the measured thickness. In some embodiments, the measurement includes using a strain gauge.

[0107] In some embodiments, including any of the foregoing embodiments, the method includes: acquiring historical displacement data regarding charge-discharge cycles of the electrochemical cell in the module, and determining the state of health (SOH) based on the historical displacement data.

[0108] In one embodiment, this application describes a method for pumping coolant, comprising: providing the module described in this application, having compressible coolant bags or bladders containing coolant and connected to a cooling system between laminated bags; expanding and contracting the laminated bags by charging and discharging an electrochemical cell; and pumping coolant using the mechanical force generated by the laminated bags.

[0109] In one embodiment, this application describes a method for cooling the module described in this application, comprising: absorbing heat from the ESA through tabs. In some embodiments, cooling occurs simultaneously with a fast charging event.

[0110] In one embodiment, this application describes a method for cooling the module described in this application, comprising: absorbing heat from the ESA through the edge of the laminated bag. In some embodiments, cooling occurs simultaneously with a fast charging event. In other embodiments, the edge is a bottom edge. In other embodiments, the edge is a side edge.

[0111] In one embodiment, this application describes a method for cooling the module described in this application, comprising: absorbing heat from the electrochemical cell through the side of a laminated bag. In other embodiments, cooling occurs simultaneously with a fast charging event.

[0112] In one embodiment, this application describes a method for cooling the module described in this application, comprising: absorbing heat from the electrochemical cell through the face or main surface of the laminated bag. In other embodiments, cooling occurs simultaneously with a fast charging event. Example

[0113] Example 1

[0114] An assembled battery stack is provided, comprising at least one cathode current collector, at least one cathode containing liquid electrolyte, at least one separator, and at least one anode current collector. A foam block is added to the top of the battery stack, aligning the foam with the rest of the battery stack. Current collector tabs are welded on.

[0115] Place one half-laminated bag on top of the battery stack. Flip the battery stack over. After flipping, place the other half-laminated bag on top of the battery stack. Then seal the edges of the two half-laminated bags together.

[0116] The above embodiments and examples are intended to be illustrative and non-limiting only. Those skilled in the art will recognize or be able to identify numerous equivalents of specific compounds, materials, and steps using no more than conventional experiments. All such equivalents are within the scope of and covered by the appended claims.

Claims

1. A module comprising at least two electrochemical stack components (ESAs), each ESA comprising: One or more electrochemical cells, each electrochemical cell including a solid electrolyte; The framework surrounding the one or more electrochemical cells; and A laminated bag surrounding the frame and the one or more electrochemical cells; The module also includes a flexible cooling plate or a compressible cooling bag between adjacent laminated bags.

2. The module according to claim 1, comprising an alignment portion that engages with the side edge or bottom edge of the laminated bag.

3. The module according to claim 1 or 2, wherein the frame is a structural support component of the module.

4. The module according to claim 3, wherein the structural support is selected from the group consisting of an aircraft wing strut, a motorcycle body, and a car body.

5. The module according to claim 3, wherein the structural support is a component of a honeycomb structure.

6. The module according to any one of claims 1-5, wherein the frame has three sides, and the module further comprises an end that closes a fourth side of the frame.

7. The module according to any one of claims 1-6, wherein the thickness of one of the at least two ESAs is greater than the thickness of the other.

8. The module according to any one of claims 1-7, wherein the laminated bags are arranged in a close-packed manner to minimize the gaps between adjacent laminated bags.

9. The module according to any one of claims 1-8, wherein the laminated bag provides dimensional stability to the module.

10. The module according to any one of claims 1-9, wherein the laminated bags are stacked vertically in the module.

11. The module according to any one of claims 1-9, wherein the laminated bags are arranged horizontally in the module.

12. The module according to claim 11, wherein the flexible cooling plate contains metal.

13. The module according to any one of claims 1-10, wherein the compressible cooling bag comprises coolant.

14. The module according to any one of claims 1-13, comprising about 10 to about 1000 ESAs.

15. The module according to any one of claims 1-14, wherein the capacity of the module is approximately 100 kWh.

16. The module according to any one of claims 1-15, wherein the internal pressure of the laminated bag is 300 Pa.

17. The module according to any one of claims 1-16, comprising a laminated bag laid flat relative to the ground.

18. The module according to any one of claims 1-16, comprising a laminated bag arranged in accordance with a skateboard battery pack.

19. The module according to any one of claims 1-18, comprising at least two laminated bags of different sizes.

20. The module according to claim 1, wherein the frame includes a central wall or a central plate.

21. The module of claim 20, wherein the one or more electrochemical cells are disposed within the frame, the frame comprising a central wall or a central plate.

22. The module according to claim 20 or 21, wherein the frame including the central wall or central plate is adjacent to at least a portion of the laminated bag.

23. The module according to claim 20 or 21, wherein the frame including the central wall or central plate is adjacent to the main surface of the laminated bag.

24. The module according to claim 1, wherein the frame does not include a central wall or a central plate.

25. A method for determining the state of charge (SOC), comprising: Measure the thickness of the laminated bag in the module according to any one of claims 1-24, wherein the thickness is proportional to the state of charge (SOC); The SOC is determined based on the measured thickness.

26. The method of claim 25, wherein the measurement includes using a strain gauge.

27. The method according to claim 25 or 26 further includes acquiring historical displacement data of the electrochemical cell charge-discharge cycle in the module, and determining the state of health (SOH) based on the historical displacement data.

28. A method for pumping coolant, comprising: A compressible cooling bag or bladder is provided, the compressible cooling bag or bladder comprising a coolant and connected to a cooling system, the compressible cooling bag or bladder being disposed between adjacent laminated bags in the module of any one of claims 1-24; The laminated bag expands and contracts as the electrochemical cell is charged and discharged. The coolant is pumped using the mechanical force generated by the expansion and contraction of the laminated bag.

29. A method for cooling the module of any one of claims 1-24, comprising absorbing heat from the ESA via a tab.

30. The method according to claim 28, wherein the cooling and fast charging events occur simultaneously.

31. A method for cooling the module of any one of claims 1-24, comprising absorbing heat from the ESA through the side or bottom edge of the laminated bag.

32. The method according to claim 31, wherein the cooling and fast charging are performed simultaneously.

33. A method for cooling the module according to any one of claims 1-24, wherein heat is absorbed from the electrochemical cell through the side or bottom edge of the laminated bag.

34. The method according to claim 33, wherein the side is the surface of the laminated bag.

35. The method according to claim 28 or 29, wherein the cooling and fast charging events occur simultaneously.

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