Battery with lithium metal coating

Abstract

The invention relates to a battery with a lithium metal coating. The present invention relates to a battery pre-lithiation assembly, and more specifically, to a battery pre-lithiation assembly comprising a housing and an electrode disposed in the housing. The electrode assembly includes a current collector, an active material disposed on the current collector, and a perforation extending through the active material and the current collector. The battery pre-lithiation assembly also includes a lithium metal coating on the interior of the housing. The perforations are configured to enable Li + ions to migrate from the lithium metal coating to the electrode via a pre-lithiation process when the housing receives an electrolyte.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 693,578, filed on September 11, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates in its entirety to batteries configured to supply power to 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 pre-lithiated components and processes for such batteries. Background Technology

[0004] Some batteries (such as those mentioned above) undergo a pre-lithiation process, which causes lithium cations (Li+ ions) to react with the battery's anode during battery formation (e.g., before the battery is used to power a load). Pre-lithiation processes can employ redox reactions to reduce or mitigate initial active lithium loss during battery cycling phases (e.g., early cycling phases), improve local voltage uniformity, and / or maintain battery stability and performance. Unfortunately, conventional pre-lithiation processes can be cumbersome, expensive, insufficient, and / or ineffective. Therefore, improved systems and methods are now recognized. Summary of the Invention

[0005] The following outlines some of the 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.

[0006] In one embodiment, the battery pre-lithiation assembly includes a housing and electrodes disposed within the housing. The electrode assembly includes a current collector, an active material disposed on the current collector, and perforations extending through the active material and the current collector. The battery pre-lithiation assembly also includes a lithium metal coating on the inner surface of the housing. The perforations are configured to allow Li+ ions to migrate from the lithium metal coating to the electrodes via a pre-lithiation process when the housing receives an electrolyte.

[0007] In another embodiment, the battery pre-lithiation assembly includes a housing, an anode disposed within the housing, and a cathode disposed within the housing. The anode includes an anode current collector, an anode active material disposed on the anode current collector, and a first perforation extending through the anode current collector and the anode active material. The cathode includes a cathode current collector, a cathode active material disposed on the cathode current collector, and a second perforation extending through the cathode current collector and the cathode active material. The battery pre-lithiation assembly also includes a lithium metal coating located on the inner surface of the housing, wherein the first and second perforations are configured to allow Li+ ions to migrate from the lithium metal coating to the anode via the pre-lithiation process.

[0008] In another embodiment, a method of manufacturing a battery includes: providing a current collector through an electrode and an active material of the electrode, wherein the active material is disposed on the current collector. The method further includes: coating an inner surface of a housing with lithium metal; disposing of the electrode in the housing; and disposing of an electrolyte in the housing to initiate a pre-lithiation process in which Li+ ions are transferred from the lithium metal to the electrode through the perforation.

[0009] Various modifications to the features described above may be possible with respect 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 of the foregoing aspects 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

[0010] 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.

[0011] Figure 1 This is a block diagram of an electronic device according to an embodiment of the present disclosure;

[0012] Figure 2 The embodiment of this disclosure is used in the pre-lithiation process to form a structure configured to be directed toward a load (such as... Figure 1 A block diagram of a pre-lithiated component for a battery powered by an electronic device.

[0013] Figure 3 It is based on the implementation scheme of this disclosure. Figure 2 A cross-sectional view of the cathode of a pre-lithiated assembly, wherein the cathode includes a perforation through a cathode current collector and cathode active material located on the opposite side of the cathode current collector.

[0014] Figure 4 It is based on the implementation scheme of this disclosure. Figure 2 A cross-sectional view of the anode of a pre-lithiated assembly, wherein the anode includes a perforation through an anode current collector and an anode active material located on the opposite side of the anode current collector; and

[0015] Figure 5 It is based on the implementation scheme of this disclosure. Figure 2 A cross-sectional view of a pre-lithiated component, wherein a lithium metal coating is disposed on the inner surface of the housing;

[0016] Figure 6 It is based on the implementation scheme of this disclosure by Figure 5 A cross-sectional view of the battery formed by the pre-lithiation components; and

[0017] Figure 7 This is a process flow diagram illustrating a method for manufacturing a battery according to an embodiment of the present disclosure. Detailed Implementation

[0018] 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 “generally,” “approaching,” “about,” “close to,” and / or “substantially” should be understood to mean including approximation to an objective (e.g., design, value, and quantity), such as within limits of any suitable or conceivable error (e.g., within 0.1% of the objective, within 1% of the objective, within 5% of the objective, within 10% of the objective, within 25% of the objective, 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).

[0019] This disclosure relates generally to embodiments of batteries (such as secondary batteries or rechargeable batteries (e.g., lithium-ion batteries)), and more specifically to embodiments of pre-lithiation components and processes for batteries, wherein the pre-lithiation components include perforated electrodes and a lithium metal coating disposed on one or more internal surfaces of a housing, the perforated electrodes being disposed within the housing. Generally, employing pre-lithiation components and processes in battery formation reduces initial active lithium loss and improves local voltage uniformity, battery performance, battery stability, and energy density compared to conventional systems and technologies.

[0020] 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, at least one 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 into a jelly roll, while in other embodiments, the electrode assemblies are arranged in a stacked configuration or other types of configuration.

[0021] During its lifespan, a battery can be cycled through various discharge and charge sequences. In conventional constructions, initial active lithium loss may occur during some of these cycles, which can affect battery stability, performance, and / or energy density. According to this disclosure, pre-lithiation components and processes (e.g., during battery formation) can be employed to introduce a lithium source (e.g., a lithium metal coating), such as a sacrificial lithium source, which mitigates initial active lithium loss and improves local voltage uniformity, battery performance and stability, as well as other technical benefits.

[0022] As detailed in the accompanying drawings, the lithium source may include a lithium metal coating disposed on one or more internal surfaces of a housing (e.g., a battery housing). Furthermore, the electrodes may include perforations therethrough. For example, each electrode may include a current collector and an active material disposed on opposite sides of the current collector, wherein the perforations extend through the current collector and the active material. The perforations in the electrodes and the pores in the separators form channels that facilitate the movement of lithium cations (Li+ ions) associated with or corresponding to the lithium metal coating surrounding the interior of the housing. For example, introducing an electrolyte into the housing allows Li+ ions to move from the lithium metal coating toward the anode during the electrolyte aging portion of a pre-lithiation process. The perforations also allow the electrodes to undergo desired diffusion and wetting by the electrolyte. A redox reaction may occur between the Li+ ions and the anode, causing active lithium to transfer to the anode, thereby reducing, eliminating, or otherwise preventing initial active lithium loss and / or localized voltage inhomogeneities.

[0023] As described above and in more detail below, the currently disclosed systems and techniques improve local voltage uniformity, reduce initial active lithium loss, and improve battery performance, stability, and energy density compared to conventional systems and techniques. Furthermore, the currently disclosed systems and techniques may be cheaper and less complex than conventional techniques. Moreover, the use of a lithium metal coating on the inner surface of the casing, relative to conventional constructions, can reduce the amount of space occupied by the lithium source within the casing, thereby improving the volumetric energy density of the battery formed from pre-lithiated components. It should be noted that although some embodiments of this disclosure are discussed in the context of lithium-ion (Li-ion) batteries, similar systems and techniques can also be used in other batteries with other material compositions. These and other aspects of this disclosure are described in detail below with reference to the accompanying drawings.

[0024] 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., via or through 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.

[0025] 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 1The 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, discrete hardware components, dedicated hardware finite state machine, or any other suitable entity capable of performing computational or other manipulations 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.

[0026] exist Figure 1 In the electronic device 10, a processor 12 may be operatively coupled to a memory 14 and a non-volatile storage device 16 to execute various algorithms. Such programs or instructions executed by the processor 12 may be stored in any suitable article of writing comprising one or more tangible computer-readable media. The tangible computer-readable media may individually or collectively include the memory 14 and / or the non-volatile storage device 16 to store instructions or routines. The memory 14 and the 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 the processor 12 to enable the electronic device 10 to provide various functions.

[0027] 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.

[0028] The input structure 22 of electronic device 10 enables 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 interact 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, for example, one or more interfaces for: Personal Area Network (PAN), such as Ultra Wideband (UWB), or... Network; Local Area Network (LAN) or Wireless Local Area Network (WLAN), such as one of the protocols in the IEEE 802.11x series (e.g. Networks; and / or wide area networks (WANs), such as any standards related to 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) networks. Cellular networks, Long Term Evolution License Auxiliary Access (LTE-LAA) cellular networks, 5G cellular networks and / or New Radio (NR) cellular networks, 6G or beyond 6G cellular networks, satellite networks, non-terrestrial networks, etc. Specifically, network interface 26 may include one or more interfaces for cellular communication standards, such as those for using defined and / or implemented 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 via the aforementioned networks (e.g., 5G, Wi-Fi, LTE-LAA, etc.).

[0029] Network interface 26 may also include one or more interfaces for, for example, a broadband fixed wireless access network (e.g., Mobile broadband wireless network (mobile) Asynchronous digital subscriber lines (e.g., ADSL, VDSL) and terrestrial digital video broadcasting Network and its extension DVB handheld devices Networks, ultra-broadband (UWB) networks, alternating current (AC) power lines, etc.

[0030] The power source 29 of the electronic device 10 may include any suitable power source, such as a rechargeable lithium polymer (Li-poly) battery or a lithium-ion (Li-ion) battery and / or an alternating current (AC) power converter. According to this disclosure, the battery of the power source 29 may be formed at least partially by a pre-lithiation assembly and process. The pre-lithiation assembly may include a housing, an electrode assembly located within the housing, and a lithium metal coating located on one or more internal surfaces defining the interior of the housing. Furthermore, the electrode assembly may include various electrodes, such as various anodes and cathodes, having perforations therethrough. Introducing an electrolyte into the housing of the pre-lithiation assembly allows Li+ ions to migrate from the lithium metal coating on the internal surface of the housing toward the anode during the electrolyte aging portion of the pre-lithiation process. The perforations in the electrodes facilitate electrolyte diffusion, electrolyte wetting of the electrodes, and the migration of Li+ ions around the interior of the housing toward the anode. A redox reaction may occur between the Li+ ions and the anode, causing active lithium to transfer to the anode, thereby reducing, eliminating, or otherwise preventing initial active lithium loss and / or localized voltage inhomogeneities that may occur during battery formation and / or initial battery cycling. In some embodiments, at least a portion of the pre-lithiation assembly is a precursor to the battery. In other words, various components of the pre-lithiation assembly (including the housing and electrode assemblies) can also be components of the battery following the pre-lithiation process. Therefore, in certain aspects of this disclosure, the pre-lithiation assembly may be referred to as a battery pre-lithiation assembly. These and other aspects of this disclosure will be described in more detail below.

[0031] Figure 2 It is used in the pre-lithiation process to form a structure that is configured to be directed toward the load (such as...) Figure 1 A block diagram of an embodiment of a pre-lithiation assembly 40 for a battery powered by an electronic device 10. In the illustrated embodiment, the pre-lithiation assembly 40 includes a housing 42, an electrode assembly 44 having an anode 46, a cathode 48, and a separator 50, and a lithium metal coating 52, among other possible features. According to this disclosure, the lithium metal coating 52 may be disposed on one or more internal surfaces 54 defining the interior 55 of the housing 42. As shown, the separator 50 is disposed between the anode 46 and the cathode 48. Although for clarity, Figure 2 Only one example of anode 46 and one example of cathode 48 are illustrated, but it should be understood that multiple examples of anode 46 and multiple examples of cathode 48 may be employed in some embodiments. Furthermore, according to this disclosure, electrode assembly 44 may include a stacked configuration (e.g., where anode 46, cathode 48, and separator 50 are stacked one on top of another) or a jelly roll configuration (e.g., where anode 46, cathode 48, and separator 50 are wound around an axis).

[0032] During the pre-lithiation process employing the pre-lithiation assembly 40, an electrolyte 56 may be introduced into the interior 55 of the housing 42 of the pre-lithiation assembly 40. The introduction of the electrolyte 56 causes Li+ ions to migrate from the lithium metal coating 52 through the interior 55 of the housing 42 toward the anode 46. As described in detail below with reference to the accompanying drawings, the anode 46 and cathode 48 may include perforations therethrough, which improve the wetting of the anode 46 and cathode 48 by the electrolyte 56, and the migration of Li+ ions from the lithium metal coating 52 around the interior 55 of the housing 42 toward the anode 46. Furthermore, the separator 50 may include a porous separator, wherein the pores of the separator 50 are configured to improve the migration of Li+ ions from the lithium metal coating 52, around the interior 55 of the housing 42, toward the anode 46. During the electrolyte aging portion of the pre-lithiation process, a redox reaction may occur between Li+ ions and the anode 46, causing active lithium to transfer to the anode 46, thereby reducing, eliminating, or mitigating initial active lithium loss and improving local voltage uniformity and / or battery stability and performance.

[0033] Figure 3 yes Figure 2 A cross-sectional view of an embodiment of the cathode 48 of the pre-lithiation assembly 40. In the illustrated embodiment, the cathode 48 includes a cathode current collector 70, a first cathode active material layer 72 located on a first side of the cathode current collector 70, a second cathode active material layer 74 located on a second side of the cathode current collector 70 opposite to the first side, and a perforation 76 formed through the cathode current collector 70, the first cathode active material layer 72, and the second cathode active material layer 74. For example, the first cathode active material layer 72 and the second cathode active material layer 74 may contain metal oxides, such as lithium cobalt oxide, lithium manganese oxide, lithium iron phosphate, and / or lithium nickel manganese cobalt oxide, and the cathode current collector 70 may contain aluminum.

[0034] As shown, each of the cathode current collector 70, the first cathode active material layer 72, and the second cathode active material layer 74 extends in the lateral direction 78. A perforation 76 extends through the cathode 48 (e.g., through the cathode current collector 70, the first cathode active material layer 72, and the second cathode active material layer 74) in a vertical direction 80 that is transverse to (e.g., perpendicular to) the lateral direction 78. Furthermore, the size and spacing of the perforations 76 allow only 1% to 1.5% of the active material corresponding to the first cathode active material layer 72 and the second cathode active material layer 74 to be removed, resulting in a relatively small reduction in volumetric energy density caused by the perforations 76. In other embodiments, more than 1.5% of the active material corresponding to the first cathode active material layer 72 and the second cathode active material layer 74 can be removed via the perforations 76. As previously described, the perforations 76 are configured to enable, promote, and / or improve (e.g., compared to conventional configurations) the migration of Li+ ions from the lithium metal coating through the interior of the housing toward the anode of the pre-lithiated assembly. In some embodiments, additional perforations may be provided through the cathode 48 in the lateral direction 78 (e.g., through the cathode active material layers 72, 74) (e.g., through the perforations 76 extending laterally to and along the vertical direction 80).

[0035] Figure 4 yes Figure 2 A cross-sectional view of an embodiment of the anode 46 of the pre-lithiation component 40. In the illustrated embodiment, the anode 46 includes an anode current collector 90, a first anode active material layer 92 located on a first side of the anode current collector 90, a second anode active material layer 94 located on a second side of the anode current collector 90 opposite to the first side, and a perforation 96 through the anode current collector 90, the first anode active material layer 92, and the second anode active material layer 94. For example, the first anode active material layer 92 and the second anode active material layer 94 may comprise carbon-based materials (such as graphite and / or silicon), and the anode current collector 90 may comprise copper.

[0036] As shown, each of the anode current collector 90, the first anode active material layer 92, and the second anode active material layer 94 extends in the lateral direction 98. A perforation 96 extends through the anode 46 (e.g., through the anode current collector 90, the first anode active material layer 92, and the second anode active material layer 94) in a vertical direction 100 that is transverse to (e.g., perpendicular to) the lateral direction 98. Furthermore, the size and spacing of the perforations 96 allow only 1% to 1.5% of the active material corresponding to the first anode active material layer 92 and the second anode active material layer 94 to be removed, resulting in a relatively small reduction in volumetric energy density caused by the perforations 96. In other embodiments, more than 1.5% of the active material corresponding to the first anode active material layer 92 and the second anode active material layer 94 can be removed via the perforations 96. As previously described, the perforations 96 are configured to enable, promote, and / or improve (e.g., compared to conventional configurations) the migration of Li+ ions from the lithium metal coating through the interior of the housing toward the anode of the pre-lithiated assembly. In some embodiments, additional perforations may be provided through the anode 46 in the lateral direction 98 (e.g., through the anode active material layers 92, 94) (e.g., through the perforations 96 extending laterally to and along the vertical direction 100).

[0037] Figure 5 yes Figure 2A cross-sectional view of an embodiment of the pre-lithiation component 40, wherein a lithium metal coating 52 is disposed on an inner surface 54 of a housing 42. For example, the inner surface 54 of the housing 42 includes an upper inner surface 54a, a lower inner surface 54b opposite to the upper inner surface 54a, a first side inner surface 54c, and a second side inner surface 54d opposite to the first side inner surface 54c. The lithium metal coating 52 may include a first lithium metal coating portion 52a disposed on the upper inner surface 54a, a second lithium metal coating portion 52b disposed on the lower inner surface 54b, a third lithium metal coating portion 52c disposed on the first side inner surface 54c, and a fourth lithium metal coating portion 52d disposed on the second side inner surface 54d. In certain embodiments of this disclosure, the various portions 52a, 52b, 52c, and 52d of the lithium metal coating 52 may be referred to as various coatings (e.g., first lithium metal coating 52a, second lithium metal coating 52b, third lithium metal coating 52c, fourth lithium metal coating 52d, etc.). Although not shown in the illustrated embodiment, a fifth lithium metal coating portion and a sixth lithium metal coating portion (or “coating”) may be provided on the front and rear inner surfaces of the housing 42. Generally, compared to conventional constructions, by employing a lithium metal coating 52 (e.g., lithium metal coating portions 52a, 52b, 52c, 52d) on the inner surfaces 54 of the housing 42 (e.g., inner surfaces 54a, 54b, 54c, 54d), the amount of space occupied by the lithium source within the interior 55 of the housing 42 can be reduced, thereby improving the volumetric energy density of the battery formed by the pre-lithiation assembly 40.

[0038] As shown in the figure, the lithium metal coating portions 52a, 52b, 52c, and 52d may not be provided on the entire inner surface 54a, 54b, 54c, and 54d of the housing 42. For example, the upper inner surface 54a and the first side inner surface 54c may intersect to form a first corner 110, in which neither the first lithium metal coating portion 52a nor the third lithium metal coating portion 52c is provided; the upper inner surface 54a and the second side inner surface 54d may intersect to form a second corner 112, in which neither the first lithium metal coating portion 52a nor the fourth lithium metal coating portion 52d is provided; and the lower inner surface 54b and the first side inner surface 54c may intersect to form a third corner 114, in which neither the second lithium metal coating portion 52b nor the third lithium metal coating portion 52c is provided. Typically, lithium metal coating portions 52a, 52b, 52c, and 52d may extend across at least a majority of the internal surfaces 54a, 54b, 54c, and 54d. For example, a first lithium metal coating portion 52a may extend across 50%, 75%, 90%, or 95% of the upper internal surface 54a; a second lithium metal coating portion 52b may extend across 50%, 75%, 90%, or 95% of the lower internal surface 54b; a third lithium metal coating portion 52c may extend across 50%, 75%, 90%, or 95% of the first side internal surface 54c; and a fourth lithium metal coating portion 52d may extend across 50%, 75%, 90%, or 95% of the second side internal surface 54d. In other embodiments, at least one of the lithium metal coating portions 52a, 52b, 52c, or 52d covers the entire corresponding internal surface 54a, 54b, 54c, or 54d.

[0039] In some embodiments, the battery terminal assembly 115 is disposed in a fourth corner 116 located at or adjacent to the end (or intersection of) the bottom inner surface 54b and the second side inner surface 54d, and neither the second lithium metal coating portion 52b nor the fourth lithium metal coating portion 52d is disposed in the fourth corner 116. As shown, the battery terminal assembly 115 includes a terminal 118 (e.g., a cathode terminal) and at least one electrical insulator 120 located between the terminal 118 and the housing 42, wherein the terminal 118 is electrically coupled to the cathode current collector 70 (e.g., a cathode current collector tab) of the cathode 48. Additionally or alternatively, in an illustrated embodiment, the anode current collector 90 (e.g., an anode current collector tab) of the anode 46 is electrically coupled to the housing 42 such that the housing 42 forms an additional terminal (e.g., an anode terminal).

[0040] As previously described, an electrolyte can be introduced into the interior 55 of the housing 42 to initiate the pre-lithiation process of the pre-lithiation assembly 40. For example, during the electrolyte aging portion of the pre-lithiation process, the electrolyte can cause Li+ ions to move from the lithium metal coating 52 (e.g., lithium metal coating portions 52a, 52b, 52c, 52d) toward the anode 46. Perforations 76 in the cathode 48, perforations 96 in the anode 46, and pores in the separator 50 facilitate the movement (e.g., diffusion) of the electrolyte and Li+ ions corresponding to the lithium metal coating 52 (e.g., lithium metal coating portions 52a, 52b, 52c, 52d) around the interior 55 of the housing 42.

[0041] As previously described, a redox reaction may occur between Li+ ions and anode 46, causing active lithium to transfer to anode 46, thereby reducing, eliminating, or otherwise preventing the loss of initial active lithium. That is, upon completion of the pre-lithiation process (including its electrolyte aging portion), as active lithium is transferred to anode 46, all or most of the lithium metal coating portions 52a, 52b, 52c, 52d may be depleted from the internal surfaces 54a, 54b, 54c, or 54d of the housing 42. For example, Figure 6 It is by Figure 5 A cross-sectional view of an embodiment of a battery 200 formed by a pre-lithiation component 40. In the illustrated embodiment, the battery 200 includes components with... Figure 5 The pre-lithiation component 40 in the housing 42 has the same or similar features, except that the inner surfaces 54a, 54b, 54c or 54d of the housing 42 do not have lithium metal coating portions 52a, 52b, 52c, 52d, because the active lithium has been transferred to the inner surfaces 54a, 54b, 54c or 54d of the housing 42. Figure 6 Anode 46 in the battery 200 illustrated in the example.

[0042] Figure 7 This is a process flow diagram illustrating an embodiment of method 300 for manufacturing a battery. In the illustrated embodiment, method 300 includes providing (block 302) a current collector through an electrode (e.g., an anode) and a perforation of the active material of the electrode. As previously described, the active material may be disposed on the opposite side of the current collector. In some embodiments, method 300 includes providing additional perforations through an additional current collector and additional active material of an additional electrode (e.g., a cathode). According to this disclosure, any number of anodes and cathodes may be used.

[0043] Method 300 also includes coating the interior surface of the housing with lithium metal (box 304). For example, the lithium metal coating may be applied across the entire interior surface or less than the entire interior surface (e.g., a large portion of the interior surface). In some embodiments, lithium metal is coated on multiple interior surfaces of the housing, such as four or more (e.g., six) interior surfaces of the housing.

[0044] Method 300 also includes disposing an electrode (e.g., an anode) (block 306) within a housing. As previously described, multiple electrodes (e.g., anodes and cathodes, multiple anodes and multiple cathodes, etc.) may be employed, each of which is disposed within the housing. Furthermore, one or more spacers may be employed between adjacent electrode pairs (e.g., between each pair of anodes and cathodes). As previously described, one or more spacers may include apertures. Generally, apertures may be smaller than the perforations through the electrodes. For example, the cross-sectional width of each aperture may be smaller than the cross-sectional width of each perforation.

[0045] Method 300 further includes placing an electrolyte in the housing to initiate a pre-lithiation process (block 308), in which Li+ ions are transferred from lithium metal to an electrode (e.g., an anode) through perforations. In embodiments employing multiple anodes, Li+ ions are transferred to each anode. Perforations through the electrodes and pores in one or more separators allow the electrolyte and Li+ ions to move around the interior of the housing. For example, during the electrolyte aging portion of the pre-lithiation process, Li+ ions can be transferred from the lithium metal to the anode. The electrolyte aging portion of the pre-lithiation process may require, for example, less than one day or at most three days.

[0046] The embodiments disclosed herein employ pre-lithiation components and corresponding processes, wherein a lithium metal coating is provided on one or more internal surfaces of the housing (e.g., a battery housing) to improve local voltage uniformity, battery stability, battery performance and / or volumetric energy density relative to conventional constructions, and to reduce, eliminate and / or mitigate initial active lithium loss.

[0047] 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.

[0048] 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).

[0049] 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. In particular, personally identifiable information data should be managed and processed to minimize the risk of unintentional or unauthorized access or use, and the nature of authorized use should be clearly explained to users.

Claims

1. A battery pre-lithiation assembly, the battery pre-lithiation assembly comprising: case; An electrode is disposed in the housing and includes a current collector, an active material disposed on the current collector, and a perforation extending through the active material and the current collector; and A lithium metal coating is located on the inner surface of the housing, wherein the perforations are configured to allow Li+ ions to migrate from the lithium metal coating to the electrode via a pre-lithiation process when the housing receives an electrolyte.

2. The battery pre-lithiation assembly of claim 1, wherein the battery pre-lithiation assembly includes an additional electrode disposed in the housing and includes an additional current collector, an additional active material disposed on the additional current collector, and an additional perforation extending through the additional active material and the additional current collector, wherein the additional perforation is configured to allow Li+ ions to migrate from the lithium metal coating to the electrode via the pre-lithiation process when the housing receives the electrolyte.

3. The battery pre-lithiation assembly of claim 2, wherein the electrode comprises an anode and the additional electrode comprises a cathode.

4. The battery pre-lithiation assembly of claim 2, wherein the electrode is coupled to the housing, and the additional electrode is insulated from the housing.

5. The battery pre-lithiation assembly according to claim 2, wherein the battery pre-lithiation assembly includes a porous separator disposed between the electrode and the additional electrode.

6. The battery pre-lithiation assembly of claim 1, wherein the battery pre-lithiation assembly includes an additional lithium metal coating disposed on an additional internal surface of the housing.

7. The battery pre-lithiation assembly of claim 1, wherein the electrode includes an additional perforation extending laterally to the perforation.

8. A battery pre-lithiation assembly, the battery pre-lithiation assembly comprising: case; An anode is disposed in the housing, wherein the anode includes an anode current collector, an anode active material disposed on the anode current collector, and a first perforation extending through the anode current collector and the anode active material; A cathode is disposed in the housing, wherein the cathode includes a cathode current collector, a cathode active material disposed on the cathode current collector, and a second perforation extending through the cathode current collector and the cathode active material; and A lithium metal coating is located on the inner surface of the housing, wherein the first perforation and the second perforation are configured to allow Li+ ions to migrate from the lithium metal coating to the anode via a pre-lithiation process.

9. The battery pre-lithiation assembly of claim 8, wherein the anode is coupled to the housing and the cathode is coupled to a terminal insulated from the housing.

10. The battery pre-lithiation assembly of claim 8, wherein the battery pre-lithiation assembly includes an additional lithium metal coating on an additional internal surface of the housing.

11. The battery pre-lithiation assembly of claim 10, wherein the inner surface extends transversely to the additional inner surface.

12. The battery pre-lithiation assembly of claim 8, wherein the battery pre-lithiation assembly includes a porous separator extending between the anode and the cathode.

13. The battery pre-lithiation assembly according to claim 8, wherein: The anode current collector is disposed between the first anode active material portion and the second anode active material portion of the anode active material; The first perforation extends through the first anodic active material portion and the second anodic active material portion; The cathode current collector is disposed between the first cathode active material portion and the second cathode active material portion of the cathode active material; and The second perforation extends through the first cathode active material portion and the second cathode active material portion.

14. The battery pre-lithiation assembly of claim 8, wherein the battery pre-lithiation assembly includes an electrolyte disposed in the housing and configured to initiate the pre-lithiation process.

15. A method of manufacturing a battery, the method comprising: A perforation is provided through a current collector passing through the electrode and an active material of the electrode, wherein the active material is disposed on the current collector; The inner surface of the casing is coated with lithium metal; The electrode is disposed in the housing; as well as An electrolyte is placed in the housing to initiate a pre-lithiation process in which Li+ ions are transferred from the lithium metal to the electrode through the perforations.

16. The method of claim 15, wherein the method comprises: An additional perforation is provided through an additional current collector and an additional active material of the additional electrode, wherein the additional active material is disposed on the additional current collector; The additional electrode is disposed in the housing; as well as The electrolyte is disposed in the housing to initiate the pre-lithiation process, in which Li+ ions are transferred from the lithium metal to the electrode through the perforations and the additional perforations.

17. The method of claim 16, wherein the electrode is an anode and the additional electrode is a cathode.

18. The method of claim 16, wherein the method comprises providing a porous separator between the electrode and the additional electrode.

19. The method of claim 16, wherein the method comprises: Couple the electrodes to the housing; as well as The additional electrode is insulated from the housing.

20. The method of claim 15, wherein the method comprises coating an additional internal surface of the housing with additional lithium metal.

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