System and method for perforated jelly-roll battery

Abstract

Methods and systems for a perforated jellyroll battery are provided. In one example, the perforated jellyroll battery can include a perforated anode including an anode active material layer, an anode current collector, and an anode perforation, a perforated cathode including a cathode active material layer, a cathode current collector, and a cathode perforation, and a separator positioned between the perforated anode and the perforated cathode. The anode perforation and the cathode perforation are axially and radially aligned with respect to the jellyroll battery.

Description

Technical Field

[0001] This specification generally relates to systems and methods for perforated jelly roll batteries. Background Technology

[0002] Battery-powered systems can have battery packs comprising multiple battery cells connected in series and parallel. Alternatively, a single large-format battery cell configured to output the required current and voltage can be used. Because the cell size of a jelly roll battery is limited by the ability of the electrolyte to penetrate to the axial center of the jelly roll battery as the cell size increases, large-format battery cells can be configured in a stacked architecture rather than a jelly roll (e.g., wound) architecture. However, since winding is a faster manufacturing process than stacking, and the jelly roll architecture provides a direction for venting escaping gases, a jelly roll architecture can be chosen instead of a stacked architecture.

[0003] Attempts to address effective electrolyte distribution have included adding cuts or perforations to the separators of the battery cells or to any axial end of the jelly roll battery. Summary of the Invention

[0004] In one example, a perforated jelly roll battery is provided, comprising: a perforated anode including an anode active material layer, an anode current collector, and an anode perforation perpendicularly passing through the anode active material layer and the anode current collector relative to the axis of the unfolded perforated anode; a perforated cathode including a cathode active material layer, a cathode current collector, and a cathode perforation perpendicularly passing through the cathode active material layer and the cathode current collector relative to the axis of the unfolded perforated cathode; and a separator positioned between the perforated anode and the perforated cathode, wherein the anode perforation and the cathode perforation are radially and axially aligned relative to the axis of the perforated jelly roll battery. In this way, the axial length of the battery in the jelly roll architecture can be independent of the axial distribution of the electrolyte. By increasing the axial length, the energy storage capacity of a single jelly roll battery cell can be increased.

[0005] As an example, the cathode perforation is a mirror image of the anode perforation, and both the anode and cathode include multiple perforations laterally offset from each other. In this way, sufficient pathways are provided for the active material to radially penetrate the entire electrode for the electrolyte. Furthermore, the lateral offset can mitigate localized heating caused by interruptions in the current flow through the current collector.

[0006] It should be understood that the above description of the invention is provided to present a series of concepts further described in the detailed embodiments in a simplified form. This is not intended to identify key or essential features of the claimed subject matter, the scope of which is uniquely defined by the claims appended to the detailed embodiments. Furthermore, the claimed subject matter is not limited to embodiments that address any shortcomings mentioned above or in any part of this disclosure. Attached Figure Description

[0007] Figure 1 A diagram of a battery system including a prismatic battery casing and a jelly roll battery is shown.

[0008] Figure 2 Illustrations show conventional and large-format prior art jelly roll batteries.

[0009] Figure 3 An illustration shows a first example of a perforated jelly roll battery.

[0010] Figure 4 An illustration of a second example of a perforated jelly roll battery is shown.

[0011] Figure 5 An illustration of a third example of a perforated jelly roll battery is shown.

[0012] Figure 6 An illustration of a fourth example of a perforated jelly roll battery is shown.

[0013] Figure 7 An illustration of a fifth example of a perforated jelly roll battery is shown.

[0014] Figure 8 A flowchart illustrating an example of a method for forming a perforated jelly roll battery is shown.

[0015] Figure 9 A diagram illustrating a roll-to-roll manufacturing process for forming jelly roll batteries is shown.

[0016] Figure 10 A cross-section is shown of perforated anodes stacked on perforated cathodes to form a perforated jelly roll battery. Detailed Implementation

[0017] The following description relates to systems and methods for perforated jelly roll battery architectures. Due to the perforations, the jelly roll battery can be a large-format jelly roll battery. A single large-format jelly roll battery architecture can be included in a prismatic battery housing (such as... Figure 1(as shown in the casing). Including a single large-format jelly roll battery in a prismatic battery casing may be superior to multiple conventional-sized jelly roll batteries. Large-format jelly roll batteries may be longer axially than conventional jelly roll batteries. In the prior art, increasing the axial length of the jelly roll battery may result in unwetted portions of the battery, such as... Figure 2 As shown. By providing perforations in the current collectors and electrodes at both the anode and cathode, radial paths for electrolyte permeation into the jelly roll battery can be introduced, thereby enabling large-format jelly roll batteries, such as those that can be included in... Figure 1 A jelly roll battery in a prismatic battery casing. Figures 3 to 7 An example of a perforated electrode and the resulting perforated jelly roll battery is shown. Figure 8 The diagram shows the method for forming Figures 3 to 7 The flowchart illustrates an example of a method for manufacturing a perforated jelly roll battery. The perforated jelly roll battery can be manufactured via a roll-to-roll process, such as... Figure 9 As shown. Figure 10 The illustration in the diagram shows as Figure 8 An example of a perforated cathode stacked on a perforated anode as part of the manufacturing process described herein.

[0018] Turn now Figure 1 It illustrates a battery system 101 including a prismatic battery casing 100. Reference axes 102, including x, y, and z axes, are provided for comparison. Figures 1 to 7 as well as Figures 9 to 10 The diagram illustrates this. The y-axis can be parallel to the longitudinal direction relative to the battery casing and the unfolded battery electrodes (e.g., anode and cathode), and can also be parallel to the axial direction of the jelly roll battery. The x-axis can be parallel to the transverse direction relative to the battery casing and the unfolded battery electrodes, and can also be parallel to the radial direction of the jelly roll battery. The z-axis can be parallel to the vertical direction relative to the battery casing and the battery electrodes, and can also be parallel to the radial direction of the jelly roll battery.

[0019] The prismatic battery housing 100 can be formed as a rectangular prism having a longitudinal length 104, a transverse length 106, and a height 108. The transverse length 106 can be shorter than the longitudinal length 104, and the height 108 can be shorter than both the longitudinal length 104 and the transverse length 106. In one example, the longitudinal length 104 can be ≥300 mm, the transverse length 106 can be in the range of 9 mm to 120 mm, and the height 108 can be in the range of 15 mm to 30 mm. As another example, the longitudinal length 104 can be 590 mm, the transverse length 106 can be 105 mm, and the height 108 can be 15.5 mm. The prismatic battery housing may include terminals 110 configured to electrically connect the prismatic battery housing 100 to a load. In one example, the load can be a vehicle including a motor powered by a jelly roll battery 112 positioned within the prismatic battery housing 100. The terminals 110 can be positioned on the transverse side 114 of the prismatic battery housing 100. The lateral side 114 can be the smallest face of the prismatic battery casing 100.

[0020] The jelly roll battery 112 can be a single battery cell positioned within a prismatic battery casing 100. The jelly roll battery 112 can be formed from vertically stacked anodes, separators, and cathodes spirally wound around an axis 116. The outer surface 124 of the jelly roll battery 112 can be a current collector for the anode or cathode. The radial cross-section of the jelly roll battery 112 can include repeating layers of cathode current collectors, cathode active material, separators, anode active material, and anode current collectors. The current collector can be formed from metal foil.

[0021] The jelly roll battery 112 can be formed as an elliptical cylinder. The jelly roll battery 112 can have an axial length of 118, the major axis of the elliptical cross-section can be parallel to the transverse direction and can be 120, and the minor axis of the elliptical cross-section can be parallel to the vertical direction and can be 122. To ensure that the capacity of the jelly roll battery 112 meets the required energy output of the load, the size of the jelly roll battery 112 can be selected to provide sufficient electroactive material to achieve the target capacity. To increase the amount of electroactive material, the size of the jelly roll battery can be increased. The lengths 120 and 122 may be limited by the desired shape factor of the prismatic battery casing 100. For this reason, the axial length 118 of the jelly roll battery 112 is increased to provide a large-format jelly roll battery. In one example, the axial length of the large-format jelly roll battery can be greater than 300 mm. In another example, the axial length of the large-format jelly roll battery can be greater than 600 mm. The large-format jelly roll battery can have a higher theoretical capacity than a conventional jelly roll battery. As an example, large-format jelly roll batteries can have a theoretical capacity ranging from 110 Ah to 250 Ah and can store energy ranging from 350 Wh to 800 Wh. As another example, large-format jelly roll batteries can have a theoretical capacity greater than or equal to 126 Ah and can store 407 Wh of energy.

[0022] The electrolyte required for the operation of the lithium-ion battery can be positioned within the prismatic battery housing 100 along with the jelly roll battery 112. Conventionally, the electrolyte can permeate into the jelly roll battery 112 via capillary action through the axial ends of the jelly roll battery 112 defined by an elliptical cross-section of minor axis 122 and major axis 120, rather than through the outer surface 124, because the current collector is an impermeable metal foil, thus limiting the axial length of a conventional jelly roll battery. The jelly roll battery 112 can be a perforated jelly roll battery, with perforations providing additional channels for electrolyte permeation, resulting in a large-format perforated jelly roll battery with no bare spots where electrolyte is not reached.

[0023] about Figure 2 The illustration further illustrates the limitations of conventional jelly roll batteries. Figure 2A conventional anode 202 and a conventional cathode 204 are shown. The conventional anode 202 may include an anode current collector 206. An anode active material layer 208 may be positioned in coplanar contact with the surface of the anode current collector 206. The anode active material layer 208 may include an anode active material capable of intercalating and deintercalating lithium ions. The anode active material layer 208 may be deposited onto the surface of the anode current collector 206, thereby leaving a portion of a bare anode current collector at the longitudinal end of the conventional anode 202. The conventional cathode 204 may include a cathode current collector 212. A cathode active material layer 210 may be positioned in coplanar contact with the surface of the cathode current collector 212. The cathode active material layer 210 may include a cathode active material layer having lithium ions and capable of intercalating and deintercalating lithium ions. The cathode active material layer 210 may be deposited onto the surface of the cathode current collector 212, thereby leaving a portion of a bare cathode current collector at the longitudinal end of the conventional cathode 204. The exposed portions of the anode current collector 206 and the cathode current collector 212 can be used to electrically connect the jelly roll battery to terminals, such as... Figure 1 Terminal 110.

[0024] A jelly roll battery (such as a conventional jelly roll battery 214) can be formed by stacking a conventional anode 202 and a conventional cathode 204 (with the anode active material layer 208 facing the cathode active material layer 210) and a separator layer positioned therebetween. The separator can be an electrically insulating porous membrane that allows the electrolyte and lithium ions to pass through. The conventional anode 202 and conventional cathode 204 can be positioned such that the exposed portions of their respective current collectors are longitudinally opposite each other. The stack can be helically wound relative to the conventional anode 202 and conventional cathode 204 in a transverse direction (e.g., parallel to the x-axis) to form the conventional jelly roll battery 214. The longitudinal length 218 of the conventional anode 202 and conventional cathode 204 can be equal to the longitudinal length of the resulting jelly roll battery.

[0025] The longitudinal length 218 can be the axial length of a conventional jelly roll battery 214. Although the outer surface of a jelly roll battery, such as a conventional jelly roll battery 214, is formed by a current collector, it is shown... Figures 2 to 5 The image shows a jelly roll battery, illustrating the permeation of electrolyte 216 through the jelly roll battery. The electrolyte can permeate into a conventional jelly roll battery 214 along the axial direction indicated by arrow 224. The longitudinal length 218 of the conventional jelly roll battery 214 can be short enough that the electrolyte 216 permeates through the entire axial length of the conventional jelly roll battery 214.

[0026] Figure 2An example of a conventional large-format jelly roll battery 226 is also shown. The conventional large-format jelly roll battery 226 can be formed by increasing the length 218 to a large-format length 220. The large-format length 220 can be greater than 300 mm. In some examples, the large-format length can be greater than 600 mm. The conventional large-format jelly roll battery 226 may be limited to the axial diffusion of the electrolyte, as indicated by arrow 224. For this reason, the conventional large-format jelly roll battery 226 may include an electrolyte 216 permeated into the axial ends, and an electrolyte-free segment 222 may exist in the axial central portion. The electrolyte-free segment 222 may not be able to transport ions and may not contribute to the battery's capacity. For this reason, the conventional large-format jelly roll battery may not be suitable for a single-cell battery system (such as...). Figure 1 The battery system 101) provides the required capacity.

[0027] To prevent the presence of electrolyte-free sections (such as electrolyte-free section 222), perforated anodes and cathodes can be used to form a perforated jelly roll battery. In addition to the conventional axial direction, the perforations also provide openings for the electrolyte to penetrate radially through the wound jelly roll structure. In this way, efficient roll-to-roll manufacturing and directional venting provided by the jelly roll architecture can be maintained, while providing an increase in capacity over a large area.

[0028] Figures 3 to 7 An example of a perforated anode and cathode, and the resulting perforated jelly roll battery, is shown. The perforated anode and cathode may include components as described above. Figure 2 The components described are similar to those of conventional anodes and cathodes. Such components are similarly labeled and will not be repeated. The anode perforation can be formed as a longitudinal mirror image of the cathode perforation (e.g., mirror image across the yz plane) relative to the unfolded perforated anode and cathode. In this way, when forming a perforated jelly roll battery, the anode perforation can be radially and axially aligned with the cathode perforation relative to the wound perforated jelly roll battery, thereby providing a continuous radial path for electrolyte permeation.

[0029] Turn now Figure 3 This illustrates a first example of a perforated anode 302 and a perforated cathode 304. The perforated anode 302 and perforated cathode 304 can each be examples of a large-format anode and cathode, and can have the features described above. Figure 2 The described lateral length is 220. The perforated anode 302 may include an anode current collector 206 and an anode active material layer 208. The perforated anode 302 may also include a lateral anode perforation 306. The lateral anode perforation 306 may be formed as an intermittent slit extending vertically relative to the unfolded perforated anode through both the anode active material layer 208 and the anode current collector 206. Anode perforation (including lateral anode perforation and in...) Figures 4 to 7Other anode perforations described herein can extend linearly from a first longitudinal edge of the perforated anode 302 to a second longitudinal edge of the perforated anode 302 across the x-axis opposite to the first longitudinal edge. Rows of lateral anode perforations 306 can be parallel to the lateral edges of the perforated anode 302. The lateral anode perforations 306 can have a length 310 and can be spaced apart by a distance 312. In some examples, the length 310 can be in the range of 1 mm to 50 mm. The longitudinal width of the lateral anode perforations 306 (e.g., along the y-axis) can be ≤1 mm. In some examples, the distance 312 can be in the range of 1 mm to 50 mm. In one example, the lateral anode perforations 306 can be longitudinally equidistant from the lateral edges of the anode active material layer 208. In alternative examples, the lateral anode perforations 306 can include multiple rows of perforations, each row extending linearly from the first longitudinal edge to the second longitudinal edge. In examples where the lateral anode perforations include multiple rows, the multiple rows can be longitudinally distributed uniformly or non-uniformly across the anode active material layer 208.

[0030] The perforated cathode 304 may include a cathode current collector 212 and a cathode active material layer 210. The perforated cathode 304 may also include a lateral cathode perforation 308. The cathode perforations described herein (including lateral cathode perforations 308 and...) Figures 4 to 7 Other cathode perforations described herein can be longitudinal mirror images of the corresponding anode perforations across the yz plane. For example, a transverse cathode perforation 308 can be a longitudinal mirror image of a transverse anode perforation 306 across the yz plane and can extend vertically through both the cathode active material layer 210 and the cathode current collector 212. The dimensions of the transverse cathode perforation 308 (e.g., transverse length, longitudinal width, and spacing) can be substantially the same as the dimensions of the anode perforation 306 (e.g., within + / - 5%). The amount and longitudinal positioning of the transverse cathode perforation 308 can be substantially the same as the amount and longitudinal positioning of the transverse anode perforation 306. In this way, when the perforated anode 302 and the perforated cathode 304 are stacked, the transverse cathode perforation 308 can be vertically positioned in line with the corresponding transverse anode perforation.

[0031] As described above, stacking and rolling the perforated anode 302 and perforated cathode 304 together with a separator can produce a perforated jelly roll battery 314. The lateral anode perforations 306 and lateral cathode perforations 308 can be aligned axially and radially. When the perforated jelly roll battery 314 is placed in a housing containing an electrolyte, in addition to axial permeation, the electrolyte can also radially permeate into the perforated jelly roll battery 314 through the anode and cathode perforations in the direction indicated by arrow 316. For this reason, even if the perforated jelly roll battery 314 is a large-format jelly roll battery with a length 220 greater than or equal to 300 mm, the electrolyte 216 can be present throughout the perforated jelly roll battery 314 without any anode or cathode active material layer having an electrolyte-free section. In an alternative example, the length 220 can be greater than or equal to 600 mm.

[0032] Turn now Figure 4 A second example of a perforated anode 402 and a second example of a perforated cathode 404 are shown. The second examples of the perforated anode 402 and perforated cathode 404 may respectively include a diagonal anode perforation 406 and a diagonal cathode perforation 408. The diagonal anode perforation 406 may include slits formed at an inward staggered angle relative to the longitudinal edge of the anode to form a zigzag pattern. The diagonal anode perforation 406 may extend laterally from a first longitudinal edge of the anode active material layer 208 to a second longitudinal edge of the anode active material layer 208. The diagonal anode perforation 406 may include slits having a length 410 and spaced apart by a distance 412. In one example, the length 410 may be in the range of 1 mm to 50 mm. The longitudinal width of the diagonal anode perforation 406 (e.g., along the y-axis) may be ≤1 mm. The distance 412 may be in the range of 1 mm to 50 mm. In some examples, the diagonal anode perforation 406 may include a single zigzag perforation starting in the longitudinal middle of the anode active material layer 208. In an alternative example, the diagonal anode perforations 406 may include a plurality of zigzags extending between the longitudinal edges of the anode active material layer 208. The plurality of zigzags may be longitudinally spaced uniformly or non-uniformly across the anode active material layer 208.

[0033] A second example of a perforated cathode 404 may include a diagonal cathode perforation 408. The diagonal cathode perforation 408 may be a longitudinal mirror image of the diagonal anode perforation 406 across the yz plane. In this way, when the perforated anode 402 is stacked on the perforated cathode 404 (with the anode active material layer 208 facing the cathode active material layer 210) and a spacer is positioned therebetween, the diagonal anode perforation 406 and the diagonal cathode perforation 408 can be aligned laterally and longitudinally.

[0034] The second perforated anode 402 and the second perforated cathode 404 can be used to form the second perforated jelly roll battery 414. When the second perforated jelly roll battery 414 is placed within a housing including an electrolyte 216, the electrolyte 216 can penetrate axially into the second perforated jelly roll battery as shown by arrow 224 and radially as shown by arrow 416. The radial penetration of the electrolyte can be achieved through diagonal anode perforations 406 and diagonal cathode perforations 408. In this way, the electrolyte 216 can permeate the entire active material layer of the second perforated jelly roll battery 414, even if the second perforated jelly roll battery 414 may be an example of a large-format battery with an axial length greater than or equal to 300 mm or greater than or equal to 600 mm.

[0035] Turn now Figure 5 A third example of a perforated anode 502 and a third example of a perforated cathode 504 are shown. The third examples of perforated anode 502 and perforated cathode 504 may respectively include variable-spaced anode perforations 506 and variable-spaced cathode perforations 508. The variable-spaced anode perforations 506 may include a plurality of laterally extending perforations, each laterally extending perforation including a perforation of length 510 intermittently spaced between a first distance 512 and a second distance 514. In some examples, the length 510 may be in the range of 1 mm to 50 mm. The longitudinal width (e.g., along the y-axis) of the variable-spaced anode perforations may be ≤1 mm. In one example, the first distance 512 and the second distance 514 may each be in the range of 1 mm to 50 mm. In some examples, the first distance 512 may be shorter than the second distance 514. Adjacent laterally extending perforations may be offset from each other in the lateral direction. Each of the laterally extending perforations may be substantially identical to the adjacent laterally extending perforation. In this way, the first and second distances are staggered in the longitudinal direction and do not completely overlap. Placing the perforations in this manner helps mitigate potential localized heating and increased cell resistance due to interruptions in current flow through the current collector to the battery system terminals. In one example, the plurality of laterally extending perforations may include three laterally extending perforations, but other numbers of laterally extending perforations can be used. The plurality of laterally extending protrusions may be uniformly longitudinally spaced across the anode active material layer 208. In alternative examples, the longitudinal spacing between the plurality of laterally extending perforations may be unequal.

[0036] The third perforated cathode 504 may include variable-spaced cathode perforations 508. The dimensions of the variable-spaced cathode perforations 508 may be substantially the same as those of the variable-spaced anode perforations 506 mirrored across the y-axis. In this way, when the third perforated cathode 504 and the third perforated anode 502 are stacked (with the anode active material layer 208 facing the cathode active material layer 210), the variable-spaced anode perforations and the variable-spaced cathode perforations can be aligned in both the lateral and longitudinal directions. In this way, when spirally wound to form the third perforated jelly roll battery 516, radial pathways for the electrolyte are formed.

[0037] The third perforated anode 502 and the third perforated cathode 504 can be used to form the third perforated jelly roll battery 516. When the third perforated jelly roll battery 516 is placed within a housing including an electrolyte 216, the electrolyte 216 can penetrate axially into the second perforated jelly roll battery as shown by arrow 224 and radially as shown by arrow 518. The radial penetration of the electrolyte can be achieved through the variablely spaced anode perforations 506 and the variablely spaced cathode perforations 508. In this way, the electrolyte 216 can permeate the entire active material layer of the third perforated jelly roll battery 516, even if the third perforated jelly roll battery 516 is an example of a large-format battery with an axial length greater than or equal to 300 mm. In some examples, the axial length of the large-format battery can be greater than or equal to 600 mm. The lateral offset of the variablely spaced anode perforations 506 and the variablely spaced cathode perforations 508 can help mitigate localized temperature rises and increases in cell resistivity due to partial interruptions in axial current flow during operation of the battery system.

[0038] Turn now Figure 6 An example of a fourth perforated anode 602 and a fourth perforated cathode 604 is shown. The fourth perforated anode 602 and the fourth perforated cathode 604 may include a coating 606 covering both the perforations of the fourth perforated anode 602 and the fourth perforated cathode 604. In some examples, the coated perforations may be lateral anode perforations 306 and lateral cathode perforations 308. In alternative examples, perforations of other patterns, such as..., may be covered by the coating 606. Figures 3 to 5The coating can be applied to one or more of the anolyte active material layer 208 and the cathode active material layer 210, as shown. Alternatively, the coating can be applied to the perforations and to the anode current collector 206 and / or the cathode current collector 212. The coating 606 can cover and penetrate into the slits of the transverse anode perforation 306 and the transverse cathode perforation 308. The coating 606 can cover a continuous rectangular area where the anode or cathode perforation is approximately centered. In one example, the longitudinal width 607 of the coating 606 can be less than the longitudinal width of the anolyte active material layer 208. In an alternative example, the longitudinal width 607 can be equal to the longitudinal width of the anolyte active material layer 208 and less than the length 220.

[0039] Coating 606 may be electrolyte-permeable and conductive. In some examples, coating 606 may be formed from one or more of an electroactive material, a conductive agent, and a binder. The electroactive material may include one or more of a metal oxide and iron phosphate. In some examples, the metal oxide may be a lithium metal oxide (e.g., lithium nickel manganese cobalt oxide), and the iron phosphate may be lithium iron phosphate. The conductive agent may be one or more of, for example, carbon black, carbon nanotubes, and polyvinylidene fluoride (PVDF). In one example, the binder forming coating 606 may include one or more of a carboxymethyl cellulose (CMC) binder and a styrene-butadiene rubber (SBR) binder.

[0040] The fourth perforated anode 602 and the fourth perforated cathode 604 can be assembled into a fourth perforated jelly roll battery 608. When the fourth perforated jelly roll battery 608 is placed within a housing including an electrolyte 216, the electrolyte 216 can penetrate axially into the fourth perforated jelly roll battery 608 as shown by arrow 224 and radially as shown by arrow 610. The coating 606 can be electrolyte-permeable and may not prevent the electrolyte from radially permeating through the perforations. In this way, the length 220 of the fourth perforated jelly roll battery 608 can be greater than or equal to 300 mm and can be greater than or equal to 600 mm.

[0041] Turn now Figure 7 An example of a fifth perforated anode 702 and a fifth perforated cathode 704 is shown. The fifth perforated anode 702 and the fifth perforated cathode 704 may respectively include an anode die-cut perforation 706 and a cathode die-cut perforation 708. The die-cut perforations (such as the anode die-cut perforation 706 and the cathode die-cut perforation 708) can be formed into shapes having a certain length and a considerably large width, which is consistent with... Figures 3 to 5The perforation described herein is the opposite of a slit of a certain length. In one example, the die-cut perforation may be circular, with a diameter ranging from 1 mm to 10 mm. In one example, the die-cut perforation may include multiple laterally extending rows of die-cut perforations. In alternative examples, the die-cut perforations may be positioned in other patterns, such as... Figures 3 to 5 The perforation pattern is shown. In some examples, the fifth perforated anode 702 and / or the fifth perforated cathode 704 may include a coating, such as those described above. Figure 6 The coating 606 is described. The cathode die-cut perforation 708 can be positioned as a mirror image of the anode die-cut perforation 706 across the yz plane.

[0042] The fifth perforated anode 702 and the fifth perforated cathode 704 can be assembled into a fifth perforated jelly roll battery 710. When the fifth perforated jelly roll battery 710 is placed within a housing including an electrolyte 216, the electrolyte 216 can penetrate axially into the fifth perforated jelly roll battery 710 as shown by arrow 224 and radially as shown by arrow 712. The anode die-cut perforation 706 and the cathode die-cut perforation 708 can be aligned radially and axially within the fifth perforated jelly roll battery 710 to facilitate radial penetration of the electrolyte throughout the fifth perforated jelly roll battery 710. In this way, the length 220 of the fifth perforated jelly roll battery 710 can be greater than or equal to 300 mm and can be greater than or equal to 600 mm.

[0043] Turn now Figure 8 An example of a method 800 for forming a battery system including a perforated jelly roll battery is shown. The perforated jelly roll battery can be as described above regarding... Figures 3 to 7 One or more of the first to fifth roll-to-roll batteries described. At 802, method 800 includes coating anode and cathode active materials onto respective current collectors using dry coating and / or wet (e.g., slurry) coating processes. In this document, electrodes may refer to anodes and / or cathodes. In a dry coating process, coating may include first blending conductive particles (e.g., activated carbon), electroactive particles, and a binder together, applying shear force and feeding the blend onto the current collector, calendering the electrodes (e.g., anodes and cathodes), and bonding the materials to the current collector. In a wet coating process, coating may include blending or mixing electroactive materials, conductive particles, a binder, and a solvent together to form a slurry, coating the slurry onto the current collector, and calendering the coating. In one example, slitting and coating may be performed in a roll-to-roll process.

[0044] At 804, method 800 optionally includes slitting the anode and cathode. Slitting can be performed when the cathode and / or anode active material is coated using a wet coating process. Slitting can be performed in a roll-to-roll process. Slitting applies a cut to the transverse center of the electrode to divide the electrode in half, resulting in two electrode rolls being formed from a single electrode roll.

[0045] At 806, method 800 includes perforating the anode and cathode. In one example, perforation may be performed as part of a roll-to-roll manufacturing process. For example, perforation may include passing the electrode through a cutter roller. The cutter roller may cut slits through the anode and / or cathode. The slits may penetrate through the electrode active material layer and through the current collector. The slits cut by the cutter roller may be of a certain length and spaced apart based on the pattern of the cutters on the cutter roller. In an alternative example, perforation may include passing the electrode through a die-cutting machine. The die-cutting machine may cut shapes of a certain length and width and spaced apart based on the pattern of the punches on the die-cutting machine. In one example, the die-cutting machine may cut circular holes in the electrode.

[0046] At 807, method 800 includes optionally applying a conductive coating to the anodic and / or cathodic vias. The conductive coating may be as described above regarding Figure 6 The described coating may be conductive and electrolyte-permeable. In one example, the conductive coating may include one or more of an electroactive material, a conductive agent, and a binder.

[0047] Briefly turn Figure 9 An example of slitting and perforation in a roll-to-roll process is shown. A first roll 902 may include a coated but unslit electrode 904. The coated but unslit electrode 904 can be unwound from the first roll 902 and fed through a slitter 906. The slitter 906 may be a blade configured to slit and not slit the coated electrode 904 along a transverse central axis to form two coated and slit electrodes 908. Each of the coated and slit electrodes 908 can pass through a roll-to-roll perforator 910. The roll-to-roll perforator 910 may each include a vertically stacked top roller 910a and a bottom roller 910b. The coated and slit electrode 908 can pass between the top roller 910a and the bottom roller 910b. In one example, the roll-to-roll perforator 910 may be a cutter roller, and the top roller 910a may include a cutter configured to cut slits in the coated and slit electrodes. In an alternative example, the roll-to-roll piercing machine 910 may be a die-cutting machine, and the top roller 910a may include a punch configured to cut circular or other shaped holes in the coated and serrated electrode 908. After passing through the roll-to-roll piercing machine, the pierced electrode 912 may be wound onto a second roll 914.

[0048] Now return to Figure 8 At point 808, method 800 includes stacking a perforated anode and a perforated cathode, and aligning the anode perforations laterally and longitudinally with the cathode perforations. The stacking may further include positioning a spacer between the perforated anode and the perforated cathode. In the stack, the anode active material layer and the cathode active material layer may face each other across the spacer. Since the cathode perforation is a longitudinal mirror image of the anode perforation, each anode perforation may be aligned laterally and longitudinally with the cathode perforation.

[0049] Briefly turn Figure 10 The image shows a cross-sectional view of the perforated anode 1002 stacked on the perforated cathode 1004 before winding. The perforated anode 1002 and the perforated cathode 1004 can be... Figures 3 to 7 Examples of any of the first to fifth examples shown. The perforated anode may include an anode active material layer 1006, an anode current collector 1008, and an anode perforation 1010. The perforated cathode 1004 may include a cathode active material layer 1012, a cathode current collector 1014, and a cathode perforation 1016. The perforated anode 1002 and the perforated cathode 1004 may be separated by a separator 1018 positioned between the perforated anode 1002 and the perforated cathode 1004. The cathode perforation 1016 and the anode perforation 1010 may be aligned to provide an efficient radial pathway for the electrolyte through the jelly roll battery during winding.

[0050] Now return to Figure 8 At 810, method 800 includes winding a stacked perforated anode and a perforated cathode to form a perforated jelly roll battery. Winding may include winding along the transverse axis of the stacked perforated electrodes, such that extended current collectors are positioned at opposite axial ends of the perforated jelly roll battery, as... Figures 3 to 7 As shown.

[0051] At 812, method 800 includes encapsulating a perforated jelly roll battery together with an electrolyte within a prismatic battery casing. The electrolyte can penetrate axially and radially into the jelly roll battery. Radial penetration of the electrolyte can be achieved through aligned perforations at the cathode and anode. In this way, the electrolyte can permeate throughout the entire perforated jelly roll battery and may not leave any points of electrode active material that are not in contact with the electrolyte.

[0052] In this way, perforated large-format jelly roll batteries can be formed with increased usable power and cycle life compared to unperforated large-format jelly roll batteries (which may include bare points of electrode active material not in contact with the electrolyte). Perforated large-format jelly roll batteries can be used as individual cell cells in a battery system, simplifying the system and eliminating the need for complex balancing of charging and discharging between cells. Furthermore, large-format jelly roll batteries can be manufactured faster than stacked electrode battery architectures while still achieving the desired power output of a single cell. The size and relative positioning of the perforations can be selected to provide sufficient electrolyte penetration without resulting in a significant increase in cell resistance, localized heating in the perforated areas, and temperature gradients across the jelly roll battery.

[0053] The technical effect of perforating the anode and cathode as described in method 800 is to form a perforated jelly roll battery. Compared to conventional jelly roll batteries without perforations, perforated jelly roll batteries have the aforementioned advantages regarding increased electrolyte penetration. Increased electrolyte penetration allows large-format jelly roll batteries to have electrolyte-free regions without anode and cathode active materials. Furthermore, the positioning and optional coating of the perforations can help mitigate localized heating and an increase in overall cell resistivity caused by interruptions in current flow through the current collector.

[0054] As described herein, various problems with roll-up batteries, rather than double-layer capacitors, can be solved. As an example, a battery can have both an anode layer on the anode current collector and a cathode layer on the cathode current collector, rolled together in a roll-up battery architecture, thus requiring different but complementary notching patterns not considered for use in double-layer capacitors, which consist only of a single double-coated current collector. Furthermore, a lack of consideration for localized heating and current flow interruption due to current collector punctures may occur. As explained herein, these and other problems are solved at least in part by the described methods, including the following:

[0055] As one embodiment, this disclosure also provides support for a perforated jelly roll battery, the perforated jelly roll battery comprising: a perforated anode including an anode active material layer, an anode current collector, and an anode perforation perpendicularly passing through the anode active material layer and the anode current collector relative to the axis of the unfolded perforated anode; a perforated cathode including a cathode active material layer, a cathode current collector, and a cathode perforation perpendicularly passing through the cathode active material layer and the cathode current collector relative to the axis of the unfolded perforated cathode; and a separator positioned between the perforated anode and the perforated cathode, wherein the anode perforation and the cathode perforation are radially and axially aligned relative to the axis of the perforated jelly roll battery. In a first example of the system, the anode perforation and the cathode perforation each include a plurality of perforations extending laterally relative to the unfolded perforated anode and cathode. In a second example of the system optionally including the first example, the spacing between the plurality of perforations is laterally offset relative to the unfolded perforated anode and cathode. In a third example, which optionally includes one or both of the first and second examples, the perforated jelly roll battery is a large-format jelly roll battery, and the axial length of the perforated jelly roll battery is greater than or equal to 300 mm. In a fourth example, which optionally includes one or more of the first to third examples, the anode and cathode perforations are coated. In a fifth example, which optionally includes one or more of the first to fourth examples, the anode and cathode perforations are circular. In a sixth example, which optionally includes one or more of the first to fifth examples, the cathode perforation is a longitudinal mirror image of the anode perforation relative to the unfolded perforated anode and cathode.

[0056] This disclosure also provides support for a method for forming a perforated jelly roll battery, the method comprising: perforating an anode in a roll-to-roll process, the anode comprising an anode active material layer deposited on an anode current collector, wherein the perforation penetrates both the anode active material layer and the anode current collector to form an anode perforation; perforating a cathode in the roll-to-roll process, the cathode comprising a cathode active material layer deposited on a cathode current collector, wherein the cathode perforation penetrates both the cathode active material layer and the cathode current collector to form a cathode perforation; stacking the perforated anode and perforated cathode, wherein stacking includes aligning the anode perforation and cathode perforation laterally and longitudinally relative to the perforated anode and cathode; and winding the stacked perforated anode and cathode to form the perforated jelly roll battery. In a first example of the method, the method further comprises: encapsulating the perforated jelly roll battery in a prismatic battery housing, wherein the prismatic battery housing comprises an electrolyte. In a second example, which optionally includes the first example, the electrolyte permeates the perforated jelly roll battery in both the axial and radial directions relative to the perforated jelly roll battery through the cathode perforation and the anode perforation. In a third example, which optionally includes one or both of the first and second examples, the method further includes applying a coating to the anode and cathode perforations prior to stacking, wherein the coating is formed of one or more of an electroactive material, a conductive agent, and a binder. In a fourth example, which optionally includes one or more of the first to third examples, or each of them, perforating the anode and / or perforating the cathode includes passing the anode and / or cathode through a cutter roller. In a fifth example, which optionally includes one or more of the first to fourth examples, or each of them, the method further includes slitting the anode and / or cathode prior to perforating them. In a sixth example, which optionally includes one or more of the first to fifth examples or each of the methods, perforating the anode and / or perforating the cathode includes passing the anode and / or cathode through a die-cutting machine.

[0057] This disclosure also provides support for a battery system comprising: a prismatic battery housing; a perforated jelly roll battery positioned within the prismatic battery housing, wherein the perforated jelly roll battery comprises: a perforated anode, the perforated anode including an anode current collector, an anode active material layer, and an anode perforation extending through the anode current collector and the anode active material layer; and a perforated cathode, the perforated cathode including a cathode current collector, a cathode active material layer, and a cathode perforation extending through the cathode current collector and the cathode material layer, and wherein the perforated anode includes an anode perforation radially and axially aligned with the cathode perforation of the perforated cathode relative to the perforated jelly roll battery; and an electrolyte, wherein the electrolyte is distributed throughout the anode active material layer and the cathode material layer. In a first example of the system, the axial length of the perforated jelly roll battery is greater than or equal to 300 mm. In a second example of the system, optionally including the first example, the axial length of the perforated jelly roll battery is greater than or equal to 600 mm. In a third example, which optionally includes one or both of the first and second examples, the prismatic battery housing includes terminals positioned on the smallest facet of the prismatic battery housing. In a fourth example, which optionally includes one or more of the first to third examples, the perforated anode and perforated cathode further include a permeable and conductive coating. In a fifth example, which optionally includes one or more of the first to fourth examples, the lateral lengths of the anode and cathode perforations are in the range of 1 mm to 50 mm and are spaced apart by a distance in the range of 1 mm to 50 mm. As used herein, unless otherwise specified, the term "about" is interpreted as indicating ±5% of a range.

[0058] Figures 1 to 7 and Figures 9 to 10Exemplary configurations with the relative positioning of various components are shown. In at least one example, such components may be referred to as directly contacting or directly connected if shown to be in direct contact or directly connected. Similarly, in at least one example, components shown to be adjacent or adjacent to each other may be adjacent or adjacent to each other. As an example, components that are in coplanar contact with each other may be referred to as coplanar contact. As another example, in at least one example, components positioned apart from each other with only space between them and no other components may be referred to as such. As yet another example, components shown to be above / below each other, on opposite sides of each other, or to the left / right of each other may be referred to as such relative to each other. Furthermore, as shown in the figures, in at least one example, the topmost component or the apex of a component may be referred to as the “top” of the component, and the bottommost component or the lowest point of a component may be referred to as the “bottom” of the component. As used herein, top / bottom, upper / lower, above / below may be relative to the vertical axis of the figures and are used to describe the positioning of the components of the figures relative to each other. Thus, in one example, an component shown above other components is located directly above the other components. As another example, the shapes of the elements depicted in the accompanying drawings may be described as having those shapes (e.g., such as circular, straight, planar, curved, rounded, chamfered, angled, etc.). Furthermore, in at least one example, elements shown as intersecting each other may be described as intersecting elements or intersecting one another. Further still, in one example, an element shown as being inside another element or outside another element may be described as such.

[0059] The appended claims specifically point to certain combinations and sub-combinations that are considered novel and non-obvious. These claims may refer to an “a” element or a “first” element or its equivalent. Such claims should be understood to include combinations of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and sub-combinations of the disclosed features, functions, elements, and / or properties may be claimed by amending these claims or by setting new claims in this application or related applications. Such claims, whether broader, narrower, equivalent, or different in scope from the original claims, are also considered to be included within the subject matter of this disclosure.

[0060] According to the present invention, a perforated jelly roll battery is provided, comprising: a perforated anode, the perforated anode including an anode active material layer, an anode current collector, and an anode perforation perpendicularly passing through the anode active material layer and the anode current collector relative to the axis of the unfolded perforated anode; a perforated cathode, the perforated cathode including a cathode active material layer, a cathode current collector, and a cathode perforation perpendicularly passing through the cathode active material layer and the cathode current collector relative to the axis of the unfolded perforated cathode; and a separator positioned between the perforated anode and the perforated cathode, wherein the anode perforation and the cathode perforation are radially and axially aligned relative to the axis of the perforated jelly roll battery.

[0061] According to an embodiment, the anode perforation and the cathode perforation each include a plurality of perforations extending laterally relative to the unfolded perforated anode and cathode.

[0062] According to an embodiment, the spacing between the plurality of perforations is offset from each other laterally relative to the unfolded perforated anode and cathode.

[0063] According to an embodiment, the perforated jelly roll battery is a large-format jelly roll battery, and the axial length of the perforated jelly roll battery is greater than or equal to 300 mm.

[0064] According to an embodiment, the anodic and cathodic perforations are coated.

[0065] According to an embodiment, the anode and cathode perforations are circular.

[0066] According to an embodiment, the cathode perforation is a longitudinal mirror image of the anode perforation relative to the unfolded perforated anode and cathode.

[0067] According to the present invention, a method for forming a perforated jelly roll battery includes: perforating an anode in a roll-to-roll process, the anode comprising an anode active material layer deposited on an anode current collector, wherein the perforation penetrates both the anode active material layer and the anode current collector to form an anode perforation; perforating a cathode in the roll-to-roll process, the cathode comprising a cathode active material layer deposited on a cathode current collector, wherein the cathode perforation penetrates both the cathode active material layer and the cathode current collector to form a cathode perforation; stacking the perforated anode and the perforated cathode, wherein stacking includes aligning the anode perforation and the cathode perforation laterally and longitudinally relative to the perforated anode and cathode; and winding the stacked perforated anode and cathode to form the perforated jelly roll battery.

[0068] In one aspect of the invention, the method includes encapsulating the perforated jelly roll battery in a prismatic battery housing, wherein the prismatic battery housing includes an electrolyte.

[0069] In one aspect of the invention, an electrolyte permeates the perforated jelly roll battery in the axial and radial directions relative to the perforated jelly roll battery through the cathode perforation and the anode perforation.

[0070] In one aspect of the invention, the method includes applying a coating to the anode and the cathode via prior to stacking, wherein the coating is formed of one or more of an electroactive material, a conductive agent, and a binder.

[0071] In one aspect of the invention, perforating the anode and / or perforating the cathode includes passing the anode and / or cathode through a cutter roller.

[0072] In one aspect of the invention, the method includes slitting the anode and / or cathode before perforating the anode and / or cathode.

[0073] In one aspect of the invention, perforating the anode and / or perforating the cathode includes passing the anode and / or cathode through a die-cutting machine.

[0074] According to the present invention, a battery system is provided, comprising: a prismatic battery housing; a perforated jelly roll battery positioned within the prismatic battery housing, wherein the perforated jelly roll battery comprises: a perforated anode, the perforated anode including an anode current collector, an anode active material layer and an anode perforation extending through the anode current collector and the anode active material layer; and a perforated cathode, the perforated cathode including a cathode current collector, a cathode active material layer and a cathode perforation extending through the cathode current collector and the cathode material layer, and wherein the perforated anode includes an anode perforation radially and axially aligned with the cathode perforation of the perforated cathode relative to the perforated jelly roll battery; and an electrolyte, wherein the electrolyte is distributed throughout the anode active material layer and the cathode material layer.

[0075] According to an embodiment, the axial length of the perforated jelly roll battery is greater than or equal to 300 mm.

[0076] According to an embodiment, the axial length of the perforated jelly roll battery is greater than or equal to 600 mm.

[0077] According to an embodiment, the prismatic battery housing includes terminals positioned on the smallest face of the prismatic battery housing.

[0078] According to an embodiment, the perforated anode and perforated cathode further include an electrolyte-permeable and conductive coating.

[0079] According to an embodiment, the lateral lengths of the anode perforation and the cathode perforation are in the range of 1 mm to 50 mm and are spaced apart by a distance in the range of 1 mm to 50 mm.

Claims

1. A perforated jelly roll battery, comprising: A perforated anode, the perforated anode comprising an anode active material layer, an anode current collector, and an anode perforation that passes vertically through the anode active material layer and the anode current collector relative to the axis of the unfolded perforated anode; A perforated cathode, comprising a cathode active material layer, a cathode current collector, and a cathode perforation that passes vertically through the cathode active material layer and the cathode current collector relative to the axis of the unfolded perforated cathode; and A separator is positioned between the perforated anode and the perforated cathode, wherein the anode perforation and the cathode perforation are radially and axially aligned relative to the axis of the perforated jelly roll battery.

2. The perforated jelly roll battery of claim 1, wherein the anode perforation and the cathode perforation each comprise a plurality of perforations extending laterally relative to the unfolded perforated anode and cathode.

3. The perforated jelly roll battery of claim 2, wherein the spacing between the plurality of perforations is laterally offset relative to the unfolded perforated anode and cathode.

4. The perforated jelly roll battery as claimed in claim 1, wherein the perforated jelly roll battery is a large-format jelly roll battery, and the axial length of the perforated jelly roll battery is greater than or equal to 300 mm.

5. The perforated jelly roll battery of claim 1, wherein the anode perforations and cathode perforations are coated.

6. The perforated jelly roll battery as claimed in claim 1, wherein the anode perforation and cathode perforation are circular.

7. The perforated jelly roll battery of claim 1, wherein the cathode perforation is a longitudinal mirror image of the anode perforation relative to the unfolded perforated anode and cathode.

8. The perforated jelly roll battery of claim 1, wherein the lateral lengths of the anode perforation and the cathode perforation are in the range of 1 mm to 50 mm and are spaced apart by a distance in the range of 1 mm to 50 mm.

9. A method for forming a perforated jelly roll battery, comprising: In a roll-to-roll process, the anode is perforated, the anode comprising an anode active material layer deposited on an anode current collector, wherein the perforation penetrates both the anode active material layer and the anode current collector to form an anode perforation; In the roll-to-roll process, the cathode is perforated, the cathode comprising a cathode active material layer deposited on a cathode current collector, wherein the cathode is perforated through both the cathode active material layer and the cathode current collector to form a cathode perforation; Stacking the perforated anode and the perforated cathode, wherein stacking includes aligning the anode perforations and cathode perforations laterally and longitudinally relative to the perforated anode and cathode; as well as The stacked perforated anode and cathode are wound up to form the perforated jelly roll battery.

10. The method of claim 9, further comprising encapsulating the perforated jelly roll battery in a prismatic battery housing, wherein the prismatic battery housing comprises an electrolyte.

11. The method of claim 10, wherein the electrolyte permeates the perforated jelly roll battery in the axial and radial directions relative to the perforated jelly roll battery through the cathode perforation and the anode perforation.

12. The method of claim 9, further comprising applying a coating to the anode and cathode vias prior to stacking, wherein the coating is formed of one or more of an electroactive material, a conductive agent, and a binder.

13. The method of claim 9, wherein perforating the anode and / or perforating the cathode comprises passing the anode and / or cathode through a cutter roller.

14. The method of claim 9, further comprising slitting the anode and / or cathode prior to perforating the anode and / or cathode.

15. The method of claim 9, wherein perforating the anode and / or perforating the cathode comprises passing the anode and / or cathode through a die-cutting machine.

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