Battery electrode having layered structure and perforations

Abstract

An electrode assembly includes an electrode having a laminate foil disposed between a first active material layer and a second active material layer, where the laminate foil includes a polymer substrate disposed between the first laminate layer and the second laminate layer. The electrode assembly also includes a plurality of perforations extending through the first active material layer, the second active material layer, and the laminated foil.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 694,540, filed on September 13, 2024, the entire contents of which are incorporated herein by reference. Background Technology

[0003] This disclosure relates throughout to batteries configured to power loads such as electronic devices (e.g., consumer electronic devices), such as secondary batteries or rechargeable batteries (e.g., lithium-ion batteries). More specifically, this disclosure relates to an electrode assembly for a battery comprising a layered structure and perforations through the layered structure.

[0004] Lithium-ion batteries operate by the movement of lithium cations (Li+ ions) between one or more anodes and one or more cathodes (collectively referred to as electrodes). For example, the movement of Li+ ions from the anode to the cathode facilitates the flow of electrons in one direction through a discharge circuit to power a load (e.g., during a discharge cycle). Conversely, the flow of electrons in the opposite direction through a charging circuit facilitates the movement of Li+ ions from the cathode to the anode to charge the lithium-ion battery (e.g., during a charging cycle). The electrolyte acts as the path or medium through which the Li+ ions move.

[0005] Unfortunately, conventional lithium-ion batteries may suffer from poor electrolyte distribution and / or Li+ ion migration, resulting in degraded battery performance. Additionally or alternatively, conventional lithium-ion batteries may be susceptible to metal burrs in certain components, which can lead to reduced battery performance, short circuits, or other negative effects. Therefore, improved systems and methods are now recognized. Summary of the Invention

[0006] The following provides a summary of some embodiments disclosed herein. It should be understood that these aspects are presented merely to provide the reader with a concise overview of these particular embodiments, and are not intended to limit the scope of this disclosure. In fact, this disclosure may cover many aspects that may not be set forth below.

[0007] In one embodiment, an electrode assembly includes an electrode having a laminated foil disposed between a first active material layer and a second active material layer, wherein the laminated foil includes a polymer substrate disposed between the first and second laminated layers. The electrode assembly also includes a plurality of perforations extending through the first active material layer, the second active material layer, and the laminated foil.

[0008] In another embodiment, the battery includes a housing and an electrode assembly disposed within the housing. The electrode assembly includes a cathode having a laminated aluminum foil disposed between a first cathode active material layer and a second cathode active material layer. A first plurality of perforations extend through the first cathode active material layer, the second cathode active material layer, and the laminated aluminum foil. The electrode assembly also includes an anode having a laminated copper foil disposed between the first anode active material layer and the second anode active material layer. A second plurality of perforations extend through the first anode active material layer, the second anode active material layer, and the laminated copper foil. The electrode assembly also includes a separator disposed between the cathode and the anode.

[0009] In another embodiment, a method includes: disposing a polymer substrate between a first laminate layer and a second laminate layer to form a laminated foil of an electrode; disposing the laminated foil between a first active material layer and a second active material layer of the electrode; and forming a plurality of perforations through the first active material layer, the second active material layer and the laminated foil.

[0010] Various modifications to the features described above may be made to the various aspects of this disclosure. Other features may also be incorporated into these aspects. These modifications and additional features may exist individually or in any combination. For example, the various features discussed below with respect to one or more embodiments of the illustrated embodiments may be incorporated individually or in any combination into any aspect of the foregoing description of this disclosure. The brief summary presented above is intended only to familiarize the reader with certain aspects and context of embodiments of this disclosure and does not limit the claimed subject matter. Attached Figure Description

[0011] Various aspects of this disclosure can be better understood by reading the following detailed description and referring to the accompanying drawings, in which the same reference numerals refer to the same parts.

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

[0013] Figure 2 It is configured to, according to the embodiments of this disclosure, to, such as Figure 1 A block diagram of a battery that powers loads such as electronic devices;

[0014] Figure 3 It is possible to implement the scheme according to this disclosure. Figure 2 A perspective cross-sectional view of an electrode used in a battery, the electrode including perforations through a layered structure of the electrode;

[0015] Figure 4 It is possible to implement the scheme according to this disclosure. Figure 2A top view of an electrode used in a battery, the electrode including perforations through a layered structure of the electrode;

[0016] Figure 5 It is possible to implement the scheme according to this disclosure. Figure 2 A cross-sectional side view of an electrode assembly used in a battery, the electrode assembly including an anode having a layered structure and perforations therethrough, a cathode having a layered structure and perforations therethrough, and a separator between the anode and the cathode.

[0017] Figure 6 It is possible to implement the scheme according to this disclosure. Figure 2 A cross-sectional side view of an electrode used in a battery, the electrode including cylindrical perforations through a layered structure of the electrode;

[0018] Figure 7 It is possible to implement the scheme according to this disclosure. Figure 2 A cross-sectional side view of an electrode used in a battery, the electrode including a truncated conical perforation through a layered structure of the electrode;

[0019] Figure 8 It is possible to implement the scheme according to this disclosure. Figure 2 A top view of an electrode used in a battery, the electrode comprising uneven perforations through a layered structure of the electrode; and

[0020] Figure 9 This illustrates the manufacturing process according to an embodiment of the present disclosure. Figure 2 The process flow diagram of the electrode method used in the battery, wherein the electrode includes a layered structure and perforations passing through it. Detailed Implementation

[0021] When describing elements of various embodiments of this disclosure, the articles “a,” “an,” and “the” are intended to mean one or more elements present in the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that additional elements may be present in addition to those listed. Additionally, it should be understood that references to “an embodiment” or “an embodiment” of this disclosure are not intended to be construed as excluding the existence of additional embodiments that also incorporate the described features. Furthermore, specific features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. The use of the terms “about,” “close to,” “approximately,” “close to,” and / or “substantially” should be understood to mean including close to the target (e.g., design, value, and quantity), such as within limits of any suitable or conceivable error (e.g., within 0.1% of the target, within 1% of the target, within 5% of the target, within 10% of the target, within 25% of the target, etc.). Furthermore, it should be understood that any precise values, figures, measurements, etc. provided herein should be assumed to be approximate values ​​(e.g., within a suitable or conceivable tolerance of error).

[0022] This disclosure relates generally to embodiments of batteries such as secondary or rechargeable batteries (e.g., lithium-ion batteries), and more specifically to laminated foils of electrodes (e.g., comprising a polymer substrate and a metal layer on opposite sides of the polymer substrate), perforations through the electrodes, and associated technical benefits. For example, as described in more detail below, the currently disclosed embodiments improve battery performance (e.g., by improving electrolyte distribution through the battery, movement of Li+ ions around the battery, or both) and reduce metal burrs (or their effects) compared to conventional configurations.

[0023] According to this disclosure, among other features, a battery (e.g., a lithium-ion battery) may also include electrodes (e.g., at least one anode and at least one cathode), at least one separator, an electrolyte, and a housing in which the electrodes, a separator, and the electrolyte are disposed. The electrodes and separator of the battery may be referred to herein as electrode assemblies. In some embodiments, the electrode assemblies are wound in a jelly roll configuration, while in other embodiments, the electrode assemblies are arranged in a stacked configuration or other types of configuration.

[0024] Each electrode includes a layered structure having a laminated foil (e.g., a current collector) and an active material layer on opposite sides of the laminated foil. For example, the laminated foil may include a polymer substrate, a first metal layer laminated (e.g., via sputtering) on ​​a first side of the polymer substrate, and a second metal layer laminated (e.g., via sputtering) on ​​a second side of the polymer substrate opposite the first side. In some embodiments of this disclosure, the first metal layer may be referred to as a first sputtered metal layer, and the second metal layer may be referred to as a second sputtered metal layer. The material composition of the polymer substrate, the metal layer (e.g., the sputtered metal layer), and the active material layer may vary (e.g., the cathode may include a first set of material compositions, while the anode may include a second set of material compositions different from the first set), and will be described in more detail with reference to the accompanying drawings. Each electrode also includes a perforation through the layered structure (e.g., through the active material layer, the metal layer, and the polymer substrate). Generally, the laminated foil is configured to block, eliminate, or reduce metal burrs (or their effects) that might otherwise be caused by the process that creates the perforation. The perforation is configured to improve, relative to conventional configurations, the electrolyte distribution around the battery, the movement of Li+ ions around the battery and between the cathode and anode, or both. Through the features described above, the currently disclosed embodiments are configured to improve battery performance, reduce or eliminate short circuits, or both, relative to conventional configurations. These and other aspects of this disclosure are described in detail below with reference to the accompanying drawings.

[0025] Now continue referring to the attached diagram. Figure 1 This is a block diagram of an electronic device 10 according to an embodiment of the present disclosure. Among other things, the electronic device 10 may also include one or more processors 12 (for convenience, they are collectively referred to herein as a single processor, which may be implemented in any suitable form of processing circuitry), memory 14, non-volatile storage device 16, display 18, input structure 22, input / output (I / O) interface 24, network interface 26, and power supply 29. Figure 1 The various functional blocks shown may include hardware elements (including circuitry), software elements (including machine-executable instructions), or combinations of hardware and software elements (which may be referred to as logic units). Processor 12, memory 14, non-volatile storage device 16, display 18, input structure 22, input / output (I / O) interface 24, network interface 26, and / or power supply 29 may each be directly or indirectly communicatively coupled to each other (e.g., through or via another component, communication bus, network) to send and / or receive signals between them. It should be noted that... Figure 1 This is merely one example of a specific implementation and is intended to illustrate the types of components that may be present in electronic device 10.

[0026] By way of example, electronic device 10 may include any suitable computing device, including desktop or laptop computers, portable or handheld electronic devices (such as wireless electronic devices or smartphones), tablet computers, wearable electronic devices, and other similar devices. In additional or alternative embodiments, electronic device 10 may include access points such as base stations, routers (e.g., wireless routers or Wi-Fi routers), hubs, switches, etc. It should be noted that Figure 1 The processor 12 and other related items may be embodied, in whole or in part, as software, hardware, or both. Furthermore, Figure 1 The processor 12 and other related items may be a single, contained processing module, or may be integrated, wholly or partially, into any other element within the electronic device 10. The processor 12 may be implemented using a combination of a general-purpose microprocessor, microcontroller, digital signal processor (DSP), field-programmable gate array (FPGA), programmable logic device (PLD), controller, state machine, gated logic unit, discrete hardware unit, dedicated hardware finite state machine, or any other suitable entity capable of performing computation or other manipulation of information. The processor 12 may include one or more application processors, one or more baseband processors, or both, and performs the various functions described herein.

[0027] exist Figure 1 In the electronic device 10, processor 12 may be operatively coupled to memory 14 and non-volatile storage device 16 to execute various algorithms. Such programs or instructions executed by processor 12 may be stored in any suitable article of writing comprising one or more tangible computer-readable media. The tangible computer-readable media may individually or collectively include memory 14 and / or non-volatile storage device 16 to store instructions or routines. Memory 14 and non-volatile storage device 16 may include any suitable article of writing for storing data and executable instructions, such as random access memory, read-only memory, rewritable flash memory, hard disk drive, and optical disk. Furthermore, programs (e.g., operating systems) encoded on such computer program products may also include instructions executable by processor 12 to enable the electronic device 10 to provide various functionalities.

[0028] In some embodiments, display 18 may facilitate a user's viewing of images generated on electronic device 10. In some embodiments, display 18 may include a touchscreen that facilitates user interaction with the user interface of electronic device 10. Furthermore, it should be understood that in some embodiments, display 18 may include one or more liquid crystal displays (LCDs), light-emitting diode (LED) displays, organic light-emitting diode (OLED) displays, active-matrix organic light-emitting diode (AMOLED) displays, or some combination of these and / or other display technologies.

[0029] Input structure 22 of electronic device 10 allows a user to interact with electronic device 10 (e.g., pressing a button to increase or decrease the volume level). Like network interface 26, I / O interface 24 enables electronic device 10 to interface with a variety of other electronic devices. In some embodiments, I / O interface 24 may include I / O ports for hardwired connections to enable charging and / or content manipulation using standard connectors and protocols such as Lightning connectors, Universal Serial Bus (USB), or other similar connectors and protocols. Network interface 26 may include one or more interfaces for, for example, the following: a personal area network (PAN), such as an ultra-wideband (UWB) or Bluetooth network; a local area network (LAN) or wireless local area network (WLAN), such as a network employing one of the protocols in the IEEE 802.11x family (e.g., Wi-Fi); and / or a wide area network (WAN), such as any standard associated with the 3rd Generation Partnership Project (3GPP), including, for example, 3rd generation (3G) cellular networks, Universal Mobile Telecommunications System (UMTS), 4th generation (4G) cellular networks, Long Term Evolution (LTE) cellular networks, Long Term Evolution Licensed Assisted Access (LTE-LAA) cellular networks, 5th generation (5G) cellular networks and / or New Radio (NR) cellular networks, 6th generation (6G) or beyond 6G cellular networks, satellite networks, non-terrestrial networks, etc. Specifically, network interface 26 may include one or more interfaces for using cellular communication standards, such as those for defining and / or implementing frequency ranges for wireless communication, including millimeter-wave (mmWave) frequency ranges (e.g., 24.25 GHz to 300 GHz). Network interface 26 of electronic device 10 may allow communication over the aforementioned networks (e.g., 5G, Wi-Fi, LTE-LAA, etc.).

[0030] Network interface 26 may also include one or more interfaces for, for example, the following: broadband fixed wireless access networks (e.g., WiMAX), mobile broadband wireless networks (mobile WiMAX), asynchronous digital subscriber lines (e.g., ADSL, VDSL), digital video terrestrial broadcast (DVB-H) networks and their extended DVB handheld (DVB-T) networks, ultra-wideband (UWB) networks, AC power lines, etc.

[0031] The power source 29 of the electronic device 10 may include any suitable power source, such as a rechargeable battery (e.g., a lithium-ion battery) and / or an alternating current (AC) power converter. According to this disclosure, the battery of the power source 29 may include at least one electrode having a layered structure having a laminated foil (e.g., a current collector) and active material layers on opposite sides of the laminated foil. The laminated foil may include, for example, a polymer substrate and metal foil layers on opposite sides of the polymer substrate. Perforations may be provided through the layered structure (e.g., through the two active material layers, the two metal layers of the laminated foil, and the polymer substrate of the laminated foil) to improve electrolyte distribution through the battery, movement of Li+ ions around the battery, or both. The laminated foil may block, eliminate, or reduce metal burrs (or their effects) that might otherwise be caused by the process that creates the perforations. Reference is made below. Figures 2 to 9 These and other aspects of this disclosure are described.

[0032] Figure 2 It is configured to send to, for example Figure 1 A block diagram of an embodiment of a battery 40 (e.g., a lithium-ion battery) powering a load such as an electronic device 10. In the illustrated embodiment, the battery 40 includes a battery housing 42 and an electrode assembly 44 disposed within an interior 46 of the battery housing 42. The electrode assembly 44 includes an anode 48, a cathode 50, and a separator 52 between the anode 48 and the cathode 50. For simplicity, Figure 2 Only one example of anode 48, only one example of cathode 50, and only one example of separator 52 are shown. However, it should be understood that battery 40 may include multiple examples of anode 48 and multiple examples of cathode 50 arranged in an alternating configuration. Furthermore, battery 40 may include one or more examples of separator 52 that operate to separate adjacent examples of anode 48 and cathode 50.

[0033] Anode 48 may include a laminated foil, such as a laminated copper foil (e.g., a copper laminate), an active material layer on opposite sides of the laminated foil, and perforations. The laminated foil may include, for example, a polymer substrate (e.g., an anode polymer substrate) and a metal layer (e.g., a copper layer, a copper laminate) on opposite sides of the polymer substrate. The active material layer of anode 48 may include, for example, a carbon-based material, such as graphite and / or silicon. Perforations may extend through the laminated foil (e.g., the polymer substrate and the metal layer) and the active material layer on opposite sides of the laminated foil. The size of the perforations, described in more detail with respect to the later figures, may be substantially smaller than the holes (e.g., micropores) in separator 52. For example, the diameter and / or cross-sectional area of ​​each perforation may be substantially smaller than the diameter and / or cross-sectional area of ​​each hole (e.g., micropore) in separator 52.

[0034] The cathode 50 may include a laminated foil, such as a laminated aluminum foil (e.g., an aluminum laminate), an active material layer on opposite sides of the laminated foil, and perforations. The laminated foil may include, for example, a polymer substrate (e.g., a cathode polymer substrate) and a metal layer (e.g., an aluminum laminate) on opposite sides of the polymer substrate. The active material layer of the cathode may include, for example, a metal oxide, such as lithium cobalt oxide, lithium manganese oxide, lithium iron phosphate, or lithium nickel manganese cobalt oxide. The perforations may extend through the laminated foil (e.g., the polymer substrate and the metal layer) and the active material layer on opposite sides of the laminated foil. The size of the perforations, which are described in more detail with respect to the figures below, may be substantially smaller than the holes (e.g., micropores) in the separator 52. For example, the diameter and / or cross-sectional area of ​​each perforation may be substantially smaller than the diameter and / or cross-sectional area of ​​each hole (e.g., micropore) in the separator 52.

[0035] Generally, the polymer substrates used for the anode 48 and cathode 50 reduce metal burrs (or their effects) that could otherwise be caused by processes configured to produce the perforations described above. Additionally or alternatively, the perforations can improve electrolyte distribution around the interior 46 of the housing 42, the movement of Li+ ions between the anode 48 and cathode 50, or both. Aspects of the perforations (e.g., size, shape, etc.) are described in detail below with reference to the accompanying drawings.

[0036] Figure 3 It is possible Figure 2 A perspective cross-sectional view of an embodiment of the electrode used in battery 40, the electrode including perforations through a layered structure of the electrode. For clarity, Figure 3 The electrodes in are Figure 2 The anode 48 is described in the context of the example and the description above. However, it should be understood that a similar layered structure (but with different material composition and other possible differences) may also be used for the cathode 50.

[0037] In the illustrated embodiment, the anode 48 includes a laminated foil 60. The laminated foil 60 includes a polymer substrate 62, a first metal layer 64 on a first side of the polymer substrate 62, and a second metal layer 66 on a second side of the polymer substrate 62 opposite to the first side. In some embodiments, the first metal layer 64 and the second metal layer 66 may include aluminum. The first metal layer 64 and the second metal layer 66 may be laminated onto the polymer substrate 62 (e.g., via a sputtering process). The anode 48 also includes a first active material layer 68 and a second active material layer 70 on opposite sides of the laminated foil 60. For example, the laminated foil 60 may be sandwiched between the first active material layer 68 and the second active material layer 70. The first active material layer 68 and the second active material layer 70 may include, for example, carbon-based materials such as graphite and / or silicon. The first active material layer 68, the first metal layer 64, the polymer substrate 62, the second metal layer 66, and the second active material layer 70 may be referred to as a layered structure 81 of the anode 48.

[0038] As shown, a perforation 82 may pass through the anode 48. The perforation 82 may extend through the first active material layer 68, the first metal layer 64, the polymer substrate 62, the second metal layer 66, and the second active material layer 70. As shown, the perforation 82 may include a cylindrical shape, but other shapes (e.g., a truncated conical shape) are also possible. The size, spacing, and other aspects of the perforation 82 may vary depending on the embodiment. As an example, Figure 4 It is possible Figure 2 The electrodes used in battery 40 (e.g., Figure 3 A top view of an embodiment of the anode 48. The diameter 90 of each perforation 82 can be between 50 micrometers and 500 micrometers, between 100 micrometers and 400 micrometers, between 200 micrometers and 300 micrometers, or between 225 micrometers and 275 micrometers. As shown, in some embodiments, the perforations 82 can be arranged in a grid pattern with rows 92 and columns 94, but in other embodiments, the pattern can vary. Figure 4 The first spacing 96 (e.g., first distance) between adjacent perforations 82 in each row 92 can be between 100 micrometers and 10,000 micrometers, between 1,000 micrometers and 9,000 micrometers, between 2,000 micrometers and 8,000 micrometers, or between 3,000 micrometers and 7,000 micrometers. Figure 4The second spacing 98 (e.g., a second distance) between adjacent perforations 82 in each column 94 can be between 100 micrometers and 10,000 micrometers, between 1,000 micrometers and 9,000 micrometers, between 2,000 micrometers and 8,000 micrometers, or between 3,000 micrometers and 7,000 micrometers. In some embodiments, the first spacing 96 is substantially equal to the second spacing 98, while in other embodiments, the first spacing 96 is different from the second spacing 98 (e.g., the first spacing 96 is greater than the second spacing 98, or the second spacing 98 is greater than the first spacing 96). In some embodiments, the perforations 82 can remove approximately 0.5% to 2% of the first active material layer 68 and / or the second active material layer 70. As previously described, Figure 2 The cathode 50 may include a cathode 50 with Figure 3 and Figure 4 The anode 48 described above has similar features, except that the cathode 50 may include different material compositions.

[0039] Figure 5 It is possible Figure 2 A cross-sectional side view of an embodiment of the electrode assembly 110 used in the battery 40, the electrode assembly including an anode 48 having a layered structure 81 and through-holes 82, a cathode 50 having a layered structure 111 and through-holes 112, and a separator 52 between the anode 48 and the cathode 50. The layered structure 111 of the cathode 50 includes a laminated foil 120 having a polymer substrate 122, a first metal layer 124 on a first side of the polymer substrate 122, and a second metal layer 126 on a second side of the polymer substrate 122 opposite to the first side. In some embodiments, the first metal layer 124 and the second metal layer 126 may include copper. The first metal layer 124 and the second metal layer 126 may be laminated onto the polymer substrate 122 (e.g., via a sputtering process). The cathode 50 also includes a first active material layer 128 and a second active material layer 130 on opposite sides of the laminated foil 120. For example, the laminated foil 120 may be sandwiched between a first active material layer 128 and a second active material layer 130. The first active material layer 128 and the second active material layer 130 may include, for example, metal oxides, such as lithium cobalt oxide, lithium manganese oxide, lithium iron phosphate, or lithium nickel manganese cobalt oxide. The first active material layer 128, the first metal layer 124, the polymer substrate 122, the second metal layer 126, and the second active material layer 130 may be referred to as the layered structure 111 of the cathode 50.

[0040] In some embodiments, the polymer substrate 62 of the anode 48 comprises the same or similar material composition as the polymer substrate 122 of the cathode 50, while in other embodiments, the material composition differs between polymer substrate 62 and polymer substrate 122. As previously described, generally, relative to conventional configurations, the polymer substrates 62, 122 in the laminated foils 60, 120 are configured to reduce or eliminate metal burrs (or their effects) associated with perforation techniques configured to create perforations 82, 112 in the anode 48 and cathode 50, respectively. Furthermore, the perforations 82, 112 are configured to improve electrolyte distribution and / or the movement of Li+ ions between the anode 48 and cathode 50 relative to conventional configurations.

[0041] As previously described, perforations 82 and 112 may have a cylindrical shape, a truncated conical shape, or some other shape. For example, Figure 6 and Figure 7 The shape of the perforation 82 in the anode 48 is illustrated. It should be understood that the same or similar shape may also be used for the perforation 112 in the cathode 50. Figure 6 In the middle, perforation 82 has a cylindrical shape, while... Figure 7 In the middle, perforation 82 has a truncated conical shape. Figure 6 In this process, the diameter 90 of the perforation 82 (e.g., the cross-sectional diameter) is essentially constant and can be between 50 micrometers and 500 micrometers, 100 micrometers and 400 micrometers, 200 micrometers and 300 micrometers, or 225 micrometers and 275 micrometers. Figure 7 In this embodiment, the perforation 82 has a variable diameter, which includes a maximum diameter 140 (e.g., a maximum cross-sectional diameter) and a minimum diameter 142 (e.g., a minimum cross-sectional diameter). The maximum diameter 140 can be between 50 micrometers and 500 micrometers, between 100 micrometers and 400 micrometers, between 200 micrometers and 300 micrometers, or between 225 micrometers and 275 micrometers. The minimum diameter 142 can be between 25 micrometers and 475 micrometers, between 75 micrometers and 375 micrometers, between 175 micrometers and 275 micrometers, or between 200 micrometers and 250 micrometers. In some embodiments, the maximum diameter 140 can be approximately 110% to 200% of the minimum diameter 142, 120% to 175% of the minimum diameter 142, or 130% to 150% of the minimum diameter 142.

[0042] Figure 8 It is possible Figure 2 A top view of an embodiment of an electrode used in battery 40, the electrode comprising uneven perforations through a layered structure of the electrode. In some embodiments, such as Figure 4 In the illustrated embodiment, the size, shape, and / or pattern of the perforations 82 can be uniform, while in other embodiments, such as Figure 8 The illustrated implementation may employ non-uniform perforation. For example, relatively large perforations and / or relatively high perforation density may be selectively located in certain electrode regions or areas prone to electrolyte and / or Li+ ion blockage, thereby better promoting electrolyte distribution and the movement of Li+ ions in said electrode regions or areas, and relatively small perforations and / or relatively low perforation density may be selectively located in certain other electrode regions or areas less prone to electrolyte and / or Li+ ion blockage, thereby reducing the impact on the battery's volumetric energy density. For the same or similar reasons, other different perforation characteristics, such as perforation shape and / or pattern, may also be employed, as described below regarding... Figure 8 More detailed description.

[0043] For clarity, Figure 8 The electrodes are described in the context of anode 48. However, it should be understood that cathode 50 may include the same or similar features, except that cathode 50 may include a different material composition. In the illustrated embodiment, anode 48 includes a first region 150 (e.g., a first segment), a second region 152 (e.g., a second segment), and a third region 154 (e.g., a third segment). The perforations 82a in the first region 150 differ in size, shape, and / or spacing from the perforations 82b in the second region 152 and 82c in the third region 154, and the perforations 82b in the second region 152 differ in size, shape, and / or spacing from the perforations 82c in the third region 154. For example, the diameter 90a of the perforation 82a in the first region 150 differs from the diameter 90b of the perforation 82b in the second region 152. Alternatively or additionally, the spacing 96a, 98a between adjacent perforations 82a in the first region 150 differs from the spacing 96b, 98b between adjacent perforations 82b in the second region 152. Alternatively or additionally, the perforations 82c in the third region 154 include a pattern different from that of the perforations 82a in the first region 150 and the perforations 82b in the second region 152. For example, while the perforations 82a in the first region 150 and the perforations 82b in the second region 152 form a grid pattern with rows and columns, the perforations 82c in the third region 154 are staggered (e.g., in a zigzag pattern). It should be noted that other perforation variations are also possible. For example, perforation size, shape, pattern, and / or density may be functionally graded along the electrodes.

[0044] Figure 9 This is an example of manufacturing that can be done Figure 2A process flow diagram of an embodiment of method 200 for using electrodes in battery 40, wherein the electrodes include a layered structure and through-holes therethrough. The electrodes may include, for example, an anode or a cathode. In an illustrated embodiment, method 200 includes: disposing a polymer substrate (box 202) between a first laminate (e.g., a first metal layer) and a second laminate (e.g., a second metal layer) to form a laminated foil for the electrode. For example, if the electrode is an anode, the first and second laminates (e.g., a first metal layer and a second metal layer) may include copper, and if the electrode is a cathode, the first and second laminates (e.g., a first metal layer and a second metal layer) may include aluminum. In some embodiments, the first laminate (e.g., a first metal layer) is sputtered onto a first side of the polymer substrate, and the second laminate (e.g., a second metal layer) is sputtered onto a second side of the polymer substrate opposite the first side.

[0045] Method 200 further includes: disposing a laminated foil (frame 204) between a first active material layer and a second active material layer of the electrode. For example, if the electrode is an anode, the first and second active material layers may comprise carbon-based materials, such as graphite and / or silicon, and if the electrode is a cathode, the first and second active material layers may comprise metal oxides, such as lithium cobalt oxide, lithium manganese oxide, lithium iron phosphate, or lithium nickel manganese cobalt oxide.

[0046] Method 200 further includes forming (frame 206) a plurality of perforations through the first active material layer, the second active material layer, and the laminated foil (e.g., the first laminate, the polymer substrate, and the second laminate). According to this disclosure, the plurality of perforations through the electrodes can be formed by mechanical drilling processes (e.g., mechanical perforation techniques), laser drilling processes (e.g., laser perforation techniques), combinations thereof, or some other suitable techniques for reducing metal burrs or their effects.

[0047] Currently disclosed embodiments include electrodes having a layered structure and perforations through the layered structure, which improve electrolyte distribution, Li+ ion mobility, and / or battery performance compared to conventional configurations. Additionally or alternatively, the layered structure includes a laminated foil (e.g., a polymer substrate having a metal layer on opposite sides of a polymer substrate), which reduces or eliminates metal burrs (or their effects) compared to conventional configurations.

[0048] The specific embodiments described above have been shown by way of example, and it should be understood that various modifications and alternatives are permissible. It should also be understood that the claims are not intended to be limited to the specific forms disclosed, but rather to cover all modifications, equivalents, and alternatives falling within the substance and scope of this disclosure.

[0049] The techniques presented and claimed herein are referenced and applied to specific examples of physical and practical nature that significantly improve the art and are therefore not abstract, intangible, or purely theoretical. Furthermore, if any claim appended to this specification contains one or more elements designated as “means for [performing] [function]…” or “steps for [performing] [function]…”, it is intended that such elements should be interpreted in accordance with 35U.SC112(f). However, for any claim containing elements designated in any other manner, it is intended that such elements should not be interpreted in accordance with 35U.SC112(f).

[0050] As is widely recognized, the use of personally identifiable information should comply with privacy policies and practices that are generally accepted to meet or exceed industry or governmental requirements for protecting user privacy. Specifically, personally identifiable information data should be managed and processed to minimize the risk of unintentional or unauthorized access or use, and the nature of authorized use should be clearly explained to users.

Claims

1. An electrode assembly, the electrode assembly comprising: An electrode, the electrode comprising a laminated foil disposed between a first active material layer and a second active material layer, wherein the laminated foil comprises a polymer substrate disposed between the first laminated layer and the second laminated layer; and Multiple perforations extend through the first active material layer, the second active material layer, and the laminated foil.

2. The electrode assembly according to claim 1, wherein the electrode assembly comprises: An additional electrode, the additional electrode comprising an additional laminated foil disposed between an additional first active material layer and an additional second active material layer, wherein the additional laminated foil comprises an additional polymer substrate disposed between the additional first laminated layer and the additional second laminated layer; and Multiple additional perforations are provided, which extend through the additional first active material layer, the additional second active material layer, and the additional laminated foil.

3. The electrode assembly according to claim 2, wherein the electrode assembly includes a partition disposed between the electrode and the additional electrode.

4. The electrode assembly of claim 3, wherein the separator comprises a plurality of micropores, and each of the plurality of micropores has a first cross-sectional area, the first cross-sectional area being less than: The second cross-sectional area of ​​each of the plurality of perforations; and The third cross-sectional area of ​​each of the additional perforations.

5. The electrode assembly according to claim 2, wherein: The electrode includes a cathode, the first laminate includes a first aluminum laminate, and the second laminate includes a second aluminum laminate; and The additional electrode includes an anode, the additional first laminate includes a first copper laminate, and the additional second laminate includes a second copper laminate.

6. The electrode assembly of claim 1, wherein the perforation of the plurality of perforations has a truncated conical shape.

7. The electrode assembly of claim 1, wherein the perforations in the plurality of perforations have a cylindrical shape.

8. The electrode assembly of claim 1, wherein the perforations in the plurality of perforations have a cross-sectional diameter of 50 micrometers to 500 micrometers.

9. The electrode assembly of claim 1, wherein the plurality of perforations includes a first perforation and a second perforation, the first perforation and the second perforation being separated by a distance between 100 micrometers and 10,000 micrometers.

10. The electrode assembly of claim 1, wherein the laminated foil is configured to reduce metal burrs or their effects associated with a perforation technique configured to produce the plurality of perforations.

11. A battery, the battery comprising: case; and Electrode assembly, the electrode assembly being disposed within the housing, wherein the electrode assembly comprises: The cathode includes a laminated aluminum foil disposed between a first cathode active material layer and a second cathode active material layer; The first plurality of perforations extend through the first cathode active material layer, the second cathode active material layer, and the laminated aluminum foil; The anode includes a laminated copper foil disposed between a first anode active material layer and a second anode active material layer; A second plurality of perforations, the second plurality of perforations extending through the first anodic active material layer, the second anodic active material layer, and the laminated copper foil; and A partition is disposed between the cathode and the anode.

12. The battery according to claim 11, wherein: The laminated aluminum foil includes a cathode polymer substrate disposed between a first aluminum laminate and a second aluminum laminate; and The laminated copper foil includes an anolyte polymer substrate disposed between a first copper laminate and a second copper laminate.

13. The battery of claim 11, wherein the perforation in the first plurality of perforations has a truncated conical shape or a cylindrical shape.

14. The battery of claim 11, wherein the electrode assembly has a jelly roll configuration or a stacked configuration.

15. The battery of claim 11, wherein the perforations in the first plurality of perforations have a cross-sectional diameter of 50 micrometers to 500 micrometers.

16. The battery of claim 11, wherein the first plurality of perforations includes a first perforation and a second perforation, the first perforation and the second perforation being separated by a distance between 100 micrometers and 10,000 micrometers.

17. A method, the method comprising: A polymer substrate is disposed between a first laminate and a second laminate to form a laminated foil for electrodes; The laminated foil is disposed between the first active material layer and the second active material layer of the electrode; as well as Multiple perforations are formed through the first active material layer, the second active material layer, and the laminated foil.

18. The method of claim 17, wherein the method comprises: The plurality of perforations are formed through the first active material layer, the second active material layer, and the laminated foil via mechanical perforation or laser perforation, wherein the laminated foil is configured to reduce or eliminate metal burrs or their effects associated with the mechanical perforation or laser perforation.

19. The method of claim 17, wherein the method comprises: The polymer substrate is disposed between the first laminate and the second laminate by sputtering the first laminate and the second laminate on opposite sides of the polymer substrate.

20. The method of claim 17, wherein the method comprises: An additional polymer substrate is disposed between the additional first laminate and the additional second laminate to form an additional laminate foil for the additional electrode; The additional laminated foil is disposed between the additional first active material layer and the additional second active material layer of the additional electrode; Forming additional perforations through the additional first active material layer, the additional second active material layer, and the additional laminated foil; as well as A partition is provided between the electrode and the additional electrode.

Images