Mechanical cutting machine and use thereof

Abstract

The present invention relates to methods, systems, apparatuses, controllers, software, and compositions of matter related to performing rotational cutting on a target starting material to generate a component. The component can be used in an energy manipulation device, e.g., a battery. The component can be a component of a battery cell, e.g., a stacked arrangement of battery cells.

Description

[0001] Priority application

[0002] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 566,656, filed March 18, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention relates to the production of components for energy manipulation devices (e.g., batteries). These energy manipulation devices are capable of undergoing electrical charging and discharging. In some embodiments, the production of such components is adaptable, precise, and / or low-cost. This disclosure includes apparatus, methods, systems, devices (e.g., control systems), and software suitable for producing said components, for example, by mechanical cutting. The production of said components may include fabrication and / or manufacturing.

[0004] The present invention relates to methods and structures for electrode assemblies, etc., for energy manipulation (e.g., storage) devices (e.g., secondary batteries), energy manipulation (e.g., storage) devices employing such structures, methods for manufacturing such structures and / or energy manipulation devices, and applicable systems, devices (e.g., control systems) and software.

[0005] The present invention relates to methods and structures for electrode assemblies, etc., for energy manipulation (e.g., storage and / or release) devices (e.g., batteries), energy manipulation devices employing such structures, methods for manufacturing such structures and energy manipulation devices, and applicable systems, devices (e.g., control systems) and software. Background Technology

[0006] A battery is an energy manipulation device having an electrochemical cell within which current-carrying ions migrate via an electrolyte between a cathode and an anode structure. The anode and cathode structures in the cell are separated by a gap. The cell may include a separator structure. The separator structure may be incorporated into the cell during battery assembly and remains incorporated during battery operation. Anode and cathode current collectors of the respective anode and cathode collect current from the respective active electrochemical electrodes and enable the current to be transferred (e.g., flow) to the external environment of the battery.

[0007] The fabrication (e.g., manufacturing) and / or processes of such energy manipulation devices present numerous disadvantages. Efficient cutting of energy manipulation (e.g., battery) cell components may require design changes, for example, based at least in part on the required arrangement of the energy manipulation device as part of the electronic product it serves (e.g., the target product). Some cutting tools (a) operate relatively slowly, (b) adapt to design changes slowly, (c) adapt to design changes at a high cost, and / or (d) introduce (e.g., cause) deformation in the cell components during cutting the required component to the required dimensions. Adapting to design changes may include materializing the design change to produce a change in the cut component, for example, adjusting the cutting tool to cut according to the modified design. The component may include a battery cell component. The introduced deformation may include degradation introduced in the cut component. The introduced deformation may include introduced deformation of electrode portions, for example, deformation of active material operatively coupled to a current collector (e.g., deformation within the active material). The operative coupling may include contact and / or electrical coupling.

[0008] A lithium-based secondary battery is an energy storage device comprising individual cells. Within each cell, current-carrying ions (e.g., lithium ions, sodium ions, potassium ions, calcium ions, or magnesium ions) migrate between a cathode and an anode structure via an electrolyte. The anode and cathode structures are separated by a membrane structure during battery assembly and operation. Anode and cathode current collectors converge current from their respective active electrochemical electrodes, enabling the current to be transferred to the external environment of the battery.

[0009] The manufacture of secondary batteries and the processes involved in their production have several drawbacks. For example, secondary battery electrodes are typically manufactured using laser cutting techniques. However, laser cutting can cause electrode material to redeposit onto the electrode surface due to vaporization and debris. Furthermore, some electrode materials may degrade during the laser cutting process, resulting in non-functional active materials. Other techniques used in the industry include mechanical cutting using linear dies and / or stamping. However, these techniques require start-stop processing and do not allow for continuous roll-to-roll processing of electrodes. Therefore, this paper discloses a system and method for mechanically cutting secondary battery electrodes using rotary die-cutting techniques as an alternative to laser cutting. The system and method disclosed herein enable faster, more precise, and cleaner cutting while allowing for continuous roll-to-roll processing of secondary battery electrodes. Summary of the Invention

[0010] In some aspects, this disclosure addresses one or more of the difficulties and / or disadvantages described above. In some embodiments, this disclosure provides solutions for mitigating the aforementioned difficulties and / or disadvantages. These solutions include methods (one or more), apparatus (one or more), devices (one or more), systems (one or more), and / or designs (one or more). In some aspects, the present invention relates to methods (one or more), apparatus (one or more), devices (one or more), systems (one or more), and designs (one or more) for batteries comprising battery cells (one or more). This document discloses methods, apparatuses, devices, program instructions, and structures for cutting a desired design, the cutting being adaptable to different designs quickly and / or at low cost. Cutting a desired design using these dynamically adjustable cutting tools can be configured to minimize the introduction of defects into the resulting cut portion.

[0011] In some aspects, this document discloses dynamically adjustable cutting tools (e.g., rotary cutters) and suitable methods, systems, devices (e.g., control systems) and software. The adjustable cutting tool may include a textured structure configured to cut or slit the target object into a desired design when pressed against it, thereby forming a mold having the desired design. The textured structure is a raised element relative to a plane (e.g., sheet or foil), the design protruding beyond a planar (e.g., flat) background of the textured structure. The target object may be in the form of an elongated foil or sheet. The textured structure may include a sharp design formed of a rigid material (e.g., a solid material) for cutting and / or pressing against the target starting material. The target starting material may be fed (e.g., continuously) into the adjustable cutting tool to sequentially generate the desired part according to the textured design. The adjustable cutting tool may be configured to progressively cut the design along one or more perimeter sides. The textured design can be a sheet material operatively coupled to the rollers of the adjustable cutting tool. The textured design can be generated relatively quickly. The textured structure (e.g., sheet material) can be easily replaced within the adjustable cutting tool. The adjustable cutting tool can be controllable, for example, using any of the control systems disclosed herein, such as control software.

[0012] In another aspect, a method for manufacturing electrodes for a secondary battery using a rotary die assembly includes: manufacturing a cathode component of the electrode assembly of the secondary battery using a first die of the rotary die assembly; manufacturing an anode component of the electrode assembly of the secondary battery using a second die of the rotary die assembly; and manufacturing a separator component of the electrode assembly of the secondary battery using a third die of the rotary die assembly.

[0013] In another aspect, a rotary die assembly for manufacturing electrodes for a secondary battery includes a first die, a second die, and a third die, wherein the rotary die assembly is configured to: use the first die of the rotary die assembly to manufacture a cathode component of the electrode assembly of the secondary battery; use the second die of the rotary die assembly to manufacture an anode component of the electrode assembly of the secondary battery; and use the third die of the rotary die assembly to manufacture a separator component of the electrode assembly of the secondary battery.

[0014] On the other hand, an apparatus for processing a target starting material includes: a frame; an inner roller having a first transverse axis, the inner roller being operatively coupled to the frame, the inner roller being configured to be operatively coupled to a mold to generate a mold roller, the inner roller being configured to be coupled to the mold such that, as the inner roller rotates (e.g., turns), the mold remains (e.g., substantially) stationary relative to the inner roller; and a support roller having a second transverse axis parallel to the first transverse axis (e.g., substantially), the support roller being separated from the inner roller by a gap, the support roller and the inner roller being configured to rotate relative to each other such that, during their rotation, (i) the target starting material is drawn into the gap, (ii) the target starting material interacts with the mold, the interaction of the mold with the target starting material causing a pattern of the mold to be pressed onto the target starting material to cut, press, or cut and press the target starting material, thereby generating a product according to the pattern of the mold, or (iii) any combination of (i) and (ii). In some embodiments, (a) the apparatus is configured to process the target starting material comprising a planar material operably coupled to a particulate material body, the planar material comprising a foil or sheet, without causing (e.g., substantially) deformation of the particulate material body; (b) the apparatus is configured to dynamically change the gap; (c) the apparatus is configured to dynamically change the compression of the die on the target starting material; (d) the die is optimized to reduce the variation in the force required to press the die onto the target starting material, the variation depending at least in part on the design layout of the die; and (e) the inner roller is configured to at least in part use a suction... (f) The device is configured to operate in an enclosed space having an internal environment different from the surrounding environment outside the enclosed space, and the product is susceptible to one or more reactive agents present in the surrounding environment; (g) at least one component of the device is configured for temperature regulation; (h) the mold includes at least one coating configured to reduce the occurrence of partial adhesion of the target starting material to the mold after processing the target starting material; (i) the mold and the target starting material include at least one common material type; or (j) any combination thereof. In some embodiments, the device is configured to process the target starting material comprising a planar material operatively coupled to the particulate material body. In some embodiments, the particulate material body is an anolyl active material, and the planar material is a current collector coupled to the anolyl active material. In some embodiments, the anolyl active material includes a protective material configured to be removed from the product. In some embodiments, the protective material includes an adhesive or a coating.In some embodiments, the apparatus is configured to process the particulate material body without causing (e.g., substantially) deformation of the particulate material body. In some embodiments, deforming the particulate material body includes introducing one or more defects, including cracks, dislocations, unwanted growth centers, any type thereof, or any combination thereof. In some embodiments, the unwanted growth centers include (a) crystallization centers, (b) metallurgical phases, (c) growth centers formed by the accumulation of a reduced phase of charge carriers, (d) any of several types thereof, or (e) any combination thereof. In some embodiments, the apparatus is configured to dynamically change the gap. In some embodiments, the dynamic change of the gap depends at least in part on the target starting material, the relative rotation of the die roller relative to the support roller, the design of the die, the required fidelity of the product, or any combination thereof. In some embodiments, (I) the higher the fidelity, the lower the rotation speed; (II) the greater the fragility of the material, the lower the rotation speed. In some embodiments, the gap is changed using at least in part using a control system. In some embodiments, the gap is changed using (a) a feedback control scheme, (b) a feedforward control scheme, (c) a lookup table, (d) historical measurements, or (e) any combination thereof. In some embodiments, the device is configured to dynamically change the compression of the die onto the target starting material. In some embodiments, the dynamic change in compression depends at least in part on the target starting material, the relative rotation of the die rollers relative to the support rollers, the design of the die, the fidelity required by the product, or any combination thereof. In some embodiments, (I) the higher the fidelity, the lower the rotation speed; (II) the more fragile the material, the lower the rotation speed. In some embodiments, the gap is changed using at least in part using a control system. In some embodiments, the gap is changed using (a) a feedback control scheme, (b) a feedforward control scheme, (c) a lookup table, (d) historical measurements, or (e) any combination thereof. In some embodiments, the die is optimized to reduce the variation in the force required to press the die onto the target starting material during the interaction, the variation depending at least in part on the design (e.g., design layout) of at least one groove in the die. In some embodiments, the design of the at least one ridge is minimized such that (A) the die cuts a minimum range of the target starting material each time it interacts with the target starting material while the device is operating, and / or (B) the die cuts a similar range of the target starting material each time it interacts with the target starting material while the device is operating; in some embodiments, the inner roller is configured to be operatively coupled to the die at least partially by using the attractive force. In some embodiments, the attractive force includes magnetic force, mechanical force, hydraulic force, gas force, or any combination thereof.In some embodiments, the gas force includes aerodynamic force or vacuum. In some embodiments, the attractive force includes magnetic force. In some embodiments, the device is configured to operate in an enclosed space having an internal environment different from the surrounding environment outside the enclosed space, and the product is susceptible to one or more reactive agents present in the surrounding environment. In some embodiments, the enclosed space includes a cleanroom. In some embodiments, the enclosed space is configured to separate the internal environment of the enclosed space from the surrounding environment outside the enclosed space. In some embodiments, the separation includes a seal. In some embodiments, the seal may be a tight seal. In some embodiments, the seal includes a particulate material (e.g., dust) seal, a liquid seal, a gas seal, or any combination thereof. In some embodiments, the one or more reactive agents include oxygen, water, alcohol, thiol, sulfuric acid, phosphoric acid, carboxylic acid, hydrogen sulfide, any combination thereof, or any combination thereof. In some embodiments, the internal environment includes argon, nitrogen, clean dry air, or any combination thereof. In some embodiments, the internal environment has a temperature, pressure, and / or one or more reactive agents different from those in the surrounding environment. In some embodiments, the at least one component of the device is configured for temperature regulation. In some embodiments, the at least one component includes the inner roller, the support roller, the frame, or any combination thereof. In some embodiments, the temperature regulation is controlled. In some embodiments, the temperature regulation includes heating. In some embodiments, the temperature regulation includes cooling. In some embodiments, the at least one component is operatively coupled to, or includes, one or more channels configured to change the temperature of the at least one component. In some embodiments, the one or more channels are configured for fluid flow. In some embodiments, the fluid includes a gas, a liquid, a semi-solid, or any combination thereof; wherein the one or more components include a rod configured for heat transfer. In some embodiments, the rod includes an elemental metal or a metal alloy. In some embodiments, the rod includes silver, copper, aluminum, graphene, gold, aluminum nitride, or boron arsenide. In some embodiments, the temperature of the at least one component is changed during product generation using the apparatus. In some embodiments, the temperature change of the at least one component is controlled at least in part by a control system. In some embodiments, the temperature regulation is active. In some embodiments, the temperature regulation is passive. In some embodiments, the temperature regulation includes heating. In some embodiments, the temperature regulation includes cooling. In some embodiments, the temperature regulation contributes to improving the accuracy, fidelity, and / or integrity of the product. In some embodiments, the temperature regulation helps reduce deformation relative to the target starting material.In some embodiments, the deformation is a deformation of a particulate material body that is part of the target starting material. In some embodiments, the deformation includes the introduction of one or more defects, including cracks, dislocations, unwanted growth centers, any type thereof, or any combination thereof. In some embodiments, the unwanted growth centers include (a) crystallization centers, (b) metallurgical phases, (c) growth centers formed by the accumulation of a reduced phase of charge carriers, (d) any of the types thereof, or (e) any combination thereof. In some embodiments, the mold includes at least one coating configured to reduce the occurrence of partial adhesion of the target starting material to the mold after processing the target starting material. In some embodiments, the coating includes polytetrafluoroethylene, polyfluoroalkyl substances, perfluoroalkyl substances, anti-stick ceramic coatings, carbon steel, stainless steel, silicone, Gore-Tex, siloxanes, silanes, oxidized regenerated cellulose, any of the types thereof, or any combination thereof. In some embodiments, the apparatus is configured to be integrated with one or more other processes and / or mechanisms to produce a desired product, a system including the product, or a system including the desired product from the product. In some embodiments, the other processes include deposition, compression, calendering, roll-to-roll, cutting, forming, machining, welding, stamping, encapsulation, deposition, drying, spraying, 3D printing, calendering, compression, ablation, slitting, adhesion (e.g., glue bonding), soldering, any combination thereof, or any other combination thereof. In some embodiments, the product required for production includes manufacturing. In some embodiments, the apparatus is configured to deliver the product using at least partially attractive and / or repulsive forces. In some embodiments, the attractive force includes magnetic, mechanical, hydraulic, gaseous, electrostatic, or any combination thereof. In some embodiments, the gaseous force includes pneumatic or vacuum forces. In some embodiments, the mechanical force may include a scraper, shovel, loader, fork, gripper, mover, broom, any combination thereof, or any other combination thereof. In some embodiments, the mechanical force is part of a robotic system. In some embodiments, the attractive force includes gravity of the surrounding environment. In some embodiments, the mold and the target starting material comprise at least one common material type. In some embodiments, the target starting material comprises a current collector, and the at least one material type is the material type of the current collector. In some embodiments, the target starting material includes an end plate, and the at least one material type is the material type of the end plate. In some embodiments, the mold includes at least one material that is harder than the target starting material. In some embodiments, the mold includes a high-performance metal. In some embodiments, the target starting material does not contain a high-performance metal.In some embodiments, the high-performance metal includes stainless steel (e.g., 316), Inco nickel alloy, titanium, tungsten, tool steel, platinum, rhodium, aluminum alloy, rhenium, carbon composites, any combination thereof, or any combination thereof. In some embodiments, the carbon composite includes allotropes of elemental carbon. In some embodiments, the support roller includes (I) a material harder than the material of the mold and / or (III) a self-healing material. In some embodiments, the relative rotation of the mold roller with respect to the support roller includes rotation of the mold roller along a first direction opposite to a second direction along which the support roller rotates. In some embodiments, (a) the absolute value of the rotation of the mold roller is the same as (e.g., substantially) the absolute value of the rotation of the support roller, (b) the lateral length of the mold roller is the same as (e.g., substantially) the lateral length of the support roller, (c) the diameter of the mold roller is the same as (e.g., substantially) the diameter of the support roller, and (d) the first lateral length of the joint portion of the mold roller with the target starting material is the same as the second lateral length of the joint portion of the support roller with the target starting material. In some embodiments, (a) the absolute value of the rotation of the mold roller is the same as (e.g., substantially) the absolute value of the rotation of the support roller, (b) the lateral length of the mold roller is different from the lateral length of the support roller, (c) the diameter of the mold roller is different from the diameter of the support roller, and (d) the first lateral length of the engagement portion of the mold roller with the target starting material is different from the second lateral length of the engagement portion of the support roller with the target starting material. In some embodiments, the difference is smaller. In some embodiments, the difference is larger. In some embodiments, the mold includes an outer surface and an inner surface opposite to the outer surface, the inner surface of the mold being operatively coupled to the inner roller to generate the mold roller. In some embodiments, the mold is configured to generate one or more components of an energy manipulation device (e.g., the energy manipulation device disclosed herein). In some embodiments, the energy manipulation device includes a battery (e.g., the battery disclosed herein). In some embodiments, the battery is a rechargeable battery (e.g., the rechargeable battery disclosed herein). In some embodiments, the mold is configured to cut battery cell components. In some embodiments, the product includes electrodes, counter electrodes, separators, or spacers of the one or more battery cells. In some embodiments, the components of the product include a plurality of units having a length-to-width ratio of at least about 1:1, 2:1, 4:1, 5:1, 8:1, 10:1, 15:1, 20:1, 50:1, 100:1, 1000:1 or higher.In some embodiments, the components of the product include a plurality of units having a length-to-height aspect ratio of at least about 1:1, 2:1, 4:1, 5:1, 8:1, 10:1, 15:1, 20:1, 50:1, 100:1 or higher; and optionally, wherein the battery cell comprises at least 1, 2, 10, 20, 50, 100, 150, 200, 250 or 500 battery cells.

[0015] In another aspect, a manufacturing method includes performing one or more operations at least in part by using any of the aforementioned apparatus to process the target starting material. In some embodiments, processing the target starting material by the apparatus is at least a part of a manufacturing process that includes the product.

[0016] In another aspect, an apparatus for manufacturing includes: at least one controller configured to (a) be operatively coupled to any of the aforementioned apparatuses, and (b) perform one or more operations related to the manufacturing, or direct at least one component of the apparatus to perform the one or more operations. In some embodiments, the at least one controller is configured to be operatively coupled to a power supply and / or a communication platform. In some embodiments, the manufacturing includes fabrication. In some embodiments, the fabrication includes roll-to-roll fabrication. In some embodiments, the manufacturing is the fabrication of a system comprising the product. In some embodiments, the system includes an energy control device. In some embodiments, the energy control device is a battery.

[0017] On the other hand, one or more non-transitory computer-readable media include program instructions physically recorded thereon, which, when read by one or more processors operatively coupled to any of the aforementioned devices, are configured to: (I) perform one or more operations related to the manufacture of the product, or direct the execution of the one or more operations; (II) the one or more operations include directing at least one component of the device to perform the one or more operations. In some embodiments, the manufacture includes production. In some embodiments, the production includes roll-to-roll production. In some embodiments, the manufacture is the production of a system comprising the product. In some embodiments, the system includes an energy manipulation device. In some embodiments, the energy manipulation device is a battery. In some embodiments, the device is configured to sequentially (e.g., stepwise) cut and / or emboss the target starting material. In some embodiments, the target starting material is sequentially (e.g., stepwise) cut by the device.

[0018] In another aspect, a method includes: (a) providing any of the above-described devices; and (b) manufacturing, testing, storing, transporting, and / or using the devices to produce the product.

[0019] On the other hand, a system for implementing the operation of the methods and apparatus disclosed herein and / or operations recorded by non-transitory computer-readable program instructions (e.g., recorded on a medium / media).

[0020] In another aspect, a system for implementing the operation of the methods, apparatus, devices (one or more) disclosed herein and / or operations recorded by non-transitory computer-readable program instructions (e.g., recorded on a medium / media).

[0021] On the other hand, a means (one or more) (e.g., a device) for implementing the operation of a method, an apparatus, and / or the operation recorded by non-transitory computer-readable program instructions (e.g., recorded on a medium / medium).

[0022] In other respects, systems, devices (e.g., controllers (one or more)) and / or non-transitory computer-readable program instructions (e.g., software) implement any of the methods disclosed herein. In some embodiments, the program instructions are recorded on at least one medium (e.g., on one medium or on multiple media).

[0023] In other respects, methods, systems, apparatuses (e.g., controllers (one or more)) and / or non-transitory computer-readable program instructions (e.g., software) that implement any of the means disclosed herein and / or any operation of such means may be included. In some embodiments, the program instructions are recorded on at least one medium (e.g., on one medium or on multiple media).

[0024] In another aspect, an apparatus includes at least one controller configured (e.g., programmed) to direct a mechanism used in the methods disclosed herein to implement (e.g., facilitate) any of the methods and / or operations disclosed herein, wherein the controller(s) is operatively coupled to the mechanism. In some embodiments, the controller(s) implement any of the methods and / or operations disclosed herein. In some embodiments, the at least one controller includes, or is operatively coupled to, a hierarchical control system. In some embodiments, the hierarchical control system includes at least three, four, or five control levels. In some embodiments, at least two operations are performed or directed by the same controller. In some embodiments, at least two operations are performed or directed by different controllers.

[0025] In another aspect, an apparatus includes at least one controller configured (e.g., programmed) to implement (e.g., execute) the methods, processes, and / or operations disclosed herein, or to direct their implementation. In some embodiments, the at least one controller implements any of the methods, processes, and / or operations disclosed herein.

[0026] On the other hand, non-transitory computer-readable program instructions, when read by one or more processors, are configured to perform, or instruct to perform, the methods, processes, and / or operations disclosed herein. In some embodiments, the at least one controller implements any of the methods, processes, and / or operations disclosed herein. In some embodiments, at least a portion of the one or more processors is part of the apparatus disclosed herein, outside the apparatus, or at a location remote from the apparatus (e.g., in the cloud).

[0027] In another aspect, a system includes a device and at least one controller configured (e.g., programmed) to direct the operation of the device, wherein the at least one controller is operatively coupled to the device. In some embodiments, the device includes any of the devices or apparatuses disclosed herein. In some embodiments, the at least one controller implements or directs the implementation of any of the methods disclosed herein. In some embodiments, the at least one controller directs any of the devices (or components thereof) disclosed herein. In some embodiments, at least two operations (e.g., instructions) of the device are directed by the same controller. In some embodiments, at least two operations (e.g., instructions) of the device are directed by different controllers. In some embodiments, at least two operations (e.g., instructions) are performed by the same processor and / or the same sub-computer software product. In some embodiments, at least two operations (e.g., instructions) are performed by different processors and / or different sub-computer software products.

[0028] In another aspect, a computer software product includes a computer-readable medium (e.g., a non-transitory medium) storing program instructions therein, which, when read by a computer, cause the computer to direct an apparatus for implementing (e.g., facilitating) any method disclosed herein, wherein the non-transitory computer-readable medium is operatively coupled to the apparatus. In some embodiments, the apparatus includes a device or device component.

[0029] In another aspect, a computer system includes one or more computer processors and a non-transitory computer-readable medium / medium coupled thereto. In some embodiments, the non-transitory computer-readable medium / medium includes machine-executable code that, when executed by the one or more computer processors, implements any methods and / or operations (e.g., as disclosed herein), and / or facilitates instructions (e.g., as disclosed herein) of the controller(s).

[0030] In another aspect, a method includes performing one or more operations associated with at least one configuration of the apparatus(s) disclosed herein (e.g., devices(s)).

[0031] In another aspect, a device includes at least one controller configured to: (i) be operatively coupled to the device; and (ii) direct the execution of one or more operations associated with at least one configuration of the device(s) disclosed herein.

[0032] In another aspect, at least one controller is associated with the methods, apparatus, and software disclosed herein. In some embodiments, the at least one controller includes at least one connector configured to connect to a power source. In some embodiments, the at least one controller is configured to be operatively coupled to a power source at least partially by (I) having a power outlet and / or (II) being configured to perform wireless power transfer using inductive charging. In some embodiments, the at least one controller includes non-volatile memory, such as a solid-state device (SSD), e.g., flash memory. In some embodiments, the at least one controller is included in or comprises a hierarchical control system. In some embodiments, the hierarchical control system includes at least three hierarchical control levels. In some embodiments, the at least one controller is included in the control system disclosed herein. In some embodiments, the at least one controller is configured to control at least one other component of the apparatus (e.g., system, apparatus, or device) disclosed herein. In some embodiments, the apparatus disclosed herein is a component of a system, wherein the at least one controller is configured to (i) be operatively coupled to another component of the system and (ii) direct the operation of the other component. In some embodiments, the at least one controller is configured to at least partially direct the operation of the other component to engage the other component in the methods disclosed herein.

[0033] In another aspect, non-transitory computer-readable program instructions for the methods disclosed herein, when read by one or more processors operatively coupled to the apparatus, cause the one or more processors to direct the execution of one or more operations associated with at least one configuration of the apparatus(s) disclosed herein.

[0034] In some embodiments, the program instructions are program instructions of a computer program product.

[0035] Various embodiments of any of the foregoing aspects are composable (e.g., within one aspect), as appropriate. Individual features disclosed herein (e.g., embodiments) are composable, as applicable, as required and / or desired.

[0036] Other aspects and advantages of this disclosure will become apparent to those skilled in the art from the following detailed description, in which only illustrative embodiments of the disclosure are shown and described. It should be understood that the disclosure may have other different embodiments, and certain details thereof may be modified in various obvious ways without departing from the disclosure. Therefore, the drawings and descriptions should be considered illustrative in nature and not restrictive.

[0037] By incorporating via reference

[0038] All publications, patents and patent applications mentioned in this specification are incorporated herein by reference to the extent that each individual publication, patent or patent application is specifically and individually indicated to be incorporated by reference.

[0039] It should be understood that any patent, publication, or other disclosure incorporated herein by reference, whether in whole or in part, is incorporated only to the extent that the incorporated material does not conflict with the existing definitions, expressions, or other disclosures set forth in this disclosure. Therefore, to the extent necessary, the disclosure expressly set forth herein supersedes any conflicting material incorporated herein by reference. Any material or portion thereof incorporated herein by reference that conflicts with the existing definitions, expressions, or other disclosures set forth in this disclosure is incorporated only to the extent that it does not create a conflict between the incorporated material and the existing disclosures. Attached Figure Description

[0040] This disclosure will be described in detail with reference to the following accompanying drawings, according to one or more different embodiments. The drawings are for illustrative purposes only and depict only typical or exemplary embodiments. These drawings are provided to facilitate understanding of the concepts disclosed herein and should not be construed as limiting the breadth, scope, or applicability of these concepts. It should be noted that these drawings are not necessarily drawn to scale for clarity and ease of illustration.

[0041] The novel features of this disclosure are specifically set forth in the appended claims. The accompanying drawings, which are disclosed herein, illustrate some embodiments of the subject matter of this disclosure. The features and advantages of this disclosure will be better understood by referring to the following detailed description of illustrative embodiments utilizing the principles of this disclosure, along with the accompanying drawings (also referred to herein as “Figures”), in which:

[0042] Figure 1 Schematic examples of various battery cells are shown;

[0043] Figure 2 A schematic example of a folding option for an energy control device (e.g., a battery) component and a current collector is shown;

[0044] Figure 3 A schematic example of an energy manipulation device (e.g., a battery) and a single battery cell is shown;

[0045] Figure 4 A schematic example of a single battery cell architecture is shown;

[0046] Figure 5 A schematic exploded view of components of an energy control device (e.g., a battery) is shown;

[0047] Figure 6 An illustrative example of an energy manipulation device (e.g., a battery) component is shown;

[0048] Figure 7 Images and exploded views of components of an energy control device (e.g., a battery) are shown;

[0049] Figure 8 Images of components of an energy control device (e.g., a battery) are shown;

[0050] Figure 9 Illustrative examples of devices (e.g., batteries) and device components are shown;

[0051] Figure 10 Illustrative examples of device (e.g., battery) components are shown;

[0052] Figure 11 A perspective view of a portion of the end of a stacked battery cell is shown;

[0053] Figure 12 This is an illustrative schematic perspective view of components (e.g., electrodes for manufacturing secondary batteries) of a rotary mold assembly according to some embodiments of the subject matter of this disclosure.

[0054] Figure 13 A perspective schematic diagram of the structural frame of a rotary cutting machine is shown;

[0055] Figure 14A perspective schematic diagram of the components of a rotary cutting machine is shown;

[0056] Figure 15 A perspective schematic diagram of the components of a rotary cutting machine is shown;

[0057] Figure 16 A schematic diagram of the components of a rotary cutting machine is shown;

[0058] Figure 17 This is an illustrative view of a rotating mold (e.g., for manufacturing electrodes for secondary batteries) according to some embodiments of the subject matter of this disclosure. Figure 17 Various schematic diagrams of sheets containing textured surfaces (also referred to herein as “molds”) are shown;

[0059] Figure 18 This is an illustrative perspective view of a roller (e.g., a rotating magnetic chuck for manufacturing electrodes for secondary batteries) according to some embodiments of the subject matter of this disclosure.

[0060] Figure 19 A photographic image shows a portion of a rotary cutter coupled to a textured sheet (the textured sheet used as a mold);

[0061] Figure 20 A photographic image of a portion of a rotary cutter coupled to a sheet containing textured surfaces is shown.

[0062] Figure 21 These are illustrative photographic images of some embodiments of the subject matter of this disclosure, showing example portions of a sheet containing textured surfaces, i.e., mold portions, such as electrodes for manufacturing secondary batteries.

[0063] Figure 22 This is an illustrative flowchart of a process according to some embodiments of the subject matter of this disclosure, such as the process of manufacturing electrodes for a secondary battery using a rotary die assembly.

[0064] Figure 23 A schematic example of a control system is shown; and

[0065] Figure 24 A schematic example of a processing system is shown.

[0066] The diagrams and components therein may not be drawn to scale. Various components in the diagrams described herein may not be drawn to scale. Detailed Implementation

[0067] While various embodiments of the invention have been shown and described herein, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, modifications, and substitutions can be made by those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed. The various embodiments disclosed herein are composable, as appropriate.

[0068] The terms "various embodiments," "some embodiments," "one embodiment," "some exemplary embodiments," "one exemplary embodiment," or "embodiment" throughout the specification refer to a particular feature, structure, or characteristic described in association with any embodiment, which is included in at least one embodiment. Therefore, the appearance of the phrases "in various embodiments," "in some embodiments," "in one embodiment," "some exemplary embodiments," "one exemplary embodiment," or "in an embodiment" throughout the specification does not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0069] Singular expressions such as “a,” “an,” and “the” are not intended to refer to a single entity, but rather to include the general category to which the entity belongs, as can be illustrated by specific examples. The terminology used herein is used to describe specific embodiments of this disclosure, but its use is not limited to those specific embodiments. The term “includes” means including but not limited to, the term “including” means including but not limited to, and the term “based on” means at least partially based on.

[0070] The second feature immediately following the first feature does not have another feature set between it, and the features belong to the same type. The feature can be a real feature, a computational feature, or any other virtual feature.

[0071] When referring to a range, unless otherwise stated, the range is intended to be a range that includes the endpoints. For example, the range between value 1 and value 2 is intended to be a range that includes the endpoints and includes both value 1 and value 2. The range that includes the endpoints will cover any value from approximately value 1 to approximately value 2. As used herein, the terms “adjacent” or “adjacent to” include “immediately next to,” “adjacent to,” “contact,” and “close to.” When referring to a range (e.g., between, at least, at most, etc.), protection is also claimed for the endpoints (one or more) of the range. For example, when the range is from X to Y, protection is also claimed for the values ​​of X and Y. For example, when the range is at most Z, protection is also claimed for the value of Z. For example, when the range is at least W, protection is also claimed for the value of W.

[0072] The conjunction “and / or” used herein (including in the specification and claims) is intended to include, as applicable, the following choices: (i) X, (ii) Y, and (iii) X and Y. The phrase “including X and / or Y” is intended to have the same meaning as the phrase “including X or Y” under currently prevailing U.S. law.

[0073] The terms "operably coupled," "operably configurable," or "operably connected" refer to a first mechanism coupled (or connected) to a second mechanism to allow the intended operation of the second mechanism and / or the first mechanism. Coupling can include physical coupling or non-physical coupling. Non-physical coupling can include signal-induced coupling (e.g., wireless coupling).

[0074] When the phrase “constructed as” or “configured as” modifies an article, it refers to a structure in the article that enables the achievement of the indicated result.

[0075] The symbol “*” represents the mathematical operation of multiplication, such as “multiply by”.

[0076] The basic length scale (abbreviated as "FLS" in this document) includes any suitable scale (e.g., size) of an object. For example, the FLS of an object may include length, width, height, diameter, spherical equivalent diameter, circumcircle diameter, or circumsphere equivalent diameter.

[0077] In this article, central tendency is understood to include the mean, median, or mode. The mean can include the geometric mean.

[0078] In this text, performing a reversible first operation is understood to mean performing the first operation and being able to perform an operation opposite to that first operation (e.g., a second operation). For example, when the controller instructs the shutter to open reversibly, the shutter can also close, and the controller can selectively instruct the shutter to close. For example, when an attractor reversibly binds to a charge carrier, the attractor can also release the charge carrier after binding.

[0079] Although this disclosure refers to the cathode as an electrode, the electrode may be an anode if applicable.

[0080] While for simplicity, various parts of this document may refer to a battery as an energy manipulation device, this disclosure extends to any other energy manipulation device where applicable. As described herein, embodiments of this disclosure may relate to (e.g., secondary) batteries, structures constituting said (e.g., secondary) batteries, and methods and processes for manufacturing said structures and batteries. As used herein, the term "anode" in the context of (e.g., secondary) batteries may refer to (e.g., the negative electrode in a secondary) battery.

[0081] In the context of secondary batteries, the term "anode" refers to the negative electrode in the secondary battery. The term "cathode" refers to the positive electrode in the secondary battery.

[0082] As used herein, “anodic material” or “anodic active” can refer to one or more materials suitable for use as the negative electrode of a (e.g., secondary) battery. The term “cathode” as used herein in the context of a (e.g., secondary) battery can refer to the positive electrode of a (e.g., secondary) battery. As used herein, “cathode material” or “cathode active” can refer to one or more materials suitable for use as the positive electrode of a (e.g., secondary) battery.

[0083] In some embodiments described herein, the term "electrode" may be used to refer to either the anode or the cathode, and the term "counter electrode" may refer to the other or the opposite electrode. For illustrative purposes, embodiments may be described in accordance with "electrode" and "counter electrode." It should be understood that in these embodiments, where applicable, the term "electrode" may be replaced by the term "anode," and the term "counter electrode" may be replaced by the term "cathode." Alternatively, in these embodiments, where applicable, the term "electrode" may be replaced by the term "cathode," and the term "counter electrode" may be replaced by the term "anode."

[0084] In some embodiments, the energy manipulation device may include at least one battery. The battery may include one or more individual battery cells. The battery may be a rechargeable battery, such as a secondary battery. The charge carriers of the battery may include alkaline earth metals, alkali metal cations, multiple types of any of these, or any combination thereof. In one example, the battery includes charge carriers, such as lithium charge carriers.

[0085] In some embodiments, the energy manipulation device may include at least one battery. The battery may include one or more individual battery cells. The battery may be a rechargeable battery, such as a secondary battery. The charge carriers of the battery may include alkaline earth metals, alkali metal cations, multiple types of any of these, or any combination thereof. In one example, the battery includes charge carriers, such as lithium charge carriers. In some embodiments, charge carriers may include charge-carrying ions. In some embodiments, charge-carrying ions are supplied to the positive and / or negative electrodes by a charge-carrying ion supply layer. The charge-carrying ion supply layer may include one or more sources of lithium ions, sodium ions, potassium ions, calcium ions, magnesium ions, aluminum ions, and / or similar ions. The battery may or may not be a polymer battery, such as a lithium polymer battery.

[0086] In some embodiments, the energy manipulation device includes at least one battery cell. The energy manipulation device may include an assembly of battery cells (e.g., also referred to herein as a “cell bank”). The energy manipulation device may include an electrode connector operatively coupled to the electrode and a counter electrode connector operatively coupled to the counter electrode, wherein operative coupling includes an electrical connection. The electrode connector may also be referred to herein as an “electrode terminal”, and the counter electrode connector may also be referred to herein as a “counter electrode terminal”. The energy manipulation device may include an electrode bus, a counter electrode bus, an electrode terminal operatively coupled to the electrode bus, and a counter electrode terminal operatively coupled to the counter electrode bus. The electrode and the counter electrode of the battery cell are separated from each other by a gap, for example, to electrically isolate the electrode from the counter electrode. The gap may include a separator configured to (a) electrically isolate the electrode from the counter electrode and (b) allow charge carriers to pass through the separator. In some embodiments, each battery cell in the cell bank includes an electrode structure and a counter electrode structure separated from each other by a gap. One or more (e.g., each) battery cell in the battery cell group each includes a separator disposed in the gap. In some embodiments, the battery includes adjacent electrode sub-cells. Each of the electrode sub-cells has dimensions on the X-axis, Y-axis, and Z-axis, respectively. The X-axis, Y-axis, and Z-axis are each perpendicular to each other, similar to a Cartesian coordinate system. As used herein, the dimension of each electrode sub-cell on the Z-axis may be referred to as “height,” the dimension on the X-axis may be referred to as “length,” and the dimension on the Y-axis may be referred to as “width.” The electrode sub-cells may be combined to form one or more battery cells. A battery cell may include (a) at least one anode active material body (e.g., a layer) and / or (b) at least one cathode active material body (e.g., a layer). In some embodiments, the anode active material is separated from the cathode by the gap. In some embodiments, the cathode active material is separated from the anode by the gap. In some embodiments, the cathode active material is separated from the anode active material by the gap. The battery cell group may include at least 2, 10, 20, 50, 100, 150, 200, 250, or 500 battery cells. The battery cell group may include any number of battery cells between the above-mentioned numbers, such as 2 to 500 battery cells or 50 to 500 battery cells. The active material body may be operatively coupled to a current collector. The active material body may include one or more layers. The active material may form a gradient.

[0087] In some embodiments, the energy control device includes an electrode bus and a counter electrode bus. The electrode bus can be operatively coupled (e.g., electrically connected) to the electrode, for example, via an electrode tab. The counter electrode bus is operatively coupled (e.g., electrically connected) to the counter electrode, for example, via a counter electrode tab. The electrode bus can be operatively coupled to an electrode in the battery cell assembly, for example, via an electrode tab. The counter electrode bus is operatively coupled to a counter electrode in the battery cell assembly, for example, via a counter electrode tab. The electrode tab can be an extension of the electrode that does not contain electrode active material. The counter electrode tab can be an extension of the counter electrode that does not contain counter electrode active material.

[0088] In some embodiments, the energy control device includes a first bus and a second bus that are electrically contacted, for example, via electrode tabs, an anode(s) and a cathode(s), respectively. An electrode tab on a first side of the battery cell stack may be electrically coupled to the first bus, which may be referred to as the anode bus. An electrode tab on a second side of the battery cell stack may be electrically coupled to the second bus, which may be referred to as the cathode bus. In some embodiments, the first bus is electrically coupled to a conductive first terminal of the secondary battery. When the first bus includes an anode bus for the energy control device (e.g., the battery), the first terminal includes a negative terminal. In some embodiments, the second bus is electrically coupled to a conductive second terminal of the energy control device. When the second bus includes a cathode bus for the energy control device, the second terminal includes a positive terminal of the energy control device.

[0089] In some embodiments, the battery cell may be coupled to (e.g., a solid) bus. In some embodiments, the battery cell group may be coupled to the (e.g., a solid) bus. The bus may include a category of (e.g., solid) material. The material category may include elemental metals, metal alloys, or allotropes of elemental carbon, any of several types thereof, or any combination thereof. The bus may include (e.g., solid) material, for example, including one or more material types. At least two material types may belong to the same material category. At least two material types may belong to different material categories. The material category may be a composite material or a non-composite material. The material category may be a viscous material (e.g., a viscous connector) or a solid material (e.g., a non-viscous solid material). The material category may be, for example, a material that is fluid or non-fluid during the manufacture of energy manipulation devices such as batteries. In one example, the (e.g., solid) bus may include metal alloys and elemental metals. In one example, the (e.g., solid) bus may include two types of metal alloys. In one example, the (e.g., solid) bus may include composite materials and non-composite materials. The bus may include any conductive material disclosed herein. In one example, the bus includes copper (e.g., Cu101) and an Inco nickel alloy (e.g., N178). The material category may be an oxygen-free material. The material category may be an electronic-grade material.

[0090] In some embodiments, the busbar is attached to a current collector tab, for example, the attachment is assisted by the adhesive connector. In one example, the busbar contacts the adhesive connector that contacts the tab(s). The busbar may have a Euclidean cross-section, for example, a vertical cross-section. The busbar may have a geometrically planar cross-section, for example, a vertical cross-section. The shape may include polygons, ellipses, combinations thereof, and / or more thereof. The polygon may include rectangles or multiple rectangles. In one example, the vertical cross-section of the busbar is rectangular. In one example, the vertical cross-section of the busbar includes at least two different types of shapes, for example, rectangles. In one example, the vertical cross-section of the busbar includes at least two (e.g., substantially) identical and different shapes. The two types of shapes may include the same type of material, or may be formed from different types of materials. The two types of shapes may include the same category of material, or may be formed from different categories of materials. Two of the shapes may be separated from each other by a gap. Two of the shapes may contact each other. The cross-section of the busbar may include a recess, for example, a concave portion. The recess can be configured to accommodate: (a) a folded tab (one or more); (b) any adhesive connector; (c) any weld; or (d) any combination thereof. The recess can be configured to enhance the adhesion of the tab to the (e.g., solid) busbar. This enhanced adhesion can be achieved, at least in part, by enhancing the adhesion of the (e.g., solid) busbar to (i) any adhesive connector and / or (ii) any weld. The contact surface of the busbar is the exposed surface of one or more faces of the busbar, configured to contact: (a) the tab (one or more); (b) any adhesive connector; (c) any weld; or (d) any combination thereof. The contact surface may undergo a surface treatment prior to the contact. This surface treatment can be configured to enhance the adhesion between the busbar (e.g., solid busbar) and: (a) the tab (one or more); (b) any adhesive connector; (c) any weld; or (d) any combination thereof. The surface treatment may include roughening the contact surface. The surface treatment may include etching, scratching, or printing (e.g., 3D printing). The surface treatment may include mechanical processing types, chemical processing types, any combination thereof, or any combination thereof. The (e.g., solid) bus may include one or more perforations (e.g., holes). The perforations (one or more) may be configured to accommodate dimensional changes occurring in the battery cell, such as dimensional changes occurring during charging and / or discharging. The dimensional changes of the battery cell may occur during its (e.g., normal) operation, testing, maintenance, storage, transportation, or any combination thereof.

[0091] In some embodiments, the battery cell undergoes charge carrier preloading, for example, before its normal use. Preloading may include loading charge carriers into the battery cell, for example, “pre-lithiation” when lithium cations are the charge carriers. The preloading (also referred to herein as a “buffering”) may occur during manufacturing and / or before the battery is provided for its intended use. Preloading may facilitate the insertion of additional charge carriers from a charge carrier source, such as a lithium source, into one or more electrodes of the battery, for example, into one or more anodes. The electrodes may be short in the vertical direction. Preloading may compensate for (e.g., irreversible) charge carrier losses during the battery's formation, for example, to improve (a) the efficiency of the first cycle and / or (b) the battery cell capacity. Preloading may create a charge carrier reserve and / or a smaller cycle voltage window within the battery cell. Preloading may improve current distribution, for example, during fast charging. Preloading may improve the cycle life of the battery. Buffering or preloading can, for example, pressurize a battery cell during its first charging cycle by loading charge carriers such as lithium onto the anode. The pressure regulators described herein can help maintain overpressure in the system without applying pressure during buffering; for example, the regulator can establish a minimum overpressure / threshold overpressure in the energy manipulation device during formation without buffering the battery cells. Rough, exposed surfaces of the charge carrier plating can persist throughout the battery's lifespan and may impair battery function, for example, due to charge carrier depletion and / or due to short circuits (e.g., due to dendrite formation from the electrode to its counter electrode). In some examples, the battery geometry may include side gaps positioned adjacent to the battery cells to allow electrolyte to flow into the gaps during buffering.

[0092] In some embodiments, a battery cell includes an electrode (e.g., a reference electrode) and a counter electrode, the electrode and the counter electrode being separated from each other by a gap, also referred to herein as a “separation space”. The separation space may include a membrane, for example, a membrane having a material comprising conduits or pores (e.g., microconduits or micropores). The pores and / or conduits may be configured to facilitate the propagation of charge carriers (e.g., ions) through the membrane. The conduits may be channels. The pores of the membrane may form the conduits. The battery cell may include an insulator or be coupled to an insulator. The battery cell may include a separation space or be coupled to a separation space. At least one component may be electrically insulating, for example, the membrane body, the insulator, or at least one component of the separation space. The separation space and the separation space may have or not have the same material content. A separator material may be disposed in the separation space. The separator material may be the same or a different material type as the membrane. The membrane may be (e.g., substantially) planar or layered. The membrane may be an ion-permeable microporous material suitable for use as a separator in an electrochemical battery cell. In some embodiments, the separator layer is coated with ceramic particles on one or both sides. In some embodiments, the battery cell includes a centrally located anode current collector, which may include or be electrically coupled to one of the electrode contacts on one side of the secondary battery. In some embodiments, the battery cell includes an anode active material layer, a separator layer, a cathode active material layer, and a cathode current collector arranged in a stacked configuration along a stack axis. The cathode current collector may include a cathode contact without cathode active material. The anode current collector may include an anode contact without anode active material. The anode contact may be located on the same side as the cathode contact or on a different side (e.g., opposite sides).

[0093] In some embodiments, the cathode includes a cathode active material. The cathode active material may include cathode active materials containing any number and / or any combination of transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides, lithium-transition metal nitrides, etc. The cathode active material may include transition metal elements such as the aforementioned transition metal oxides, transition metal sulfides, transition metal nitrides, and / or any combination thereof. The cathode active material may include metal elements having a d-shell or f-shell. The cathode active material may include metal elements such as Sc, Y, lanthanides, actinides, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pb, Pt, Cu, Ag, Au, and any number and / or any combination thereof. The cathode active material may include lithium cobalt oxide (LiCoO2), LiNi... 0.5Mn 1.5 O4, Li(Ni) x Co y Al z O2, lithium metal phosphates (e.g., lithium iron phosphate, LiFePO4), Li2MnO4, V2O5, molybdenum oxide sulfides, phosphates, silicates, vanadates, sulfur, sulfur compounds, oxygen (air), lithium nickel manganese cobalt oxides (Li(Ni) x Mn y Co z The cathode (e.g., the cathode active material) is selected from transition metal oxides, transition metal sulfides, transition metal nitrides, lithium-transition metal oxides, lithium-transition metal sulfides, transition metal phosphates, lithium-transition metal phosphates, and lithium-transition metal nitrides may be used selectively. The transition metal elements of these transition metal oxides, transition metal sulfides, and transition metal nitrides may include metal elements having a d-shell or f-shell. Specific examples of such metal elements are Sc, Y, lanthanides, actinides, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pb, Pt, Cu, Ag, and Au. Additional cathode active materials include LiCoO2, LiNi... 0.5 Mn 1.5 O4, Li(Ni) x Co y Al z O2, LiFePO4, Li2MnO4, V2O5, molybdenum oxide sulfide, phosphate, silicate, vanadate, sulfur, sulfur compounds, oxygen (air), Li(Ni) x Mn y Co z O2 and combinations thereof. The cathode active material may include S (e.g., Li2S in a lithiated state), LiF, Fe, Cu, Ni, FeF2, FeO d F 3.2dThe cathode may contain any combination of the following: FeF3, CoF3, CoF2, CuF2, NiF2 (where 0 ≤ d ≤ 0.5), metal oxides, metal sulfides, metal phosphates, binders, fillers, etc. The fillers may be inert to the chemical properties of the energy control device (e.g., the chemical properties of the battery cells). The binders may include polyvinylidene fluoride and / or polytetrafluoroethylene. The cathode may include lithium cobalt oxide (LCO), nickel manganese cobalt (NMC), lithium iron phosphate (LFP), lithium manganese oxide (LMO), nickel, lithium manganese iron phosphate, lithium manganese iron phosphate, sodium ions, nickel, lithium manganese-rich lithium, lithium cobalt oxide lithium, lithium manganese oxide lithium, lithium nickel-manganese-cobalt oxide lithium, etc., etc. The cathode (and the energy control device) may be cobalt-free.

[0094] In some embodiments, the energy control device may include a battery. The energy control device may include a lithium-ion battery, a nickel-metal hydride battery, an alkaline battery, any combination thereof, or any other combination thereof. The battery may include a single cell containing Cu, Al, Ni, polyethylene, polypropylene, any derivative thereof, any combination thereof, or any other combination thereof.

[0095] In some embodiments, the anode includes an anode active material. The anode active material may include silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (Co), cadmium (Cd), any combination thereof and / or any plurality thereof. The anode active material may include alloys or intermetallic compounds containing Si, C, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, Cd, any combination thereof and / or any plurality thereof. The anode active material may include alloys and intermetallic compounds. The anode active material may include oxides, carbides, nitrides, sulfides, phosphides, selenides, tellurides, any combination thereof or any plurality thereof of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Fe, Ni, Co, V, or Cd. The anode active material may include mixtures (e.g., lithium-containing mixtures), composite materials (e.g., lithium-containing composite materials), any combination thereof and / or any plurality thereof. The anode active material may include salts (e.g., tin salts), hydroxides (e.g., tin hydroxide), lithium titanate, lithium manganese oxide, lithium aluminate, lithium-containing titanium oxides, lithium transition metal oxides, ZnCo2O4, graphite particles, carbon particles, metallic forms of charge carriers (e.g., metallic lithium), any combination thereof, and / or any plurality thereof. The anode active material may be coated. The coating may include a stabilized metallic form of the charge carrier material (e.g., metallic lithium particles). The particulate material may include lithium carbonate stabilized metallic lithium powder, lithium silicate stabilized metallic lithium powder, stabilized metallic lithium powder, or other sources of ink, any combination thereof, and / or any plurality thereof. The anode active material may include materials embedded with the charge carriers. The active material of the anode may include allotropes of silicon and / or elemental carbon. The elemental carbon allotropes may be any of those disclosed herein, such as activated carbon, graphite, carbon fibers, carbon nanotubes, amorphous carbon, and / or fullerenes. The tubular structure may include nested tubes, for example, at least two or three nested tubes. The carbon fibers can be woven, aligned (e.g., parallel to each other and / or angled relative to each other), randomly arranged, or any combination thereof (if applicable). The anode can be a 100% silicon-carbon anode. The anode can include particulate material. The anode can include a carbon scaffold on which silicon (e.g., a silicon layer) is deposited. The exposed surface of the silicon can be coated with an allotrope of the elemental carbon or at least one of the allotropes. The carbon can include black carbon. The carbon can include hard carbon and / or soft carbon. The carbon-silicon structure can include continuous layers and / or a scaffold. The carbon can include particulate material. The particulate material can be used as a substrate for depositing one or more layers. The particulate material may or may not include fissures. The one or more layers can be deposited onto the exposed surface of the fissures.Anode active materials can include carbon materials (such as graphite and soft or hard carbon) or graphene (e.g., single-walled or multi-walled carbon nanotubes), or any range of metals, half-metals, alloys, oxides, nitrides, compounds, compounds that form alloys with lithium, any number of such metals, or any combination thereof, capable of intercalating lithium. Specific examples of metals or half-metals that can be used as anode materials include graphite, tin, lead, magnesium, aluminum, boron, gallium, silicon, Si-C composites, Si / graphite mixtures, and silicon oxide (SiO). x The anode active material may include porous Si, intermetallic Si alloys, indium, zirconium, germanium, bismuth, cadmium, antimony, silver, zinc, arsenic, hafnium, yttrium, lithium, sodium, graphite, carbon, lithium titanate, palladium, mixtures thereof, any number thereof, or any other combination thereof. In some embodiments, the anode active material may include aluminum, tin, silicon, its oxides, its nitrides, its fluorides, other alloys thereof, any number thereof, or any combination thereof. In some embodiments, the anode active material may include silicon, its alloys, its composites, its oxides, any number thereof, or any combination thereof. In some embodiments, the battery may not have an active material (e.g., a simple galvanic cell).

[0096] In some embodiments, the energy manipulation device includes an electrochemical cell. The cell may include an electrode and a counter electrode separated from each other by a gap. The energy manipulation device may include, for example, a simple galvanic cell containing a passive electrode. The galvanic cell may include an anode current collector, a cathode current collector separated from the anode current collector by a gap, an electrolyte, and charge carriers. The cell may include a partially active electrode, i.e., a current collector contacting an active material body. The active material body may be a layer. The cell may include a fully active electrode, i.e., both the electrode current collector and the counter electrode current collector of the cell are each in contact with a corresponding active material body, for example, a layer.

[0097] In some examples, the energy manipulation device may include a fuel cell. In other examples, the energy manipulation device may include a primary battery, which may be a non-rechargeable battery. The primary battery may be a battery comprising metallic Li, alkaline materials, zinc-carbon, silver oxide, and / or any other suitable materials. In some examples, the energy manipulation device may include a secondary battery, which may be rechargeable. The secondary battery may be a battery comprising lithium-ion, lead-acid (lead dioxide with sulfuric acid), nickel-cadmium, nickel metal hydride, and / or any other suitable materials. Using secondary or rechargeable batteries can reduce environmental waste compared to primary or non-rechargeable batteries because the materials can be reused for multiple cycles. In some examples, the energy manipulation device described herein may include an electrochemical cell. As described above, the cell may include an anode material and a cathode material. In one example, the electrochemical cell includes a passive electrode, wherein a simple electrochemical cell includes an anode charge carrier, a cathode charge carrier separated from the anode by a gap, an electrolyte, and charge carriers. In some examples, the energy manipulation device may include one or more active electrodes, wherein a charge carrier is in contact with an active material body. The active material body may include (e.g., deposited in the form of a layer) a layer. In some examples, the energy manipulation device may include one or more fully active electrodes, wherein the charge carriers of the electrode and / or counter electrode of a battery cell are each in contact with a corresponding active material body, e.g., a layer. The active material body is configured to be operatively coupled to a corresponding current collector of the electrode. The current collector may have at least about 10 3 Siemens / cm (S / cm), 10 4 S / cm, 10 5 S / cm or 10 6 The conductivity is measured in S / cm. The current collector can have a conductivity between any of the aforementioned values, for example, approximately 10. 3 S / cm to approximately 10 6 S / cm, or approximately 10 5 S / cm to approximately 10 6 S / cm.

[0098] In some examples, the battery cell includes an active material, charge carriers, an electrolyte, any combination thereof, or any other combination thereof. The active material (e.g., a material body such as a layer) may be added to one or both sides of the battery cell or battery cell stack. In some embodiments, the electrode includes a current collector (e.g., a conductor) containing an allotrope of elemental metal, metal alloy, elemental carbon, any combination thereof, or any other combination thereof. The allotrope of elemental metal may include graphite, carbon nanotubes, carbon wires, fullerenes, hard carbon, soft carbon, any combination thereof, or any other combination thereof. The battery cell may include charge carriers containing a salt such as a lithium salt. The electrolyte material may be solid, semi-solid, liquid, any combination thereof, or any other combination thereof. The electrolyte material may include salts, acids, and / or bases, for example, salts, acids, and / or bases dissolved in one or more non-aqueous polar solvents. In some embodiments, the electrolyte may include a polymer-based electrolyte. The polymer-based electrolyte may include PEO-based polymer electrolytes, polymer-ceramic composite electrolytes, polymer-ceramic composite electrolytes, polymer-ceramic composite electrolytes, and / or similar electrolytes. In some embodiments, the electrolyte may include an oxide-based electrolyte (e.g., lanthanum titanate (Lio.34Lao.56TiO3), Al-doped lithium lanthanum zirconate (Li6.24La3ZrzAlo.24O11.98), Ta-doped lithium lanthanum zirconate (Li6.4La3Zri.4Tao.6O12), lithium aluminum titanium phosphate (Lit.4Alo.4Tit.6(PO4)3), and / or similar electrolytes). In some embodiments, the electrolyte may include a solid electrolyte (e.g., a sulfide-based electrolyte, such as lithium tin phosphide sulfide (LiioSnP2Si2), lithium phosphide sulfide (13-Li3PS4), lithium phosphide sulfide chloroiodide (Li6PS5Clo.91o.i), and / or similar electrolytes). The electrolyte may include ethylene carbonate, diethyl carbonate, dimethyl carbonate, methyl ethyl carbonate, propylene carbonate, any derivative thereof, or any combination thereof.

[0099] Figure 1Example 100 shows a schematic diagram of a single battery cell including electrodes 102a-“C” (e.g., cathode) and opposing electrodes 105a-“A” (e.g., anode). A separator is disposed in separator spaces (e.g., gaps) 103-“B”. The battery cell is disposed in a battery having a housing 109. The housing may be rigid or flexible. The housing may include rigid and / or flexible portions. The battery may optionally have an insulator 104. The insulator may include one or more materials comprising ceramics, polymers, or resins. The battery may include one or more types of insulators. In one example, a polymer may fill the cathode gap, and alumina may fill the cathode gap, the gap extending from the edge of the battery cell to the edge of its adjacent housing (also referred to herein as the “shell”). In some embodiments, the insulator may include a non-conductive material. The ceramic may include alumina (Al2O3), zirconium oxide (ZrO2), magnesium oxide (MgO), boron nitride (BN), mullite, boehmite, or silicon carbide (SiC, for example, in pure form). Under normal conditions during battery use, the main current is the load current 106 flowing from one electrode to its opposite electrode and through the separation space 103. When volume 104 includes the insulator, the insulator is in contact at least at the opposite sides 102b and 102c of electrode 102a and at the opposite sides 105b and 105c of electrode 105a.

[0100] Figure 1 Example 110 shows a schematic diagram of a single battery cell, which includes an electrode 112-“C” (e.g., cathode) and a counter electrode 115-“A” (e.g., anode). A separator is disposed in a separator space 113-“B”. The battery cell is disposed in a battery having a housing 119. The separation space extension 121 extends beyond the electrode 112, and the extension 122 extends beyond the counter electrode 115, the extensions extending along the long axis of each electrode, the long axis shown in the diagram. Figure 1 The extension may extend further in the lateral direction. The extension may form the contact. The battery has an insulator 114. Under normal conditions, a load current 116 may flow through the separation space 113.

[0101] In some embodiments, the different extension distances of the components of the battery cell in the lateral direction form a corrugated (e.g., misaligned) surface of the battery cell, thereby forming a corrugated surface of the battery cell assembly, for example, as... Figure 1 The battery cell 120 is shown in the diagram. The battery cell may include at least one non-flat side, for example, as shown in the diagram. Figure 1 As shown in 120. The uneven (e.g., misaligned) side can form the wavy side of the battery cell assembly.

[0102] Figure 2 A schematic example 200 of a current collector in the form of a film or strip is shown. The electrode active material may contact (e.g., be deposited onto) a conductive sheet, which has a thickness of, for example, up to about 6 mm, 5 mm, 2.5 mm, 1 mm, or 0.5 mm. The conductive sheet may be a foil, for example, having a thickness of up to about 0.4 mm, 0.2 mm, or 0.1 mm. The current collector may include an internal portion, for example, when assembled in the battery. The internal portion of the current collector contacts the active material of the electrode. The tab may (e.g., substantially) not have the electrode active material. The current collector has a length axis, a width, and a height. The current collector has a face type with the largest surface area, which includes segments 201 and 202. The current collector has a length 203, a width 204, and a height 205. Section 202 represents a tab of the current collector, which can be bent during assembly of the energy manipulation device, for example, to couple with a busbar; and section 201 represents a planar section of the current collector, which can be coupled to an electrode active material, for example, a powder having a binder (one or more) and / or filler (one or more). In the example shown in 200, the tab has a uniform width 204 along its length. In some embodiments, the tab tapers (e.g., narrows, such as becoming tapered) along its length (e.g., and along its longest axis 211). The longest axis 211 of the current collector intersects at a position 214 on a face of the electrode having a height 205 and a width 204, in the example of 200, where the face has a minimum surface area. The current collector has a shorter axis 212 perpendicular to axis 211. The taper taper's taper along axis 211 can be symmetrical about axis 211, for example, using mirror symmetry, where a mirror extends along axis 211.

[0103] In some embodiments, the current collector may be an anode current collector. In some embodiments, the current collector may be a cathode current collector. The anode current collector may include conductive materials such as copper, carbon, nickel, stainless steel, cobalt, titanium, and tungsten and their alloys, or any other material suitable for use as the anode current collector layer. The current collector has at least about 10 3 Siemens / cm, 10 4 Siemens / cm or 10 5 The conductivity is measured in Siemens units per centimeter. The current collector has a conductivity between any of the aforementioned values, for example, approximately 10. 3 Siemens / cm to approximately 10 5Siemens / cm. The cathode current collector may include aluminum, nickel, cobalt, titanium, and tungsten or alloys thereof, or any other material suitable for use as the cathode current collector layer. In some embodiments, the cathode current collector includes metals such as aluminum, carbon, chromium, gold, nickel, NiP, palladium, platinum, rhodium, ruthenium, silicon, and alloys of nickel, titanium, or combinations thereof. As an example, in one embodiment, the cathode current collector includes gold or alloys thereof (such as gold silicide). As another example, in one embodiment, the cathode current collector includes nickel or alloys thereof (such as nickel silicide).

[0104] Figure 2 Example 250 shows schematic vertical cross-sections of various batteries, illustrating the arrangement and / or folding of battery cells relative to a Cartesian coordinate system. In Example 251, the battery cells are arranged parallel to each other. Examples 252 through 255 show various folding arrangements of sheets comprising one or more battery cells, wherein 252 shows a zigzag fold, 253 shows a top hat fold, 254 shows a sinusoidal fold, 255 shows a spiral (e.g., winding) fold, and 256 shows an elliptical or oblong spiral (e.g., winding) fold. The battery may include battery cells folded in a winding (e.g., core) configuration having an oblong or cylindrical structure, for example, as Figure 3 As shown in 350.

[0105] In some embodiments, one or more battery cells are disposed within a housing to form the energy control device, such as a battery. The housing may isolate the battery from one or more reactive agents (also referred to herein as “reactive substances”) present in the surrounding environment outside the energy control device. The reactive agents (one or more) may include oxygen, water, alcohols, thiols, sulfuric acid, phosphoric acid, carboxylic acids, hydrogen sulfide, any number thereof, or any combination thereof. The reactive agents (one or more) may be oxygen-based, sulfur-based, and / or phosphorus-based reactive agents. The reactive agents (one or more) may include water and / or oxygen. In one example, the reactive agents (one or more) include water in liquid and / or vapor form. The water may be in droplet form. The housing may be configured to separate and / or insulate the battery cells (one or more) from the reactive agents (one or more) present in the surrounding environment outside the energy control device, for example, to inhibit (e.g., hinder or prevent) the reactive agents (one or more) from reaching the battery cells, such as reaching the electrodes (one or more).

[0106] The energy control device has (e.g., Euclidean) three-dimensional (3D) geometry. The energy control device may have an asymmetrical shape; for example, its housing may have an asymmetrical shape. The Euclidean 3D shape may include a cylinder or a prism. The prism may be a Euclidean prism or an amorphous prism. In some embodiments, the battery is a prismatic battery. In some embodiments, the battery is a cylindrical battery. The battery may have a first basic length dimension (FLS), such as a height of at least about 1 mm, 2 mm, 3 mm, 5 mm, 6 mm, 8 mm, or 10 mm (e.g., Figure 4 (431 in the text). The first FLS of the battery can be any value between the aforementioned values, for example, about 1 mm to about 10 mm. The battery may have a second FLS, such as a length of at least about 10 mm, 30 mm, 40 mm, 50 mm, 70 mm, 80 mm, 100 mm, 150 mm or 200 mm (e.g., Figure 4 (432 in the text). The battery may have a third FLS, such as a width of at least about 10 mm, 30 mm, 40 mm, 50 mm, 70 mm, 80 mm, 100 mm, 150 mm or 200 mm (e.g., Figure 4 (referring to section 433). The third FLS of the battery can be any value between the aforementioned values, for example, about 10 mm to about 200 mm. The battery can have an aspect ratio of the second FLS to the first FLS of at least about 1:1, 2:1, 4:1, 5:1, 8:1, 10:1, 15:1, 20:1, 25:1, 30:1, 35:1, 50:1, or 100:1. The battery can have an aspect ratio of the second FLS to the first FLS between the aforementioned values, for example, about 1:1 to about 10:1, about 1:1 to about 50:1, about 1:1 to about 100:1, or about 2:1 to about 50:1. The FLS (e.g., the first FLS and the second FLS) can include length, width, height, diameter, or any other FLS disclosed herein.

[0107] Figure 3 Examples of vertical cross-sections of various cells relative to a Cartesian coordinate system are shown, viewed from one side having length and height (e.g., Figure 4(Height 451 and length 452). Example 300 shows battery cells, such as battery cell 302, stacked in a direction perpendicular to the z-axis, the battery having a housing 301. During charge and discharge cycles, the battery expands and contracts. The expansion generates a force in the battery in a direction perpendicular to the stacking direction of the battery cells and toward the edge of the battery (e.g., along arrow 303). Constraints 307a and 307b are coupled to the battery cell stack to suppress this expansion, for example, the constraint is an anisotropic constraint configured to prevent expansion in the direction of arrow 303. The constraint 307a-b are disposed opposite each other (e.g., positioned) and separated by a gap. End plates 306a and 306b are disposed between the constraint and the battery cell stack, wherein each end plate contacts the distal end of the battery cell stack along the stacking direction, the end plates and the constraint are positioned symmetrically about the stacking axis (e.g., substantially), for example, in a (e.g., substantially) mirror-symmetric plane extending along the stacking axis of the battery cells. The contraction and expansion can cause pressure buildup on the battery. Heat can be released during charge and discharge cycles, for example, within the interior 304 of the battery cell stack. This heat can be dissipated from the battery along arrow 303, thereby improving battery safety, for example, by suppressing runaway reactions. Example 350 shows a battery cell 352 wound around itself about an axis perpendicular to the drawing page, for example, in a wound battery cell (e.g., core) configuration. The battery cell 352 is disposed (e.g., positioned) within a battery housing 351. The heat can be dissipated from the battery along arrow 353. Compared to the wound battery configuration shown in 350, the stacked battery cell arrangement shown in Example 300 can have better thermal conductivity. During charge and discharge cycles, the battery expands and contracts. The expansion generates forces within the battery along the stacking direction of the battery cells and toward the edges of the battery. The contraction and expansion can cause pressure buildup on the battery. One or more constraints can be added to the battery to suppress this expansion, for example, by adding an anisotropic constraint configured to prevent expansion in a direction perpendicular to arrow 303.

[0108] Figure 4Schematic perspective views of energy manipulation devices such as batteries and their individual battery cell architectures relative to a Cartesian coordinate system are shown. Example 400 shows a cylindrical battery housing having a length of 402 and a height of 401 as its diameter. The battery may include one or more battery cells forming a wound sheet. In Example 400, each of the bottom and top surfaces of the cylinder has a smaller surface area compared to the side surfaces of the cylinder (i.e., the curved surfaces of the cylinder). Example 430 shows a prismatic battery housing that is a rectangular prism or cuboid. The battery has a length of 432, a height of 431, and a width of 433. Battery cells 435 are stacked in the battery along the height 431 and along the Z-direction. In Example 430, the XY plane has a larger surface area than the XZ plane, and the XY plane has a larger surface area than the YZ plane. Example 450 shows a prismatic battery housing that is a rectangular prism or cuboid. The battery has a length of 452, a height of 451, and a width of 453. Battery cells 435 are stacked in the battery along length 452 and in the X direction. In example 450, the XY plane has a larger surface area than the XZ plane, and the XY plane has a larger surface area than the YZ plane.

[0109] In some embodiments, the battery cell is arranged (e.g., substantially) perpendicular to the face of a prismatic (e.g., cuboid) battery having the largest surface area. Sometimes, the largest surface area faces of the anode, separation space, separator, cathode, and / or separation space are arranged (e.g., substantially) perpendicular to the battery face having the largest surface area. The anode, separation space, any separator, and cathode can be arranged (e.g., substantially) parallel to each other. The battery cell components can be configured to be arranged around a stacking axis. The stacking axis can be parallel to the face of the housing (e.g., battery case, closure, or enclosure) having the largest surface area. The stacking axis can be (e.g., substantially) perpendicular to the face type of the electrode having the largest surface area. Figure 4 Example 450 illustrates a battery cell arranged perpendicular to the XY plane of the battery, which has the largest surface area among all faces of the battery. In example 450, the surface area of ​​the battery cell is at most the surface area of ​​the YZ plane of the battery or less than the surface area of ​​the YZ plane. This is in contrast to (a) a battery cell arranged parallel to the plane with the largest surface area of ​​its battery (e.g., Figure 4 (430) and / or (b) cylindrical batteries such as wound cell (e.g., core) batteries. Figure 4 Compared to 400 in the middle, battery cells arranged perpendicular to the surface with the largest surface area of ​​their respective batteries (e.g., Figure 4The 450 in the example has a larger combined cell side (e.g., edge) surface area. In some embodiments, the larger the combined cell side (e.g., edge) surface area, the greater the effect of residual current on the total current of the battery. When the cell includes at least one non-flat side (e.g., as shown in the example), the effect is more pronounced. Figure 1 As shown in 120, the uneven (e.g., misaligned) side forms the wavy side of the battery cell assembly. The wavy side may or may not contribute to the amount of residual current flowing between the anode and cathode of the battery cell (e.g., through the insulator).

[0110] In some embodiments, an energy manipulation device, such as a battery, includes battery cells. The battery cells may be stacked along an axis. Separating spaces may be provided between every two adjacent battery cells, such that a first battery cell contacts a first surface of the separating space, and a second battery cell contacts a second surface of the separating space opposite its first surface. The separating spaces may include an insulator, such as any insulator disclosed herein. The separating spaces may be configured to electrically separate one battery cell from another. The stack of battery cells may follow a pattern, which may include a sequence. The sequence may include the arrangement of the components of the battery cells relative to each other. The sequence may include an anode, a separation space, a cathode, and a separating space. The sequence may follow a CBAS pattern or a CBASABCS pattern, where “C” represents the cathode, “B” represents the separation space, “A” represents the anode, “S” represents the separating space, and “E” represents an end plate, for example, see [link to relevant documentation]. Figure 5 The battery cells can be stacked into one or more groups. The separation space can include two opposing faces. One face of the separation space contacts the anode, and the opposing face contacts the cathode. The battery cell can include a component comprising an anode, a cathode, a separation space, and an optional partition space. The partition space can include a material of the same type as the separation space. The partition space and the separation space can be (e.g., substantially) identical. The components of the battery cell can be arranged along an axis. The components of the battery cell can be arranged symmetrically along the axis (e.g., substantially), for example, mirror-symmetric, wherein the mirror extends along the axis; and / or rotationally symmetric, wherein the axis of rotation extends along the battery cell stacking axis (e.g., parallel to the axis of rotation). Figure 5(Axis 590 in the middle). At least two components of the battery cell may extend (e.g., substantially) the same distance along a direction perpendicular to the battery cell stack axis. At least two components of the battery cell may extend different distances from the axis along a direction perpendicular to the battery cell stack axis (e.g., laterally). The different distance extensions of the components may form a corrugated (e.g., misaligned) surface of the battery cell and the battery cell group, for example, as Figure 1 As shown in 120. See also Figure 5 The sides (e.g., edges) of battery cell groups 500 and 550. In one example, the cathode extends less than the anode, the extension being perpendicular to the battery cell stack axis. In one example, the separation space extends more than the anode and / or more than the cathode, the extension being perpendicular to the battery cell stack axis.

[0111] Figure 5 A schematic cross-sectional example 500 of a battery is shown, the battery including a cathode 502, an anode 505, a separation space 506, and a partition space 507. The battery cells are disposed within a volume 504 of the battery, the volume of which may include an insulator. The battery cells are stacked along an axis 590 in a repeating CBAS arrangement. Each anode “A” in the battery is operatively coupled (e.g., connected) to a current collector such as 513, which is coupled in parallel to a main anode current collector 514, which terminates at a cathode contact 511. Each cathode “C” in the battery is operatively coupled (e.g., connected) to a current collector such as 516, which is coupled in parallel to a main cathode current collector 517, which terminates at an anode contact 512.

[0112] Figure 5 A schematic cross-sectional example 550 of a battery is shown, comprising a cathode 552, an anode 555, a separation space 556, and a partition space 557. The battery cells are disposed within a volume 554 of the battery, which may include an insulator. The battery cells are stacked along axis 590 in a repeating CBASABCS arrangement. Each anode “A” in the battery is operatively coupled (e.g., connected) to a current collector such as 563, which is coupled in parallel to a main anode current collector 564, terminating at a cathode contact 561. Each cathode “C” in the battery is operatively coupled (e.g., connected) to a current collector such as 566, which is coupled in parallel to a main cathode current collector 567, terminating at an anode contact 562. Figure 5In this configuration, the main cathode current collector is disposed on a surface of the battery cell assembly that is different from the main anode current collector, and the different surfaces are opposite surfaces.

[0113] In some embodiments, the battery includes one or more main current collectors, such as those disclosed herein. The main current collector may include a bus and / or a bus extension. The main current collector may or may not contact an insulator covering the edge of the battery cell. Figure 5 In Example 500, the main current collectors 517 and 514 are separated from the insulator 504 by a gap. In the example shown in 500, the main current collectors 517 and 514 are in contact with the insulator 504.

[0114] In some embodiments, the end plate is disposed at the distal end of the battery cell assembly, for example, disposed at the relatively distal end of the battery cell assembly and along the stacking axis of the battery cells (e.g., Figure 5 (Setting 590 in the middle). Figure 5 Example 500 shows two opposing end plates disposed at two far ends of a stacked battery cell assembly, the end plates being designated by “E”, with end plate 520 contacting the insulator at its opposing lateral ends. Figure 5 550 shows an example of two opposing end plates located at the two far ends of a stacked battery cell assembly, the end plates being designated by “E”, the end plates having no insulator at their two opposing lateral ends perpendicular to the stack axis 590.

[0115] In some embodiments, an energy storage device, such as a battery, includes multiple battery cells. Each of the battery cells includes an anode separated from a cathode by a gap. The gap may include a separator. The battery cell may include one or more electrolyte types. Each of the electrodes (e.g., anode and cathode) includes a current collector of a conductive material, such as a strip, foil, or film, on which an active electrode material is disposed. The conductive material may include a single metal, a metal alloy, or an allotrope of a single metal. In one example, the single metal includes aluminum or copper. In one example, the metal alloy may include stainless steel. In one example, the allotrope of the single metal may include carbon nanotubes or carbon fibers. The tubular structure (e.g., nanotubes) may include nested tubes, for example, at least about two, three, four, or more nested tubes. The carbon fibers may be woven, randomly dispersed, or any combination thereof. The strip of the conductive material may or may not include composite materials. At least two battery cells in the energy storage device (e.g., a battery) may be stacked along (e.g., substantially) a direction perpendicular to their face with the largest surface area. The electrode has the largest surface area of ​​the electrode surface, and the counter electrode has the largest surface area of ​​the counter electrode surface. In some embodiments, the volume of the battery cell differs between the state of charge and the state of discharge of the electrodes of the battery cell. The volume of the battery cell can be repeatedly and / or reversibly changed between the state of charge and the state of discharge. The reversible discharge may not be completely reversible; for example, the properties of one or more components of the battery cell may be degraded during charge / discharge cycles. The repeated cycles between the state of charge and the state of discharge may include at least about 150 cycles, 200 cycles, 250 cycles, 300 cycles, 400 cycles, 500 cycles, 700 cycles, 800 cycles, 1000 cycles, 1200 cycles, or 1500 cycles. The repeated cycles between the state of charge and the state of discharge may include any number of cycles between the aforementioned number of cycles, for example, about 150 cycles to about 1500 cycles. In some embodiments, the volume of the battery cell differs between the state of charge and the state of discharge of the electrodes of the battery cell. The volume change may include a change of up to about 20*, 25*, 50*, 100*, 200*, 300*, or 400* in the initial volume of the battery cell. The volume change may also include a change of at least about 10*, 25*, 50*, 100*, 200*, or 300* in the initial volume of the battery cell. The volume change may include any of the aforementioned values, for example, about 10* to about 400*, about 100* to about 400*, or about 20* to about 200*. The symbol “*” represents a multiplication operation.

[0116] The energy storage device may include at least one constraint (e.g., a strut or strap). The constraint may be configured to maintain a constant size and / or volume of the energy control device during charging / discharging operations (e.g., substantially). The constraint may be configured to maintain, for example, internal pressure within the energy control device during charging / discharging operations. The internal overpressure within the energy control device may be up to about 100 PSI, 150 PSI, 200 PSI, 500 PSI, 1000 PSI, 2000 PSI, 3000 PSI, 5000 PSI, or 10000 PSI. The internal overpressure within the energy control device may be up to about 50 PSI, 100 PSI, 150 PSI, 200 PSI, 500 PSI, 1000 PSI, 2000 PSI, 3000 PSI, or 5000 PSI. The internal overpressure in the energy control device can be between the aforementioned pressures, for example, about 50 PSI to about 10,000 PSI, about 50 PSI to about 500 PSI, about 50 PSI to about 2,000 PSI, or about 100 PSI to about 3,000 PSI. The internal overpressure in the energy control device can be greater than the ambient pressure outside the energy control device, for example, above 14.6 PSI. In some embodiments, the energy storage device has a surface type with the largest surface area among its various surface types. The surface type with the largest surface area can deform (e.g., bend) during or due to the overpressure phase. The surface type with the largest surface area can be reversibly deformed (e.g., substantially) during the life of the energy control device. The substantial recovery of the deformation of the surface can be within the specifications and / or intended use of the energy control device.

[0117] In some embodiments, the battery cell packs are configured in an orthogonal stacked structure.

[0118] In some embodiments, the energy control device includes a restraint system. The restraint system may be applied to one or both of the X and Y surfaces of the energy control device (e.g., a battery). In some embodiments, the restraint system includes multiple perforations to facilitate the distribution (e.g., by flow) of an electrolyte solution after the individual battery cells or battery cell packs have been assembled. In some embodiments, the housing comprises stainless steel, aluminum, titanium, beryllium, beryllium copper (hard), copper (O2-free and / or hard), nickel, other metals or metal alloys, composite materials, polymers, ceramics, any combination thereof, or any other suitable material (if applicable).

[0119] Figure 6Example 600 shows an exploded view of a pair of constraint members 601a and 601b surrounding a stacked group of battery cells (e.g., a cluster) 602, which are part of a constraint system. Example 650 shows an exploded view of the two constraint members 601a-b closer to the stacked group of battery cells 602. Figure 6 This is shown relative to a Cartesian coordinate system. Each constraint can suppress the expansion of the battery cell during charging and / or discharging. The suppression of the expansion can be anisotropic or aisotropic. Figure 6 In the example shown, the constraint can anisotropically prevent the expansion of the battery cell along the Y-axis.

[0120] In some embodiments, the battery cell includes an anode separated from the anode by a gap. The battery cell may include a separator disposed in the gap. The battery cell may be elongated, for example, elongated box-shaped. The face of the battery cell opposite to the largest surface area of ​​the electrode (e.g., anode or cathode) may have an aspect ratio of at least about 10:1, 15:1, 20:1, 35:1, or 50:1, where the aspect ratio is the length of the face (e.g., ...). Figure 7 731 in the middle) and the height of the surface (e.g., Figure 7 The ratio of the length to the height of the battery cell is 732. The battery cell may have an aspect ratio between the aforementioned values, for example, from about 10:1 to about 50:1, where the aspect ratio is the ratio of the length to the height of the battery cell. The battery cell may have an aspect ratio of at least about 1:1, 2:1, 4:1, 5:1, 8:1, 10:1, 15:1, 20:1, 25:1, 30:1, 35:1, 50:1 or 100:1, where the aspect ratio is the height of the battery cell (e.g., 732). Figure 7 732 in the middle) and width (e.g., Figure 7 704 in the diagram shows the aspect ratio of the widths of the three battery cells. The battery cells may have an aspect ratio between the aforementioned values, for example, from about 5:1 to about 50:1, where the aspect ratio is the ratio of the height to the width of the battery cell.

[0121] Figure 7Example 700 illustrates the lateral portions of three battery cells, each including an electrode such as 701, a counter electrode such as 703, and a separator 702 disposed between each pair of adjacent electrodes and the counter electrode. In Example 700, the electrode (e.g., 701) extends less toward the lateral edge 704 of the stacked battery cells than the counter electrode 703, wherein the separator extends more toward the edge than the electrode, and subsequently the counter electrode extends less than the separator, thereby forming, for example, a corrugated or wavy lateral edge 704. Example 730 illustrates a stack of battery cells, for example, wherein the battery cells are horizontally stacked. The stacking axis of the battery cells may be parallel to the face of the battery cell having the largest surface area, for example, the face of a prismatic cell.

[0122] Example 750 illustrates a stacked battery cell assembly 751 surrounded by two opposing housings 752a and 752b. Current collectors of the stacked battery cells are coupled to connectors 753a and 753b. 753a is connected to an electrode of the battery cell assembly, and 753b is connected to a counter electrode of the battery cell assembly. The battery cells surrounded by the housings (e.g., shells or covers) are also secured by a flexible material 755 (e.g., a strip). The flexible material may include a polymer or resin. The flexible material may be an electrical insulator. The housing may include one or more openings. Figure 7 In the example, housing 752a includes, for example, elongated oval openings evenly spaced along the X direction. Figure 7 It is shown relative to the Cartesian coordinate system.

[0123] Figure 8 Example 800 shows an exploded view of a pair of constraint members 801a and 801b of a constraint system surrounding a stacked group of battery cells (e.g., a group) 802. Each of the constraint members 801a-b includes, for example, an elongated oval opening that is evenly spaced along the X direction. Figure 8 It is shown relative to a Cartesian coordinate system. The constraint can form a cage, for example, having one or more openings, such as slits, e.g., oblong slits or holes.

[0124] In some embodiments, the battery cell is configured with at least one gap portion that can be occupied during the expansion of the active material. The gap can be located between the electrode and the counter electrode, or adjacent to the edge (e.g., side) of the electrode. Some battery cells described herein include gaps located adjacent to one or more electrodes, for example, on the side (one or more) of the electrode(s). These gaps allow electrolyte to flow into the gap, for example, during buffering.

[0125] Example 830b is a microscopic image of segment 830a. The image shows a battery cell assembly comprising: (a) an anode comprising (i) an anode active material such as 831 and (ii) an anode current collector such as 832; (b) an anode comprising (iii) an anode active material such as 833 and (iv) a cathode current collector such as 834; (c) separators such as 835 and 836; and (d) an insulating material such as 837. The insulating material 837 is disposed in a side gap at the edge of the electrode. Each cathode is separated from its adjacent anode by a gap in which the separator is disposed. In the example shown in 830, a pair of adjacent separators are separated from each other. The separator extends further toward the edge of the battery cell assembly than the cathode extends further toward the edge than the anode. The insulator is disposed in the volume between the battery cell assembly and its edge. The ends of the separators along the z-direction alternate between a first pair of adjacent separator ends pointing towards each other and a second pair of adjacent separator ends facing away from each other, the ends along the z-direction. For example, the ends of separators 835 and 836 point towards each other. Each anode and cathode in the battery cell is staggered (e.g., alternately arranged) along the y-direction, the stacking direction of the battery cells. In the example shown in 830b, (a) the anode active material is disposed on both sides of a corresponding anode current collector, and (b) the cathode active material is disposed on both sides of a corresponding cathode current collector, each side along the z-direction. In the example shown in 830b, (a) the anode active material is disposed on both sides of the anode current collector such that the anode current collector (e.g., substantially, schematically, and / or generally) forms a mirror plane of the anode active material, and (b) the cathode active material is disposed on both sides of the cathode current collector such that the cathode current collector (e.g., substantially, schematically, and / or generally) forms a mirror plane of the anode active material.

[0126] Example 860b is a microscopic image of segment 860a. The image shows a battery cell assembly comprising: (a) an anode including (i) an anode active material such as 861 and (ii) an anode current collector such as 862; (b) an anode including (iii) an anode active material such as 863 and (iv) a cathode current collector such as 864; and (c) a separator such as 865. Each cathode is separated from its adjacent anode by a gap in which the separator is disposed. In the example shown in 860, the cathode active material extends along the X direction to the edge of the battery cell and bends toward the Y direction to electrically connect its adjacent cathode current collector along the Y direction. The bent portions of the cathode current collector (e.g., tabs) are joined by a material (including an adhesive connector 867) that operatively (e.g., electrically) couples the tabs to form a busbar. Figure 8 In the example shown, the cathode contacts the separator, the separator contacts the anode, and the anode contacts any additional separators in the battery cell assembly. End plates may be positioned at both ends of the battery cell assembly along the stacking direction (e.g., along the Y direction).

[0127] In some embodiments, the interior of the housing is separated from the exterior of the housing, for example, to prevent reactive substances (one or more) from the external environment from penetrating into the interior environment and causing damage. Terminals configured to conduct current flow are configured to allow electrical connection between the external environment and one or more battery cells disposed within the housing. The housing includes a seal to separate the interior environment of the housing from its external environment. The terminals extend from the interior of the housing to the external environment through the seal. Each of the terminals can be coupled to the housing (e.g., at the sealed area) via a coupler. The coupler may include a compressible material such as a stretchable material. The terminals may be secured to the housing, for example, at the seal by an adhesive. The terminals may be secured to the seal at least partially by the adhesive and / or the compressible material. The compressible material may be an adhesive. The compressible material and / or the adhesive may include polymers, resins, combinations thereof, or multiple types thereof. The adhesive may be (e.g., substantially) confined to the seal. The adhesive may include polypropylene or epoxy. The fuse may be reinforced, for example, by an adhesive to any part of the energy control device, such as the part disclosed herein. The fuse may be positioned at (e.g., reinforced to) a portion of the energy control device, the portion being sufficiently distanced from the vulnerable material(s) such that, when the fuse actuates, the damage is not caused by the activation of the vulnerable material(s) themselves. The vulnerable material may participate in the chemical reactions of the energy control device (e.g., the battery cell). The vulnerable material(s) may include any active material of the battery cell, any electrolyte, any separator, any insulator, any spacer, any current collector, any busbar, any adhesive, any plurality of such materials (e.g., a plurality of or more of the same type), or any combination thereof. The compressible material may be disposed in the seal, inside the housing, outside the housing, or any combination thereof. In some embodiments, the terminals are compressed by the compressible material, which in turn is compressed by the seal of the housing.

[0128] In some examples, the battery is housed within a pouch. The pouch isolates the contents of the battery (e.g., individual battery cells) from one or more reactive agents in the surrounding environment outside the pouch. The pouch may surround the battery casing and the individual battery cells (one or more) housed therein. The pouch may include one or more layers. These layers may include materials containing polymers, resins, elemental metals (e.g., their strips, films, foils, and / or powders), or metal alloys (e.g., their strips, films, foils, and / or powders). The layers may include one or more of these materials. The pouch may have an outer surface with colors including black, silver, or white.

[0129] In some embodiments, the battery cell(s) are enclosed in a rigid closure surrounding the battery cell(s). The rigid closure may include the restraint system and / or end plates. The closure may include elemental metals, metal alloys, allotropes of elemental carbon, polymers, resins, various types thereof, or any combination thereof. Compared to the closure, the housing may be formed of a material with (e.g., substantially) the same hardness, lower hardness (e.g., softer), or higher hardness. In one example, the housing may include a pouch with a lower hardness than the closure. Compared to the closure and / or the pouch, the pouch may be nested within a harder housing (e.g., a can). The closure may be protected by a layer that cushions the interaction between the closure and the softer housing. The protective layer may include elastic materials, polymers, resins, any number thereof, or any combination thereof. The protective layer may be in the form of strips surrounding each side of the closure. The sides may be of a side type with a smaller surface area. The sides may be different from the side type with the largest surface area. The protective layer may have thickness, elasticity, and / or durability that allows it to cushion the interaction between the closure and the adjacent softer shell. The protective layer may be sponge-shaped. It may be porous or non-porous. The protective layer may include polyurethane, polypropylene, polyethylene, and / or rubber. The protective layer may be attached to the closure by adhesion and / or by compression, for example, similar to the compression of a belt.

[0130] In some embodiments, when the battery is in a discharged state, charge carriers (e.g., Li ions) reside in the cathode, and when the battery is in a charged state, the charge carriers reside in the anode. For example, when the battery is charged, charge carriers (e.g., charge ions) migrate into one or more electrode active materials. The active material undergoes a volume change as the charge carriers move (e.g., migrate) in and out of the active material of the electrode. This movement into and out of the active material can be referred to as the inflow and outflow of the charge carriers relative to the active material. The amount of expansion can vary depending on the active material used for the electrode. For example, when a graphite electrode is charged, it can expand by about 6% to 10%. In another example, when a silicon electrode is charged, it can expand by up to 300%. In another example, when a silicon oxide electrode is charged, it can expand by up to 210%. In another example, when the silicon-containing electrode is charged, the electrode can expand to up to about 20%, 50%, 75%, 100%, 200%, 300%, or 350%, where the percentages are volume percentages.

[0131] In some embodiments, an energy storage device, such as a battery, includes multiple battery cells. Each of the battery cells includes an anode separated from a cathode by a gap. The gap may include a separator. The battery cell may include one or more electrolyte types. Each of the electrodes (e.g., anode and cathode) includes a current collector of a conductive material, such as a strip, foil, or film, on which an active electrode material is disposed. The conductive material may include a single metal, a metal alloy, or an allotrope of a single metal. In one example, the single metal includes aluminum or copper. In one example, the metal alloy may include stainless steel. In one example, the allotrope of the single metal may include carbon nanotubes or carbon fibers. The tubular structure (e.g., nanotubes) may include nested tubes, for example, at least about two, three, four, or more nested tubes. The carbon fibers may be woven, randomly dispersed, or any combination thereof. The strip of the conductive material may or may not include composite materials. At least two battery cells in the energy storage device (e.g., a battery) may be stacked along (e.g., substantially) a direction perpendicular to their face with the largest surface area. The electrode has the largest surface area of ​​the electrode surface, and the counter electrode has the largest surface area of ​​the counter electrode surface. In some embodiments, the volume of the battery cell differs between the state of charge and the state of discharge of the electrodes of the battery cell. The volume of the battery cell can change repeatedly and / or reversibly between the state of charge and the state of discharge. The reversible discharge may not be completely reversible; for example, the properties of one or more components of the battery cell may be degraded during charge / discharge cycles. The repeated cycles between the state of charge and the state of discharge may include at least about 200 cycles, 500 cycles, 800 cycles, 1000 cycles, 1200 cycles, or 1500 cycles. In some embodiments, the volume of the battery cell differs between the state of charge and the state of discharge of the electrodes of the battery cell. The volume change may include a change of up to about 20%, 25%, 50%, 100%, 200%, 300%, or 400% of the initial volume of the battery cell. The volume change may include a change of at least about 10%, 25%, 50%, 100%, 200%, or 300% of the initial volume of the battery cell. The volume change may include any of the aforementioned values, for example, about 10% to about 400%, about 100% to about 400%, or about 20% to about 200%. The charge carriers may interact with the active material (e.g., containing silicon) such as during intercalation and / or alloying processes (e.g., Li-Si alloying). The Li-Si alloying may form a material comprising Li... 15 Si4 or Li 22Si5 alloys. Compared to graphite, lithium alloying of silicon can enable silicon to store at least 5*, 10*, or 15* more lithium, where the operation "*" represents a mathematical operation of "times".

[0132] In some embodiments, the energy control device has specified conditions and / or a specified lifespan. The operation of the energy control device (e.g., a battery) may be performed during its specified lifespan, during its specified use, and / or according to governing standards relating to the energy control device. The specified lifespan may depend on the number of charge and discharge cycles, for example, the number disclosed herein. The number of cycles may be the number of times the energy control device (e.g., a battery) is fully charged before its capacity drops below 80%. The specified lifespan may be, for example, up to about 3, 5, 6, or 7 years from its manufacturing date. The energy control device may have a storage life of at least about 6 months or 12 months. The standards may include SAE J2380, MIL-STD-810G (516.6), UL (e.g., UL1642 and / or UL 2054), SAE J2380, GB31241, MSDS, UL (UL1642), CE, CB, UN (e.g., UN38.3), RoHS, REACH, IEC (e.g., IEC 60068-2-6, IEC 60068-2 and / or IEC62133), DOT, IATA, GB, CTIA, PSE, or any combination thereof. The specified operating conditions include temperatures between a lower temperature (e.g., -20°C) and a higher temperature (e.g., 80°C). The higher temperature may be up to about 60°C, 70°C, 80°C, 85°C, or 90°C. The higher temperature may be at least about 40°C, 50°C, 55°C, 60°C, 70°C, or 80°C. The lower temperature can be up to about -10°C, -20°C, -30°C, -40°C, or -60°C. The lower temperature can be at least about -20°C, -10°C, or 0°C. The temperature can be between any of the aforementioned values, for example, about 60°C to about -20°C, or about 90°C to about -40°C. Compared to the capacity of the energy control device at ambient temperature (e.g., room temperature such as 20°C or 25°C), the energy control device can maintain at least about 70%, 80%, or 85% of its capacity at the lower temperature.

[0133] In some embodiments, the energy control device is rechargeable. The energy control device can be configured to allow fast charging (e.g., allowing the battery cells (one or more) to be fully charged within five minutes). The energy control device can have a charging rate of at least about 0.2C, 0.5C, 1C, 2C, 3C, 5C, 7C, 10C, 12C, 15C, 30C, or 40C. This charging rate can charge the energy control device to 80% or 90% of its capacity. The energy control device can have a charging rate of any value between the aforementioned values, for example, about 0.2C to about 40C, about 0.2C to about 5C, about 3C to about 30C, about 10C to about 40C, or about 2C to about 7C. The energy control device can be charged in up to about 30 seconds, 3 minutes, 6 minutes, 10 minutes, 12 minutes, 15 minutes, or 30 minutes to reach 80% or 90% of its capacity. The energy control device can allow selection of a discharge mode and / or a charging mode. The discharge and / or charge can be in continuous mode, pulse mode, or a combination of continuous and pulse modes. In some embodiments, the battery has an N / P ratio greater than one. The N / P ratio can be at least about 1.05, 1.1, or 1.15. The cell configuration, cell bank architecture, and / or chemical composition (e.g., the chemical composition of the electrode active materials (one or more)) can allow buffering such as pre-lithiation. The cell, cell bank, and / or battery disclosed herein can help maintain cyclic charge carriers (e.g., lithium) in the anode, for example, also at the start of charge (BOC). The cell, cell bank, and / or battery disclosed herein can provide better conductivity and / or lower overpotential in the anode deposition material (e.g., a pie containing the active material). The cell, cell bank, and / or battery disclosed herein can reduce (a) the cycling window and / or (b) damage at least in part due to expansion and contraction during the state of charge and discharge of the cell. The battery cells, battery cell packs, and / or batteries disclosed herein can provide high voltage at BOC, for example, without buffering, for example, without preloading the charge carriers into the active material of the electrode during processes such as pre-lithiation. The nominal voltage of the energy control device can be at least about 3.6 volts (V), 3.7V, or 3.8V. The operating voltage of the energy control device can be at least about 3V, 3.7V, 3.8V, 4.0V, 4.2V, 4.35V, 4.5V, 4.75V, 4.9V, or 5.0V. The operating voltage of the energy control device can be between any of the foregoing values, for example, about 3V to about 5V, about 3V to about 4V, or about 4V to about 5V.The weight of the energy control device can be up to about 1 gram (gr), 1.5 gr, 1.8 gr, 2 gr, 3.5 gr, 6 gr, 46 gr, 47 gr, 50 gr, 69 gr, 70 gr, 71 gr, or 100 gr. The weight of the energy control device can be any value between the aforementioned values, for example, from about 1.8 gr to about 100 gr. The volumetric energy density of the energy control device can be at least about 800 watt-hours per liter (Wh / liter), 805 Wh / liter, 820 Wh / liter, 900 Wh / liter, 1300 Wh / liter, or 1500 Wh / liter. The volumetric energy density of the energy control device can be any value between the aforementioned values, for example, from about 800 Wh / liter to about 1500 Wh / liter. The gravimetric energy density of the energy control device can be at least about 300 Wh / kg, 320 Wh / kg, 350 Wh / kg, 395 Wh / kg, 400 Wh / kg, 500 Wh / kg, 1000 Wh / kg, 2000 Wh / kg, or 3000 Wh / kg. The gravimetric energy density of the energy control device can be any value between the aforementioned values, for example, about 300 Wh / kg to about 3000 Wh / kg, about 300 Wh / kg to about 400 Wh / kg, or about 400 Wh / kg to about 3000 Wh / kg. The charge capacity of the battery cell can be at least about 200 mAmph, 240 mAmph, 280 mAmph, 600 mAmph, 1 Amph, 30 Amph, 50 Amph, or 70 Amph. The charge capacity of the battery cell can be between any of the aforementioned values, for example, about 200 mAmph to about 800 mAmph, about 200 mAmph to about 1 Amph, about 1 Amph to about 30 Amph, or about 30 Amph to about 80 Amph.

[0134] In some embodiments, the silicon-containing anode is thinner than the graphite-containing anode, for example, having a shape such as Figure 2The smaller height is shown in 205. For a given anode active material loading, the anode height can be up to about 30%, 35%, 40%, 50%, 65%, 75%, or 80% of the height (i.e., thickness) of the graphite anode. For a given anode active material loading, the anode height can be at least about 10%, 20%, 30%, 35%, 40%, 50%, 65%, or 70% of the height (i.e., thickness) of the graphite anode. Compared to the graphite anode for a given anode active material loading, the anode height can be between any of the aforementioned percentages, for example, about 10% to about 70%, or about 30% to about 70%. In one example, the height difference between the graphite anode and the silicon anode during discharge is 35%. In one example, when each anode is fully formed, for a given loading, the height difference between the graphite anode and the silicon anode is that the size of the silicon anode is 65% of that of the graphite anode. A thinner anode can allow for better current distribution across the electrode and / or reduce the likelihood of charge carrier plating (e.g., reduction to their elemental state) (such as lithium plating).

[0135] In some embodiments, the battery cell includes an anode separated from the anode by a gap. The battery cell may include a separator disposed in the gap. The battery cell may be elongated, for example, it may be elongated box-shaped. The face of the battery cell opposite to the largest surface area of ​​the electrode (e.g., anode or cathode) may have an aspect ratio of at least about 10:1, 15:1, 20:1, 35:1, or 50:1, where the aspect ratio is the length of the face (e.g., ...). Figure 4 431 in the middle) and the height of the surface (e.g., Figure 4 The aspect ratio (432 in the text) is used. The battery cell may have an aspect ratio of at least about 5:1, 8:1, 10:1, 15:1, 25:1, 20:1, 35:1, or 50:1, where the aspect ratio is the height of the battery cell (e.g., ...). Figure 4 The ratio of 432 in the middle to the width.

[0136] Figure 9Illustrative examples of batteries with bus extensions according to some embodiments of the present disclosure are depicted. Example 900 shows a battery having a bus extension member connecting the bus to a proximal terminal tab. Example 900 includes a bus extension member 901 (as an example of an interconnecting component of the battery), a group of negative electrodes schematically connected at 921, a group of positive electrodes schematically connected at 922, a group of electrically insulating separator layers 943, terminal tabs 941 and 942, and a housing 972 having a top portion 972A. In some embodiments, the housing (e.g., a battery enclosure) 972 is filled with a non-aqueous electrolyte (not shown), and the cover 972A can be folded and sealed to the upper surface of the battery housing 972 to surround the negative and positive electrodes. To allow connection to an energy supply source or consumption device (not shown), the terminal tabs 941 and 942 extend beyond the sealed enclosure. The orientation of the contact patch can be parallel to or perpendicular to the stacking direction of the individual electrodes in the internal electrode stack, and parallel to the advancing direction of a series of interdigitated electrodes in each electrode structure of the internal electrode stack. The arrangement of the battery cells within the casing can be... Figures 3 to 8 Any of the arrangements shown, including the arrangement of wound-type battery cells.

[0137] In some embodiments, the extension member allows the electrode (e.g., anode or cathode) to extend from the outlet of the battery cell around one side of the battery cell to a coupler such as a sealing bushing. Figure 9As shown, Example 930 depicts an edge portion of an energy storage device (e.g., a battery). The energy control device includes battery cells comprising alternating structures of electrodes and counter electrodes separated from each other by gaps such as 932, the gaps including, for example, a separator. Each electrode type (e.g., each anode and each cathode) includes a corresponding current collector on which active material is deposited (e.g., on one or both sides). The current collector for each anode type extends laterally via an extension portion (i.e., a tab such as tab 933). The tabs of a certain electrode type of current collector extend beyond the edge of the separator in the same lateral direction, the separator extending laterally beyond each electrode type. In some embodiments, the tabs extending from each anode (e.g., tab 933) are folded relative to the remainder of the current collector, for example, folded in at least one direction along the stack axis of the battery cell. In some embodiments, a busbar 935 is connected to the tabs extending from each anode (e.g., tab 933); for clarity, the folded tabs are not shown in the example of 930. In some embodiments, terminal tabs extend from the battery (e.g., tabs 941 and 942). The battery cell assembly may be surrounded by a constraint system formed by two opposing constraint members 937a and 937b and two opposing end plates such as end plate 938. In some embodiments, example 930 includes bus 935. In some embodiments, a bus extension extends from bus 935 and connects to the terminal tabs, for example, bus extension member 901.

[0138] In some embodiments, the rotary cutter is used to fabricate various battery cell components. The rotary cutter can cut strips for fabricating battery cell components (e.g., electrodes and / or separators). The strips may include alignment structures and optional bus joints, the dimensions and shapes of which are configured to allow busbars to pass through the tabs to mechanically reinforce the structure of the battery assembly and electrically couple the tabs on the battery assembly. In some embodiments, the active material layer may include cathode and anode active materials disclosed herein, such as lithium-transition metal oxides and / or silicon-containing compounds. In some embodiments, the current collector may include elemental metals or any other material suitable for use as a current collector (e.g., aluminum or copper). Techniques suitable for forming orifices (e.g., bus joints and alignment structures) may be employed to form the orifices to the desired size and shape that allows busbars to pass through. For example, laser processing, cutting (such as by the rotary cutter), pressing, stamping, forging, and / or other mechanical cutting may be employed. The laser processing may include slitting and / or ablation. The laser processing can be slower than mechanical cutting performed by the rotary cutting machine. Laser processing may cause debris to accumulate on the cut product, for example, due to liquid material expelled by the laser operation (e.g., ablation and / or dicing). Rotary cutting machines can operate faster and / or cleaner than laser processing for producing cut and / or embossed parts. Laser processing may produce debris including slag, soot, and / or other fragments. This debris may fall onto, adhere to, melt and solidify onto, or otherwise adhere to the desired product. Laser operation may be limited to certain aspects of the desired product, such as small-design cuts / embossing, acute angles, or any combination thereof. The rotary cutting machine can be configured to produce products that reduce (e.g., do not have) the type of debris produced by the laser processing.

[0139] Figure 10 Examples of various strips for fabricating electrodes for battery cells are depicted, for example, fabricated using the rotary cutter described above. Figure 10 The strip examples are viewed horizontally, for example, from the top and / or bottom of the strip. In some embodiments, the strip may be symmetrical along its plane, for example, mirror symmetry. In some embodiments, the strip may be symmetrical along its major axis, for example, C2 rotational symmetry. The strip may be a cut section generated by the rotary cutter. The various strips have different splice section configurations. The strip may be a current collector strip covered on one or both sides with an active material. The strip may be a diaphragm strip.

[0140] Example 1000 illustrates a strip comprising an active material segment 1003 and patch segments 1004a and 1004b located at two distal ends of the active material segment 1003, each patch segment being rectangular. The strip includes alignment features 1001a and 1001b and optional busbar joints (D-grooves) 1002a and 1002b.

[0141] Example 1020 illustrates a strip comprising an active material segment 1023 and tab segments 1024a and 1024b located at two distal ends of the active material segment 1023. Each tab segment is in the form of a capital letter "T," with its top segment contacting the narrow side of the active material segment 1023. The opposite sides of each tab include curvature, and the opposite sides of the tabs are correlated with each other by mirror symmetry along a plane perpendicular to and extending along the long axis of the strip 1020. The strip includes alignment features 1021a and 1021b and optional busbar joints (D-grooves) 1022a and 1022b.

[0142] Example 1040 illustrates a strip comprising an active material segment 1043 and tab segments 1044a and 1044b located at two distal ends of the active material segment 1043. Each tab segment is generally in the form of a capital letter "T," with its top segment contacting the narrow side of the active material segment 1043. The opposite sides of each tab include curvature, and the opposite sides of the tabs are correlated with each other by mirror symmetry along a plane perpendicular to and extending along the long axis of the strip 1040. The strip includes alignment features 1041a and 1041b and optional busbar joints (D-grooves) 1042a and 1042b.

[0143] Example 1080 illustrates a strip comprising an active material segment 1083 and patch segments 1084a and 1084b located at two distal ends of the active material segment 1083. Each patch segment comprises a symmetrical trapezoid, the bottom segment of which points toward the narrow side of the active material segment 1083. The opposite sides of the patch are linear (non-curved) and correlated with each other by mirror symmetry along a plane perpendicular to and extending along the long axis of the strip 1080. The strip includes alignment features 1081a and 1081b and optional busbar joints (D-grooves) 1082a and 1082b.

[0144] In some embodiments, the patch is coupled to the bus via a coupler comprising one or more adhesive strips. Figure 11An example of a portion of a battery cell stack including individual battery cells 1103 is shown, the stack being held by constraint systems 1101a and 1101b separated from each other by gaps. A distal end plate 1104 engages with the constraint systems and contacts the battery cell stack. A busbar 1108 contacts a tab at the distal side of each electrode. Figure 11 In the example shown, bus 1108 (e.g., also) contacts the tabs of the battery cell stack via adhesive strips 1120A and 1120B.

[0145] In some embodiments, the rotary cutter is part of a multi-step fabrication process (e.g., a manufacturing process). The rotary cutter can perform a roll-to-roll fabrication process. The multi-step fabrication process can include embedding, coating, printing, laminating, calendering, pressing, laser processing, other mechanical cutting, or any combination thereof. The rotary cutter can be part of a roll-to-roll fabrication process or any other multi-step fabrication process. The multi-step fabrication process can include roll-to-roll, cutting, shaping, machining, welding, punching, encapsulation, deposition, drying, spraying, 3D printing, calendering, compression, ablation, slitting, adhesion (e.g., glue bonding), soldering, any combination thereof, or any combination thereof. In one example, a sheet of current collector material can be coated with its corresponding active material (e.g., in slurry form), followed by drying, compression, and calendering of the active material. The slurry can include a formulation providing adhesive properties such that the active material (e.g., particulate material) adheres to itself and to the current collector. Such a structure can be configured to withstand the manufacturing process, such as that performed by the rotary cutter. The treated sheet can then be cut using the rotary cutter to produce cut parts, such as... Figure 10 The strip shown. The strip can ultimately form the electrodes of the energy manipulation device. The cutter may include alignment holes, for example, cutter alignment holes. The cutter may include engagement holes, for example, for engaging the cutter with a busbar. The cutter may include electrodes, counter electrodes, or diaphragms. The alignment holes of the cutter (e.g., Figure 10 1001a and 1001b in the diagram can be configured to align the cut pieces when stacked along the stacking axis, for example, to form the battery cell stack. The electrode portions, at least partially cut by the rotary cutter, can be stacked along posts (e.g., rods and / or columns), for example, when the alignment structure engages with the posts at the two distal ends of the current collector (e.g., ...). Figure 17 1701a and 1701b in the example). The joint hole of the cut piece (e.g., Figure 101002a and 1002b in the diagram can be configured to engage the cut strip with its corresponding busbar, for example, to form an electrical connection. After fabricating the battery cell stack (e.g., and optionally engaging with the busbar), the distal segment of the cut strip, including the alignment hole of the cut strip, is removed. The resulting battery cell stack may or may not include the strip segment with the engagement hole. The resulting battery cell stack may be surrounded by a distal end plate, the restraint system, and / or a housing (e.g., a pouch or a rigid housing such as a shell). Therefore, the rotary cutter can be part of the manufacturing process of the energy manipulation device (e.g., a battery). The battery cell stack can then be buffered before being designated for (e.g., commercial) use. One or more operations of the fabrication process can be manually controlled. One or more operations of the fabrication process can be automatically controlled, for example, using a control system such as the control system disclosed herein. The calendering can include temperature regulation, for example, heating. The operation of the rotary cutter can include temperature regulation, for example, the temperature regulation disclosed herein. One or more manufacturing conditions may require temperature regulation, for example, using any temperature regulation system disclosed herein (if applicable). The control system can be configured to automatically control the temperature during said temperature regulation. The temperature regulation can be controlled manually and / or automatically, for example, using a control system such as the control system disclosed herein.

[0146] In some embodiments, at least a portion of a battery cell component is processed (e.g., further processed) via a stamping system configured to perform a punching action. The punching action may require a punch-and-die engagement that shears a target starting material disposed between a punch member and a die member of the stamping system. The target starting material to be cut may adhere to the punch member and / or be pushed by the punch member into a die member engaging with the punch member. In some embodiments, the punched part (e.g., a product) is generated by shearing. The more edges in the design to be cut by the stamping system (e.g., the design to be punched), the greater the shearing force required for punching, and thus the more violent the punching will be. This violent action of the stamping system may damage (e.g., deform) the target starting material, for example, damaging any particulate material deposited on the structure constituting the target starting material. In one example, the particulate material includes active material deposited on a current collector, the particulate material and the current collector together constituting the target starting material. In one example, the particulate material is a ceramic coupled to a polymer, which together constitute the target starting material for the diaphragm. The deformation can be any deformation disclosed herein, such as cracking and / or material separation. The press can, for example, cut all edges of the shape simultaneously in a single punch (e.g., essentially). A press configured for cutting may be more expensive than a rotary cutter because each pair of punch-die components needs to be custom-produced using industrial fabrication (e.g., molding, 3D printing, casting, and / or milling). The thinner the target starting material to be cut, the higher the precision required for the mating of the punch and die components of the press; otherwise, the material may be dragged into the gap between the punch and die components, potentially causing the stamping system (e.g., the press) to malfunction (e.g., jam). Compared to manufacturing dies for the rotary cutting machine, a stamping press requires a longer processing time for each design. For example, the fabrication of the punched parts (e.g., punch-die) involves molding, 3D printing, casting, and / or milling due to the time-consuming production of dedicated punch-die components for each stamping element. The stamping press may have lower durability compared to the dies for a rotary cutting machine due to the degree of force applied during punching, for example, to maintain the required clearance between the punch and die components during multiple punchings without deformation due to erosion, friction, and / or other wear. The materials required for durable stamping presses (e.g., punch-die components) may have higher durability requirements than those used in the dies for rotary stamping machines. The rotary stamping press may struggle to accurately and / or repeatedly punch small features. The rotary cutting machine can be configured to press the punch's embossing onto the target starting material.The rotary cutter can be configured to produce the desired product by minimizing (e.g., avoiding) the shearing of the target starting material.

[0147] In some embodiments, at least a portion of the battery cell component is processed (e.g., further processed) via the rotary cutter. The rotary cutter can cut lines (one or more) of the periphery (one or more) of the desired shape at the interaction area between the die roller and the support roller, wherein the target starting material is between (and compressed). The embossed design of the die can be aligned such that cutting / denting the smallest segment of the periphery in one pass requires less force, for example, compared to a punching method that cuts the entire periphery of the shape in one pass. The relative forces applied to the target starting material by the die roller and the support roller can be adjusted at least in part based on the geometry to be cut during compression. The force can be applied by the die roller toward the support roller, for example, moving downwards relative to the center of gravity of the surrounding environment (e.g., the Earth) where the rotary cutter is located. In one example, when cutting short segments such as opposite sides of an electrode positioned perpendicular to the axis of the roller, compared to cutting the entire side of the electrode such as parallel to the axis of the roller (e.g., ...), Figure 20 Compared to linear cutting (e.g., in 2002), a smaller force is required (e.g., and applied). Producing the product (e.g., cut parts) using a rotary cutter may be cheaper than using a stamping press, for example, because the part performing the cut is a sheet / foil coupled to the inner roller of the rotary cutter, together forming the die roller. The rotary cutter may require a shorter processing time for each design, for example, due to the die manufacturing processes (such as masking processes (e.g., photolithography) and / or embossing), while other industrial manufacturing methods (such as milling, casting, machining, and / or 3D printing) require longer times. For example, the photolithography process used to manufacture the cutter.

[0148] In some embodiments, the rotary cutter includes rollers. The rollers may include rollers coupled to a die, referred to herein as "die rollers". The rollers may include a die roller and a support roller. In one example, the die roller is configured to cut the target material according to the design of the die. In one example, the cutting action is performed by the die as the target material passes through the die roller and the support roller adjacent to the die roller. The die roller may be separated from the support roller by a gap. In one example, the cutting action is performed by the die as the target material passes through the gap between the die roller and the support roller adjacent to the die roller. The support roller may be configured to support the target material as it is cut by the die roller; for example, the support roller may provide mechanical support (e.g., apply a reaction force) and facilitate the conveying function of the rotary cutter disclosed herein. The die roller and the support roller may be positioned at a relatively adjustable height. The target material may be conveyed into, through, and out of the rotary cutter. The die roller can rotate relative to a support roller arranged adjacent to and parallel to the die roller, such that the target is pulled by the rotating die roller and the support roller to a position between the two rollers, where the target is cut by the die. A variable gap may exist between the die roller and the support roller. The variable gap can be adjusted, for example, manually and / or automatically (such as using a control system). The gap can vary at least in part based on the target material to be cut by the die. The die roller includes a textured structure referred to herein as a “die” or “cutting die.” The textured structure can be in the form of a sheet or foil. The textured structure can be wound around the surface of an inner roller to collectively form the “die roller.” The roller (e.g., the die roller and / or the support roller) can include at least one cylinder, for example, the roller can include concentric cylinders. The textured structure can be wound around the inner roller to form the outer surface of the die roller. The textured structure can be coupled to the inner roller such that during its operation, the textured structure can remain (e.g., substantially) stationary relative to the center of rotation of the resulting die roller.

[0149] In some embodiments, the target starting material comprises a planar material. The planar material may be rectangular (e.g., an elongated rectangle). The planar material may be a foil or a sheet. The foil may have a thickness of up to about 2 micrometers (μm), 5 μm, 10 μm, 12 μm, 15 μm, 20 μm, 40 μm, 50 μm, 65 μm, 80 μm, 90 μm, 100 μm, or 200 μm. The foil may have a thickness between any of the aforementioned thicknesses, for example, about 2 μm to about 200 μm, or about 5 μm to about 50 μm. The sheet may have a thickness greater than 0.2 mm, 0.25 mm, 0.5 mm, 1 mm, 2 mm, 5 mm, or 10 mm. The sheet may have a thickness between any of the aforementioned thicknesses, for example, about 0.25 mm to about 10 mm. The planar material may be a planar material of an electrode (e.g., a current collector) or a separator (e.g., a polymer and / or resin). The particulate material can be operatively coupled to the planar material to form the target starting material. The particulate material can be an electrode active material, a counter electrode active material, a material of the diaphragm, or a material of the separator. The particulate material can have a concentration tendency of FLS (e.g., average diameter) of up to about 5 μm, 8 μm, 10 μm, 15 μm, 20 μm, 50 μm, or 100 μm. The particulate material can have a concentration tendency of FLS (e.g., average diameter) between any of the above values, for example, about 5 μm to about 100 μm, about 5 μm to about 50 μm, or about 5 μm to about 30 μm.

[0150] In some embodiments, the material on which the textured structure (e.g., the mold) is provided is flexible. The flexibility of the material used to form the mold is configured to allow the mold to wrap around the outer surface of the mold roller such that the mold is flush with its contact surface, which forms the inner surface of the mold roller when in contact with the mold.

[0151] In some embodiments, the rotary cutter is configured to manipulate a target at least partially by rotating its die roller relative to the support roller. The rotation direction of the die roller may be opposite to that of the support roller. The rotary cutter may: (a) be designed with components; and / or (b) be coupled to a control system such that the two rollers (the die roller and the support roller) can rotate relative to each other about their respective longitudinal axes at relative speeds, such that: (i) a target (e.g., sheet material) is drawn into the gap between the two rotating rollers; (ii) the drawn target is pulled from one side into the gap between the die roller and the support roller, in which the target is cut by the die to produce the desired cut and the remaining material of the target; and (iii) the cut (one or more) is discharged from the rotary cutter from the side opposite to the side. Pressure is applied to the target while it is held by the die roller and the support roller on the opposite side of the target. The pressure may at least partially facilitate the cutting of the target by the die. The relative rotation of the mold rollers with respect to the support rollers allows the target to pass between the two rollers (e.g., continuously and / or intermittently), for example, with minimal intervention. In one example, the target is continuously conveyed between the two rollers. The conveying capacity of the rotary cutter allows the rotary cutter equipped with the cutting mold to continuously cut (e.g., manufacture) custom-shaped parts, such as parts for energy control devices incorporating batteries.

[0152] In some embodiments, the rotary cutter includes rollers (one or more). The rollers may include elemental metals, metal alloys, allotropes of elemental carbon, polymers or resins, any of these types, or any combination thereof, such as the materials disclosed herein. In some embodiments, the material (e.g., primarily) is a current collector material, such as aluminum or copper, for example, to minimize contaminants during the production process. The rollers may include materials (one or more) that are inert to the components (one or more) of the device for which they are produced (e.g., constituted by such materials). The outer material of the rollers may include materials (one or more) that are inert to the components (one or more) of the device for which they are produced (e.g., constituted by such materials). For example, the outer surface of the rollers (e.g., the outer coating of the mold and / or the support rollers) may be inert to the materials of the cathode and anode structure battery components, such as the cathode active materials or anode active materials disclosed herein, including NMC, LCO, silicon-containing compounds, graphite, any of these types, or any combination thereof.

[0153] In some embodiments, the textured structure (e.g., used as a mold) is coupled to the outer surface of the inner roller. The mold may be coupled using adhesives, attractive forces, mechanical forces, or any combination thereof. Any of these coupling methods may be used alone or in combination with any other techniques disclosed herein or any other techniques available in the industry to perform the same function.

[0154] In some embodiments, the textured structure (e.g., used as a mold) is coupled at least partially to the outer surface of the inner roller using an adhesive (e.g., an adhesive material). The mold may be fitted around, for example, and flush with, the outer surface of the inner roller. The mold may be coupled at least partially via one or more adhesives. The adhesive may include epoxy, industrial tape, or any other adhesive capable of assembling the mold, which will allow the mold to remain (e.g., substantially) stationary relative to the surface of the inner roller to which it is coupled during operation of the rotary cutter. In some embodiments, the adhesive may be (e.g., substantially) irreversible, such that the adhesive allows the mold to be mated to the inner roller for long-term use. In other embodiments, the adhesive may be a reversible adhesive (one or more), such as industrial tape or an adhesive that leaves negligible residue on the surface of the roller upon removal. In these embodiments with reversible adhesives, the mold can be easily removed, conveniently removed, and / or quickly replaced, for example, with a different mold.

[0155] In some embodiments, the textured structure (e.g., a textured sheet used as a mold) is at least partially coupled to the outer surface of the inner roller using an attractive force. The attractive force can include magnetic, mechanical, hydraulic, pneumatic (e.g., pneumatic or vacuum) forces, or any combination thereof. In one example, a chuck is used to mechanically couple the mold to the inner roller. The chuck can be of any type suitable for coupling the mold around the surface of the inner roller. In one example, the chuck can include a lathe chuck, a collet chuck, a magnetic chuck, a combination chuck, a power chuck, or any combination thereof. The rotary cutting machine can include a rotary joint, for example, for achieving the vacuum. The rotary joint can be operatively coupled to the inner roller, which, together with the mold, forms the mold roller. The textured structure (e.g., the mold) can be mechanically coupled to the inner roller. The mechanical coupling can include at least one fastener (e.g., a screw) for holding the mold in place. The mechanical coupling can tension the mold, for example, so that the mold remains in place during operation (e.g., substantially) to produce the desired product (e.g., cut and / or embossed) within a specified operating time using the specific mold on the rotary cutter.

[0156] In some embodiments, the mold is manufactured. The manufacture of the mold may include mask-related processes, laser forming, embossing, pressing, stamping, any combination thereof, or other methods. In some embodiments, embossing is a technique that forms a raised design on a target surface (e.g., a foil or sheet) by pressing and / or stamping the design onto the target surface. The pressing and / or stamping may be performed by pressing the design in a single action and / or continuous actions (one or more) using a metal press. In one example, a hard material (e.g., a solid) is pressed into the target surface in a propagating motion along a design to be used as the cutting edge of the mold (e.g., along the periphery of the design to be cut). The mold may be manufactured via a mask-etching technique (e.g., including photolithography). The mask may be designed using any design technique that works in conjunction with the photolithography process. For example, computer-aided design (CAD) software may define the shape of the mask, and thereby define the shape of the mold. The mask may be a negative pattern of a desired cut edge (e.g., leading edge) pattern, wherein the cut edge defines the shape of a product (e.g., a cathode, anode, or diaphragm structure) cut from the sheet material. The cut edge may form a textured structure. The mask may be made of a material compatible with the etching process and intended purpose disclosed herein, for example, a material inert to a particular electromagnetic region such as the ultraviolet or infrared region. The mask may be made of a material compatible with the etching process and intended purpose disclosed herein, for example, a laser. Using a laser to generate the cut edge(s) may help to form accurate cut edges, for example, cut edges that can be easily generated. Suitable mold materials in sheet form may include a photoresist layer to enable the processing techniques disclosed herein. The suitable mold material may include material properties suitable for the mold functions disclosed herein, including the potential for relative flexibility and / or forming (e.g., durable) cut edges, for example, sustaining the specified lifespan of the device and / or the mold under specified operating conditions. The mold material may vary at least in part depending on the target starting material to be cut. For example, for an organic separator, the mold may include a polymer, metal, any combination thereof, or a type harder than the separator. For example, for an electrode, the material may be harder than its current collector material, such as elemental metals, metal alloys, any combination thereof, or a type thereof. For example, the mold material may include elemental metals or metal alloys. The metal alloy may include stainless steel or Inco nickel alloys. The metal alloy may include high-performance alloys. The mold may include ferromagnetic materials, such as steel. The mold may facilitate the use of adhesive forces, such as magnetic forces, between the inner roller and the mold. The suitable mold material may depend at least in part on the target material to be cut.The mold mask can be generated by laser, allowing for high precision, high versatility, and rapid execution. The mold mask can also be generated using a reverse masking process, for example, using light such as ultraviolet light. The reverse fabrication process can include a photoresist mask. The masking process can include chemical etching of a sheet (e.g., metal) to create a textured structure. The time and / or temperature of the chemical etching, and the precision of the photopolymerization process (e.g., using layers and / or UV light), can determine the fidelity of the textured structure formed by the mold. The chemical etching can last for a period of time. The etchant can have a variable intensity. The required height of the edge of the mold (e.g., a cutting edge formed by the process) can be a function of etching time, etchant intensity, and / or etching temperature. The textured structure includes cutting edges as the texture. The cut edges can be sharpened and / or further refined in shape via laser processing techniques to create cleaner cut edges. The mold can include one or more surface coatings. The mold includes one or more surface finishing layers. The surface finishing layers can be configured to reduce the surface energy of the mold. The surface finishing layer can reduce adhesion to the target to be cut (e.g., to provide an anti-stick property between the mold and the target to be cut). The surface finishing layer may include polymers such as Teflon. The one or more surface coatings may include polymers or resins. The mold can be manufactured by embossing the textured structure on a sheet or foil. The embossed structure includes an embossed design that forms the cutting edge of the mold on one surface of the structure. The surface of the structure (e.g., a sheet) opposite to the embossing may be filled with a filler material, and the opposite surface is an embossed surface. The deposition design may be filled with a filler material. The filler material may include (e.g., primarily) the material forming the embossed structure, the same type of material, different types of material, or any combination thereof. The embossed structure may include a first material, and the filler structure may include a second material different from the first material. The embossed structure may include a first material, and the filler structure may include (e.g., primarily) a second material that is the first material. In one example, the embossed structure includes a metal, and the filler structure includes a metal of that type. In one example, the embossed structure includes a first metal, and the filler structure includes a second metal of a different type from the first metal. In one example, the embossed structure comprises a metal, and the filler structure comprises an organic material. The metal may include a metal alloy or a single metal. The organic material may include a polymer or a resin. The material of the textured structure, the material of the embossed structure, and / or the filler material of the embossed structure opposite the embossed structure may include single metals, metal alloys, polymers, resins, allotropes of elemental carbon, various types thereof, or any combination thereof.The materials of the textured structure, the embossed structure, and / or the filler material of the embossed structure opposite the embossed structure may include composite materials, non-composite materials, various types thereof, or any combination thereof. The materials of the textured structure, the embossed structure, and / or the embossed structure opposite the embossed structure may include one or more layers. The outer layer used as the mold may include one or more layers that minimize adhesion of the target starting material to the mold, for example, minimizing adhesion during the cutting process. The outer layer of the mold may include Teflon (e.g., polytetrafluoroethylene PTFE), polyfluoroalkyl, perfluoroalkyl substances (PFAS) (e.g., perfluorooctanoic acid (PFOA)), non-stick ceramic coatings (e.g., including silica SiO2), carbon steel, stainless steel, silicone, Gore-Tex (e.g., expanded or stretched PTFE, such as ePTFE), siloxanes (e.g., polydimethylsiloxane (PDMS)), silanes (e.g., organoalkoxysilanes), oxidized regenerated cellulose, any types thereof, or any combination thereof.

[0157] In some embodiments, the mold is generated, the mold including a structure that protrudes from the mold surface relative to the inner surface of the mold roller, for example, using magnetic adhesion. The mold may include one or more texture types. The one or more texture types may include blades, pressing portions, any combination thereof, or any combination thereof. Relative to the non-textured plane of the mold (e.g., Figure 17 (1751 in the text), the blade (e.g., Figure 17 (1705 in the text) can have different shapes and different heights (e.g., Figure 17 (1752 in the middle) and / or different angles (e.g., Figure 17(e.g., 1750°). The different angles can include right angles and / or obtuse angles. The different angles (e.g., 1750°) can include angles of at least about 90 degrees (°), 120°, 130°, 140°, 150°, 160°, or 170°. The different angles can be any value between the aforementioned values, for example, about 90° to about 170°. When the mold is pressed onto the target starting material, the textured structure can produce a cutting and / or indentation (e.g., indentation) effect on the target starting material. The texture can include low relief (e.g., shallow relief), high relief (e.g., high embossing), any type thereof, or any combination thereof. The low relief can protrude from the surface of the mold up to half the thickness of the mold, the thickness of the mold excluding the textured structure. The high relief can protrude from the surface of the mold by a height exceeding half the thickness of the mold, the thickness of the mold excluding the textured structure. The raised texture may have a height of at least about 2%, 5%, 10%, 20%, 50%, 80%, or 100% of the thickness of the mold excluding the raised texture structure. When the mold is pressed onto the target starting material, the mold may penetrate completely and / or partially into the target starting material (e.g., a sheet material to be cut). When the mold is pressed onto the target starting material, the mold may create a cut, a recess, or a partial cut. The partial cut may be created using an incomplete cut. The incomplete cut may include dotted lines and / or dashed lines, wherein the dots and / or dashes are completely cut, and other portions of the incomplete cut are not cut. Pressing the mold onto the target starting material may create a recess, an indentation, an embossing, a relief, an indentation, any combination thereof, or any combination thereof. The mold pressing that does not create a cut in the target starting material may be processed by other means disclosed herein (e.g., laser processing). In one example, a large structure can be cut by the die, and a small structure can be pressed by the die, leaving the small structure for processing by another processing type (one or more). The other processing type (one or more) can process portions of the design that are more difficult (e.g., less precise) to cut by the die. In one example, the other processing type (one or more) cuts portions of the die that may be more difficult to separate from the die after being fully cut by the die, such as alignment features, joining features, and / or objects with sharp (e.g., acute) angles as disclosed herein. The sharp angles can be up to about 90°, 60°, 30°, 15°, 10°, or 5°. The sharp angles can be any value between the foregoing values, for example, about 90° to about 5°. One or more features to be cut by the die can have rounded edges, for example, to allow easier removal of the cut from the die.Forces can be used to separate the cutting element from the mold, such as gravity of the surrounding environment (e.g., Earth), attractive forces (e.g., magnetic, vacuum, and / or electrostatic forces) disclosed herein, thrust (e.g., airflow), any combination thereof, or any combination thereof. The edges of the mold can be designed to reduce adhesion and / or attachment of the target starting material to the mold after the mold has been manipulated. The corners of the ridges in the mold can have rounded corners instead of hard edges such as those with sharp angles.

[0158] In some embodiments, the mold includes one or more mold alignment structures. The mold alignment structures can be used to align the coupling of the mold to the inner roller, for example, using mechanical adhesion. The alignment structures can include any alignment structures disclosed herein; for example, the mold alignment structure can include a slit or notch on the surface of the roller for aligning the mold to the roller as it winds around the roller. Similarly, the alignment structure can be an orifice to allow fasteners (e.g., screws) to pass through the mold into the roller of the mold roller, thereby holding the mold in place during operation. The mold alignment structure may or may not be an alignment structure for the electrodes and / or the diaphragm.

[0159] In some embodiments, the rotary cutting machine includes the support roller. The support roller may (e.g., integrally) comprise polymers, resins, composite materials, non-composite materials, ceramics, elemental metals, metal alloys, elastomers (e.g., rubber), allotropes of elemental carbon, many of these types, or any combination thereof. In some embodiments, the polymer comprises plastics or any other material disclosed herein for use as an outer layer of the mold. The support roller may include multiple layers. The outer surface of the support roller may include any other material disclosed herein for use as an outer layer of the mold. The support roller may include a surface layer formed of the aforementioned materials. The metal alloy may include stainless steel or Inco nickel alloy. The metal may include aluminum or copper. During operation of the device, the mold may puncture the support roller. The support roller may include an outer surface containing an elastic material and / or a rapidly repairable material, for example, rapidly repairable after being punched or cut by a cutting edge such as the cutting edge of the mold. The support roller may (e.g., integrally) comprise or include one or more self-healing materials, such as self-healing polymers. The self-healing polymers may include polyurethane, poly(urea-urethane), Diels-Alder adducts, many of these types, or any combination thereof. The support roller may (e.g., integrally) comprise one or more materials having dynamic covalent interactions and / or supramolecular interactions that enable rapid repair after surface damage, such as materials having variable polar bonds and / or hydrogen bonds. The support roller may include any of these materials in its surface (e.g., a surface layer). Material layers (one or more) may be added to the surface of the support roller, for example, applied as a coating (one or more) and / or coupled to the axis of the support roller via a coupling mechanism such as any coupling mechanism disclosed herein. For example, the coupling may include adhesion (such as by an adhesive material that may be (e.g., a fundamentally) irreversible adhesive (e.g., epoxy resin)) and / or mechanical coupling. The support roller may be made of a material inert to the manufactured components and / or their designated devices (such as devices for energy manipulation, e.g., batteries). The support roller may be inert to the cathode active material, the anode active material, and / or processes occurring in the energy manipulation device. These processes may occur during its storage, maintenance, buffering, transportation, and / or use. The material of the support roller (e.g., the outer material in contact with the target to be cut) may be harder or not harder than the material used to make the die. The support roller (e.g., the surface layer of the support roller) may include any material type disclosed herein suitable for intermittent and / or continuous cutting via the cutting die, for example, for a specified lifespan of the rotary cutter under specified (e.g., normal) operation.

[0160] In some embodiments, the mold roller rotates relative to the support roller. The mold roller and the support roller may each rotate in opposite directions along their longitudinal axes, for example, in a coordinated and / or synergistic manner, such as using a control system and actuators (one or more). The mold roller may rotate while the support roller remains stationary.

[0161] Figure 12 An example of a rotary cutter processing a target starting material to produce a scrap 1204 is depicted. The target starting material includes sheets or foils. The rotary cutter produces a target product in the form of a cut piece 1205 from the target starting material. The cut piece 1205 is shaped according to a peripheral pattern of a die 1203. The cut piece 1205 can be a battery component (e.g., a cathode structure, anode structure, or separator). The rotary cutter includes two parallel rollers, a die roller 1201 and a support roller 1202. The two rollers are coupled to a structural frame (not shown). The die roller 1201 and the support roller 1202 each include shafts or axles 1206a and 1206b along their respective longitudinal axes. Each of the two rollers rotates in opposite directions, as indicated by arrows 1210a and 1210b. One direction can be clockwise, and the other can be counterclockwise, or vice versa. In one example, the direction of rotation can determine the direction in which the target starting material is drawn into the rotary cutter and the direction in which the product is discharged from the rotary cutter. The product may include cut pieces and / or dents. The product may include multiple components.

[0162] In some embodiments, the rotary cutter is coupled to a frame. The frame enables the rotary cutter to be maneuverable. The maneuverability of the rotary cutter can be lateral, inward, or angled relative to the floor. The rotary cutter can be operated manually and / or automatically, for example, using a control system. The frame can be made of a durable load-bearing material, for example, a material compatible with the application of the invention disclosed herein. For example, the frame material can include elemental metals, metal alloys, polymers, resins, or allotropes of elemental metals, any of several types thereof, or any combination thereof. The frame material can include composite materials and / or non-composite materials. The metal alloy can include stainless steel or Inco nickel alloy. Figure 13 A perspective view depicts a structural frame component having a stand 1301 that can be coupled to the rotary cutter, the stand being movable along a track 1302 and using wheels such as 1303. The stand 1301 can pivot at an angle along a curved arrow 1304, thereby causing the rotary cutter fixed to the stand 1301 to pivot at said angle.

[0163] In some embodiments, the rotary cutter includes a rotating roller. The rotating roller may include or be operatively coupled to a bearing. Rotation of the roller of the rotary cutter may be achieved at least partially by coupling a bearing that minimizes friction during roller rotation, for example, to allow smooth rotation. The bearing may include an air bearing or a ball bearing. The bearing may couple an end of a shaft to (e.g., a motorized) structural frame.

[0164] In some embodiments, the die roller and the support roller may be oriented such that the axis of rotation of one of the rollers is parallel to the axis of rotation of the other roller, the axis of rotation being its longitudinal axis. The die roller and the support roller may each be positioned at an adjustable height defined along the structural frame. A defined (e.g., adjustable) width gap may exist between the die roller and the support roller. The gap may be a dynamic gap. The gap may be adjusted at least in part based on (a) the thickness of the target to be cut and / or (b) the material composition of the target to be cut. The material composition may include the current collector, the active material coupled to the current collector, the diaphragm (e.g., any layer of the diaphragm), or any combination thereof. The rotary cutter may be equipped for, for example, independently rotating the die roller and the support roller at a controlled speed and direction. The control may include manual control and / or automatic control, for example, using a control system. The roller may be coupled to an actuator such as a motor. The motor may include a servo motor. The actuator can rotate the roller via any actuation mode that allows the motor to rotate the coupled roller about the longitudinal axis of the roller (e.g., smoothly). The actuator can be directly coupled to the roller. The actuator can be coupled to the roller using one or more gears. At least one actuator of the rotary cutter can be coupled to both the die roller and the support roller. The die roller and the support roller can each be coupled to at least one different actuator. The actuation mode of the suitable actuator can be any mode that enables the motor to achieve the rotation of the roller. For example, the actuation mode can be electric, hydraulic, pneumatic, magnetic, any combination thereof, or any combination thereof. An electric servo motor can cause one roller (e.g., the die roller) to rotate in a first direction (e.g., clockwise) at a first rotational speed and cause a second roller (e.g., the support roller) to rotate in a second direction opposite to the first direction (e.g., counterclockwise). The rotation of the rollers can allow any target material in the form of sheet or foil to pass between the two rollers in a conveying manner. The mold roller may be operatively coupled to the support roller at least in part using a gear system comprising one or more gears. The mold roller may also be operatively coupled to the support roller at least in part using an actuator system comprising one or more actuators.

[0165] In some embodiments, the target starting material for cutting is a sheet or foil of material. The target starting material can be configured for roll-to-roll manufacturing. The target starting material is used to form components of an energy manipulation device, such as battery components. The components can be battery cell components. The battery cell components can include an anode, cathode, separator, and / or diaphragm. The battery cell components can include an anode current collector and / or a cathode current collector. The target starting material can include an anode current collector coupled to an anode active material and / or a cathode current collector coupled to a cathode active material, for example, the coupling can be facilitated at least partially by coating the active material onto the current collector to generate the target starting material. After processing by the rotary cutter, the target starting material can generate scrap (e.g., Figure 12 1204 in the middle) and cut parts (e.g., Figure 12 (1205 in the text). The thickness of the target starting material can be at least about 3 micrometers (μm), 5 μm, 10 μm, 12 μm, 15 μm, 18 μm, 20 μm, 50 μm, 80 μm, 90 μm, 100 μm, 250 μm, 500 μm, 800 μm, or 1000 μm. The thickness of the target starting material can be at most about 1500 μm, 1000 μm, 800 μm, 500 μm, 250 μm, 100 μm, 90 μm, 80 μm, 50 μm, or 20 μm. The thickness of the target starting material can be any value between the aforementioned values, for example, about 3 μm to about 1500 μm, about 3 μm to about 250 μm, or about 80 μm to about 1500 μm. The gap between the mold roller and the support roller can be at least about 3 micrometers (μm), 5μm, 10μm, 12μm, 15μm, 18μm, 20μm, 50μm, 80μm, 90μm, 100μm, 250μm, 500μm, 800μm or 1000μm. The gap between the mold roller and the support roller can be at most about 1500μm, 1000μm, 800μm, 500μm, 250μm, 100μm, 90μm, 80μm, 50μm, 20μm, 15μm, 10μm or 5μm. The gap between the mold roller and the support roller can be any value between the aforementioned values, for example, about 3 μm to about 1500 μm, about 3 μm to about 20 μm, about 3 μm to about 50 μm, about 3 μm to about 100 μm, about 3 μm to about 250 μm, or about 80 μm to about 1500 μm. The mold roller is separated from the support roller by the gap. The gap can depend at least in part on the height of the embossed pattern of the mold, for example, on the cutting edge (e.g., Figure 17The height of (1705) in the figure, the material, and the required pressure. In one example, the width of the gap is the distance between the die roller and the support roller, and the gap width is configured to accommodate the target starting material to be cut by the die. The width of the gap between the die roller and the support roller can be set. The gap can be (e.g., substantially) equal to or less than the thickness of the target starting material. The gap width can be up to about 1%, 2.5%, 5%, 10%, or 20% smaller than the thickness of the target starting material. The gap width can be at least about 0.5%, 1%, 2.5%, 5%, 10%, or 15% smaller than the thickness of the target starting material. The gap width can be any value between the aforementioned values ​​smaller than the thickness of the target starting material, for example, about 0.5% to about 20%, about 0.5% to about 10%, or about 5% to about 10%. The outer surface (and interior) of the support roller opposite the die is made of a material that is (a) stronger than the die; (b) more robust than the die in other respects in terms of scratches or punctures that occur during the cutting process; and / or (c) repairable material (e.g., self-healing material) after being scratched and / or punctured during the cutting process. In one example, a sheet of current collector material may be coated with its corresponding active material (e.g., in slurry form), followed by drying, compression, and calendering. The slurry may include a formulation that provides adhesive properties such that the active material (e.g., particulate material) adheres to itself and to the current collector. Such a structure may be configured to withstand the manufacturing process, for example, a manufacturing process performed by the rotary cutter. The target starting material may be subjected to tension when it is drawn into the gap between the die roller and the support roller. The tension borne by the target starting material as it passes through the die (and is cut by the die) may be at least about 1 Newton (N), 2 N, 3 N, 4 N, 5 N, or 6 N. The tension experienced by the target starting material as it passes through the mold (and is cut by the mold) can be up to about 3N, 4N, 5N, 6N, 7N, 8N, 9N, or 10N. The tension experienced by the target starting material as it passes through the mold (and is cut by the mold) can be any value between the aforementioned values, for example, about 1N to about 10N, about 3N to about 5N, about 1N to about 5N, about 5N to about 10N, or about 3N to about 5N. The mold can be configured such that the cutting edge (e.g., Figure 17(1705) The total force required to cut the sheet material may need to exceed the yield strength of the sheet material. Assuming the blade mass is negligible, the applied force can be a component of the centrifugal force in the blade section, which is at most about 3N, 4N, 5N, 6N, 7N, 8N, 9N, or 10N. During operation, the reaction forces in the rotary cutter may cause compressive shear. In one example, the force required for cutting by the die (e.g., a cutting width of 0.2mm and a lateral length of 100mm along the lateral axis of the die roller) may produce a compressive strength of at most about 5 MPa, 10 MPa, 15 MPa, 18 MPa, 20 MPa, or 30 MPa; the force can be at most about 200 Newtons (N), 300 N, 400 N, or 500 N. The compression and the force can be any value between the foregoing values, for example, a compressive strength of about 5 MPa to about 30 MPa and a force of about 200 N to about 500 N. As the target starting material (e.g., a sheet) is fed through the rotary cutter, the tension can vary (e.g., continuously). The pressure applied to the target starting material by the rotary cutter during processing can be dynamic and / or controlled. The control can be automatic, for example, using a control system such as the control systems disclosed herein. The pressure can be sensed, for example, by one or more sensors including pressure sensors and / or motion sensors. The control system can utilize closed-loop and / or open-loop control schemes to control the rotary cutter, for example, controlling the pressure applied to the target material. In some embodiments, the tension applied to the sheet material is a different and / or intentionally set amount. The open-loop control can utilize physical simulation. The physical simulation can take into account the material composition of the target starting material and / or one or more physical properties of the target starting material. The material composition can include a chemical composition, for example, the chemical compositions disclosed herein. The material composition can include a phase. The phase can include a solid, semi-solid, sheet, foil, or particulate material. The one or more physical properties can include brittleness, elasticity, strength, stretchability, compressibility, or any combination thereof. In one example, the rotary cutter can be configured to have a specific gap between the die roller and the support roller. In the case of cutting (e.g., anodizing), the gap can be slightly smaller than the total thickness of the target starting material. The tension in the die can be from about 3N to about 5N. The force exerted by the die on the target starting material can be a component of the centrifugal force in the blade section (e.g., assuming a small blade mass, at most about 10N) and a reaction force that causes compression (e.g., causing cutting). The force exerted on the die can be approximated to the average compressive strength of the target starting material.In one example, assuming a cut width of 0.2 mm, a length of 100 mm, and a compressive strength of approximately 18 MPa, the force required to cut the starting material would be approximately 400 N.

[0166] In some embodiments, one or more components of the rotary cutter are controlled. Control of the components (e.g., relative height, pressure, and / or rotational speed) can be dynamic, e.g., manual and / or automatic. The automatic control can include a control system using a control system such as the control systems disclosed herein. For example, the control can be based at least in part on the design, the segment to be cut during engagement, and / or the segment to be indented during engagement, the engagement being the engagement of the die roller and the support roller with the target starting material compressed between them, e.g., the segment to be cut in a horizontal (e.g., linear) segment is the portion of the die facing the top of the support roller. The compression depth of the die pressing into the target starting material can be variable. The compression depth can vary at least in part based on (a) the relative degree of compression between the die roller and the support roller and (b) the relative height of the raised portions in the die. The raised portions of the die can have (e.g., substantially) the same height or different heights. During relative rotation of the die roller and the support roller, some portions of the die facing the support roller can have (e.g., substantially) the same height. During the relative rotation of the mold roller and the support roller, some portions of the mold facing the support roller may have different heights.

[0167] In some embodiments, the target starting material is a multilayer material. The multilayer material may be a three-layer material. The three-layer material may include a first active material layer disposed on one side of the current collector, the current collector, and a second active material layer disposed on the opposite side of the current collector. The force borne by the sheet material is approximately the average compressive strength of the three-layer regions. The first active material layer may be the same type as or different from the second active material layer. The first active material layer may include an anodic active material, and the second active material layer may include an anodic active material. The first active material layer may include a cathodic active material, and the second active material layer may include an anodic active material. The first active material layer may include a cathodic active material, and the second active material layer may include a cathodic active material.

[0168] In some embodiments, the rotary cutter includes a die roller and a support roller that roll relative to each other in opposite directions during the cutting process. The rotational speed of each roller and the resulting conveying speed can affect the degree (e.g., amount) of adhesion to the target starting material (e.g., sheet material) adhering to the die, for example, as a result of the curing process. Such adhesion can be undesirable. Such adhesion may occur at the corners (e.g., sharp corners) of the embossed design (e.g., blade). Sometimes, the embossed design is configured to reduce (e.g., eliminate) the occurrence of sharp (e.g., acute) angles. Sharp angles in the original required design can be replaced by curves in the embossed design forming the cutting edge (one or more) (e.g., blade (one or more)) of the die.

[0169] In some embodiments, one or more parameters of the rotary cutter may be predetermined. These parameters may include: (a) the position of each roller of the rotary cutter; (b) the gap between two adjacent rollers; (c) the pressure applied to the target starting material to be processed by the rotary cutter; (d) the rotational speed of each roller; (e) the conveying speed of the target starting material; (f) the relative position of the rotary cutter in space (e.g., relative to the floor of the facility where the rotary cutter is located); (g) the torque applied to any roller of the rotary cutter; (h) any other structural parameters; (i) any functional parameters; or (j) any combination thereof. These parameters (one or more) may be determined manually and / or automatically, for example, using simulations including physical simulations. These parameters (one or more) may be controlled manually and / or automatically, for example, using simulations including physical simulations. A control system, such as the control system disclosed herein, or any control system designed to centrally control any structural and / or functional parameters of the rotary cutter, may be employed for the foregoing purposes. The control system may be coupled to one or more (a) control devices, (b) controllable components, (c) sensors, and / or (d) energy sources. The controllable devices may include actuators (e.g., motors), sensors, measurement systems, stopping systems, any combination thereof, or any other combination thereof. The sensors may include temperature sensors, motion sensors, pressure sensors, torque sensors, speed sensors, proximity sensors, compression sensors, tension sensors, optical sensors (e.g., cameras), height sensors, angle sensors, position sensors, chemical sensors, any combination thereof, or any other combination thereof. The speed sensors may include linear velocity sensors, rotational velocity sensors, or any combination thereof. The optical sensors may include charge-coupled device (CCD) cameras. The cameras may be configured to capture still images or video. The optical sensors may be configured to detect optical signals in the ultraviolet, visible, infrared, and / or X-ray regions. The position sensors may include GPS. The chemical sensors may be used for infrared spectroscopy or Raman spectroscopy. The one or more sensors may include lasers, for example, utilizing laser radiation.

[0170] In some embodiments, the rotary cutter includes one or more actuators, such as motors (e.g., servo motors) such as those disclosed herein. The actuators (one or more) may be configured (e.g., automatically) to adjust the relative rotational speed, rotational acceleration, torque and / or height, gap width, applied torque, and rotational speed of any roller of the rotary cutter (e.g., the die roller and / or the support roller) of the rotary cutter. The rotary cutter may include piezoelectric actuators and / or encoders, for example, to measure micrometer-level and / or nanometer-level motion. The encoders may include magnetic encoders, optical encoders, inductive encoders, linear encoders, rotary encoders (e.g., absolute or incremental), absolute encoders, any combination thereof, or any combination thereof. The rotary cutter may include or utilize levels, digital inclinometers, and / or laser alignment tools, for example, to calibrate the horizontal arrangement of the rollers (e.g., their axis of rotation).

[0171] In some embodiments, the rotary cutter includes one or more sensors and / or is operatively coupled to one or more sensors, such as those disclosed herein. The sensors can monitor one or more parameters associated with (e.g., belonging to) the rotary cutter. Any other measuring device, system, or combination thereof designed to control (e.g., monitor) and / or measure the one or more parameters can be utilized. As disclosed herein, control can include regulation, modulation, adjustment, maintenance, alteration, modification, domination, management, suppression, restriction, guidance, direction, supervision, administration, retention, maintenance, constraint, mitigation, or variation. The control can include continuous control and / or intermittent control. The sensors can continuously and / or intermittently record their measurements. The sensors can be operatively coupled to the control system and transmit the measurements to the control system, e.g., continuously and / or intermittently. In response, the control system can (e.g., continuously and / or intermittently) send signals to appropriate components assembled throughout the rotary device to adjust any functional aspect of the rotary cutter, e.g., to bring any functional aspect of the rotary cutter to a desired value. For example, the control system can receive signals that the applied pressure is decreasing and / or the calculated gap width is increasing; and in response, send a signal to the motor responsible for relative roller height adjustment to close / open the gap width until the required gap width value is reached (e.g., restored). Stopping devices and / or stopping systems can be implemented such that when the control system receives a measurement value exceeding a threshold (e.g., in real time) for a specific functional aspect, the control system can send a signal to the appropriate device and / or the rotary cutter to stop operation. The threshold may include a numerical value, a function, or a window. When the control system receives a measurement value from a sensor indicating that a safety threshold has been violated or is about to be violated, the control system can take remedial measures (one or more) to reduce the likelihood of the safety violation occurring / persisting (e.g., prevent the safety violation from occurring / persisting), for example, shutting down the operation of the rotary cutter to prevent potentially dangerous operation. The sensors can detect that a hazardous condition (one or more) is occurring or about to occur. The hazard may apply to the rotary cutting machine apparatus, the target starting material, the resulting cut, personnel near the rotary cutting machine, the facility where the rotary cutting machine is located, the environment where the rotary cutting machine is located, or any combination thereof. In one example, when the control system receives a measurement from a temperature sensor that the instrument temperature or roller temperature violates (e.g., exceeds) a temperature threshold, the control system shuts down the operation of the rotary cutting machine to prevent (e.g., prevent) the rotary cutting machine from operating in a potentially hazardous manner.The hazard may be directed at the rotary cutting machine, the target starting material, the resulting cut, personnel near the rotary cutting machine, the facility where the rotary cutting machine is located, the environment where the rotary cutting machine is located, or any combination thereof.

[0172] In some embodiments, the rotary cutter is employed after the target starting material, including the cell component, has undergone one or more processing operations (e.g., calendering or any other fabrication process disclosed herein). A coating operation of a slurry can apply a coating of a corresponding active material to the current collector to generate an electrode with cathode or anodic properties. The slurry can include a dry slurry or a wet slurry. Different types of slurries can be applied to the sheet to generate the target starting material. The electrode can be dried in at least one drying operation, for example, using any tools and techniques that facilitate drying the electrode (such as using an oven). Compression rollers can compress the active material of the electrode to increase its active material density, for example, increasing the density of the active material deposited on the sheet of current collector material to generate the target starting material for the rotary cutter. The compression rollers (e.g., in a calendering function) can improve the thickness uniformity of the active material coupled to the current collector sheet / foil to form the target starting material. The density of the active material layer can be at least about 0.5 g / cm³ (gr / cc), 0.7 gr / cc, 0.75 gr / cc, 0.8 gr / cc, 0.85 gr / cc, 0.9 gr / cc, 1.0 gr / cc, 2.5 gr / cc, 2.95 gr / cc, 3.15 gr / cc, 3.5 gr / cc, 4 gr / cc, 4.2 gr / cc, 4.5 gr / cc, 6 gr / cc, 6.5 gr / cc, or 7 gr / cc. The density of the active material layer can be at most about 0.6 gr / cc, 0.7 gr / cc, 0.75 gr / cc, 0.8 gr / cc, 0.85 gr / cc, 0.9 gr / cc, 1.0 gr / cc, 2.5 gr / cc, 2.95 gr / cc, 3.15 gr / cc, 3.5 gr / cc, 4 gr / cc, 4.2 gr / cc, 4.5 gr / cc, 6 gr / cc, 6.5 gr / cc, 7 gr / cc, or 10 gr / cc. The density of the active material layer can be any value between the aforementioned values, for example, about 0.5 gr / cc to about 10 gr / cc, about 0.5 gr / cc to about 2 gr / cc, or about 3.5 gr / cc to about 7 gr / cc. The density of the cathode active material can be at least about 1.5*, 2*, 3*, 4*, or 5* higher than the density of the anode active material layer, where "*" represents a mathematical operation of "times". The density of the cathode active material can be up to about 2*, 3*, 4*, or 5* higher than the density of the anodic active material layer. The density of the cathode active material can be any value between the aforementioned values ​​higher than the density of the anodic active material layer, for example, about 1.5* to about 5*, or about 1.5* to about 3*. The thickness of the target starting material can be any value disclosed herein.The compressed and / or calendered active material can have an Ra value of up to about 1.5 micrometers (μm), 3 μm, 10 μm, 5 μm, 8 μm, 17 μm, 20 μm, or 50 μm. The compressed and / or calendered active material can have an Ra value between any of the aforementioned values, for example, about 1.5 μm to about 50 μm, or about 3 μm to about 20 μm. Ra is the arithmetic mean of the absolute values ​​of surface height deviations within a specified sampling length, for example, the average roughness. In addition to the die roll and the support roll, the rotary cutter may also include one or more additional rolls. The additional rolls may include a compression roll and / or a calendering roll. The rotary cutter can be operatively coupled to the additional rolls. The compression roll can be used as a calendering device, for example, to calender the thickness of the target starting material, for example, to calender an active material layer coupled to a current collector to form the target starting material. The compression rolls and / or calendering rolls (one or more) can at least partially generate the target starting material to be supplied to the rotary cutter. At least two rolls of the rotary cutter can have (e.g., substantially) the same diameter. At least two rolls of the rotary cutter can have (e.g., substantially) different diameters. At least two rolls of the rotary cutter can have (e.g., substantially) the same lateral length portion configured to contact the target starting material. At least two rolls of the rotary cutter can have (e.g., substantially) different lateral length portions configured to contact the target starting material.

[0173] In some embodiments, the calendering apparatus can operate within a certain temperature range. This temperature range may or may not include ambient temperature. The apparatus may be located in an environment having the ambient temperature. The apparatus may be located in an environment different from the ambient environment. This other environment may differ from the ambient environment in one or more environmental characteristics, including temperature, atmospheric composition, pressure, or any combination thereof. The other environment may have one or more reactive reagents (also referred to herein as “reactive substances”) at reduced concentrations relative to the ambient environment. The reactive reagents (one or more) may include oxygen, water, alcohols, thiols, sulfuric acid, phosphoric acid, carboxylic acids, hydrogen sulfide, any combination thereof, or any combination thereof. The reactive reagents (one or more) may be oxygen-, sulfur-, and / or phosphorus-based reactive reagents. The reactive reagents (one or more) may include water and / or oxygen. In one example, the reactive reagents (one or more) include water in liquid and / or vapor form. The other environment may be an inert environment that is inert to (a) the target starting material cut by the rotary cutter and / or (b) processes occurring in energy manipulation devices such as batteries (e.g., chemical processes). The other environment may be at a temperature different from the ambient temperature (e.g., a window). The rotary cutter and / or compression (e.g., and calendering) rolls may operate in a temperature range different from and / or excluding the ambient temperature. The different temperatures (e.g., ranges) may include elevated temperatures. Calendered electrodes may be fed into the rotary cutter. One or more parameters of the rotary cutter are configured to cut a section from the target starting material, for example, without further altering the thickness of the target starting material. The central tendency (e.g., average value) of the thickness of a region of the target starting material may be the same as that of the corresponding region (e.g., substantially) in the resulting section. One or more parameters of the rotary cutter may include working gap width, pressure, temperature, or any other parameter(s) disclosed herein. In some embodiments, the rotary cutter operates in an inert environment, an environment with a reduced percentage of reactive substances (e.g., oxygen or water), or any other environment inert to the target starting material being processed.

[0174] In some embodiments, the rotary cutter is part of a multi-step manufacturing process (e.g., the multi-step manufacturing process disclosed herein). The separation of the rotary cutter from previous processing in the multi-step manufacturing process can be physical. The rotary cutter may be located in a different processing (e.g., manufacturing) production line. The different processing production lines may employ separate and different machine types, also referred to herein as “tools.” The different tools may employ separate structural frames. In one example, the tools include the rotary cutter and the calendering apparatus. In one example, the rotary cutter employs a first frame (e.g., a structural frame) and is located in a first manufacturing production line, while the calendering apparatus employs a second frame and is located in a second manufacturing production line. One or more tools may be employed in the multi-step manufacturing process. At least two of the tools(s) may use the same frame. At least two of the tools(s) may be located in the same manufacturing production line. At least two of the tools(s) may be located in different manufacturing production lines. At least two of the tools(s) may employ different frames. At least two of the tools(s) may be operatively coupled, for example, using a control system such as those disclosed herein. At least two of the tools (one or more) may be controlled sequentially, collaboratively, in parallel, or independently of each other. A first tool operating the first process may be physically separated from a second tool operating the second process, for example, simultaneously coupled within the same frame. The rotary cutting process may be physically separated from at least one other process, while simultaneously coupled within the same frame. The other processes may include processes experienced by the target material before, simultaneously with, and / or after the cutting operation performed by rotary cutting. The other processes may include deposition, compression, calendering, roll-to-roll, cutting, forming, machining, welding, stamping, encapsulation, deposition, drying, spraying, 3D printing, calendering, compression, ablation, slitting, adhesion (e.g., glue bonding), soldering, any combination thereof, or any combination thereof. For example, the same frame may include a pair of rollers coupled to perform compression and calendering operations and another pair of rollers (e.g., die rollers and support rollers) used as the rotary cutter to slit the compressed and calendered target starting material and generate the desired cut and residue. In another embodiment, the same frame can be used for compression, calendering, and rotary cutting, for example, by adding one or more additional rollers to the structural frame of the rotary cutter, wherein the one or more additional support rollers are different from the die roller. In some embodiments, the support rollers support more than one roller. The more than one roller may include a calendering roller, a compression roller, and / or a die roller. The rotary cutter can simultaneously calender and cut the target starting material via the die roller and the support rollers.The rotary cutter can simultaneously compress, calender, and cut the target starting material via the die roller and the support roller. The calendering and / or compression can be achieved by changing (e.g., decreasing or increasing) the gap between the die roller and the support roller, such that the rotary cutter simultaneously (optionally compresses), calenders, and cuts the sheet via the die as the target starting material is fed through the gap. The applied pressure is used to simultaneously (optionally compresses), calenders, and cuts the target starting material. This versatility of the rotary cutter can be based at least in part on maintaining a predetermined height of the die roller relative to the support roller. A height control system can operate by specifying a gap width for the sheet. This versatility of the rotary cutter can be based at least in part on maintaining a predetermined pressure applied to the target starting material by the die roller relative to the support roller. A pressure control system can operate by specifying a gap width for the target starting material (e.g., a sheet of material). The calendering and / or compression system can operate by dynamically applying a variable force to the target starting material as it is fed through the gap, thereby maintaining the gap width and pressing the target starting material to a uniform thickness. The rotary cutter can maintain the thickness of the part being cut (e.g., a battery component). The control system employed by such a rotary cutter can be any control system disclosed herein, for example, using pressure sensors, position sensors, and / or height sensors. One or more additional rollers can be added, for example, to help planarize the target starting material fed into the portion of the rotary cutter that performs the cutting action. The height control system and / or the pressure control system can be part of a control system such as those disclosed herein.

[0175] In some embodiments, the pressure is controlled by the rotary cutter. The pressure may be the pressure of the die roller relative to the support roller, or the pressure between any other two directly adjacent rollers of the rotary cutter, for example, as disclosed herein. The rotary cutter may be operated at least partially to control (e.g., maintain) a predetermined pressure applied to the sheet, for example, independent of or dependent on the gap width.

[0176] In some embodiments, one or more other cutting methods and / or processes may supplement the manufacturing production line. The one or more other cutting methods may include stamping and / or laser processing. The one or more other cutting methods may be performed before, during, or after the rotary cutting machine cuts the target starting material. The one or more other cutting methods may be performed before, during, or after feeding the target starting material into the rotary cutting machine. In one example, laser processing may be used to cut small features that may be difficult to remove from the mold using a rotary cutting machine.

[0177] In some embodiments, the target starting material is cut into desired cut pieces. These cut pieces can serve as components of a device (e.g., a battery cell). The cut pieces may undergo further processing, such as cleaning. Cathode or anode battery components may undergo cleaning, for example, to remove any excess or unwanted layers of active material from a predetermined location in the product. Mechanical and / or chemical methods may be used for this further processing. This further processing may include adding solvents to remove excess material and / or performing a wiping action. The target material may include a coating that allows the target starting material (e.g., its particulate material) to withstand the cutting process without substantial damage. The coating may include any coating disclosed herein, such as a coating for the mold. Substantial damage refers to measurable damage that would prevent the active material from functioning as required and / or designed in the final product in which it is intended.

[0178] Figure 14 This is a perspective view of a portion of the rotary cutting machine. Die rollers 1410 are vertically stacked above support rollers 1411, and both rollers are coupled to a frame 1413 (structural frame). Height adjustment structures 1402a and 1402b are configured to adjust the height of at least one of these rollers, for example, along directions 1412a and 1412b or opposite directions, to adjust the gap between these rollers, and / or adjust the pressure applied to any target starting material positioned between the two rollers. The height adjustment structures (e.g., 1402a and 1402b) can enable manual and / or automatic adjustment of the vertical position of at least one roller to adjust the gap between the two rollers. An actuator 1401 is operatively coupled to the support roller 1411, for example, to enable the support roller to rotate relative to the die rollers. The die rollers may have dedicated actuators for controlling their rotation. The rolling of the die rollers can be controlled using the actuators in 1402a and / or 1402b. Frame 1413 can be fixed to, for example Figure 13 The test bench 1301 and other test benches. Although Figure 14 The rotation of the rollers is electronically achieved (e.g., using actuators such as servo motors), but the rotation of the rollers (one or more) can be at least partially achieved manually. Figure 14 In the example shown, the mold roller and the support roller have the same diameter (e.g., substantially the same) and the lateral length (e.g., substantially the same) of the portion intended to contact the target starting material.

[0179] Figure 15 Is with Figure 14A similar perspective view is shown in another perspective view of the rotary cutter, in which the two rollers are vertically stacked. Each roller is coupled to a structural frame and includes shafts 1501a and 1501b. In this example, the die roller is omitted for illustrative purposes, while the support roller 1511 is in its position. The frame includes a bridging portion 1513, two opposing side coupling portions such as side coupling portion 1513b, and two opposing sides such as side portion 1513c, which can each be coupled to a frame (not shown) at their bottom portion such as 1513d. The rotary cutter has a front side and a rear side opposite to the front side. The front side is open, allowing a user to access the die roller and change the die, for example, from position 1514.

[0180] Figure 16 Example side view of parts, related components, and operating mode of the rotary cutting machine is shown. Example 1600 shows a rotary cutting machine having an upper roller 1603 that is vertically stacked above a lower roller 1602 relative to a gravity vector 1690 pointing to the center of gravity G of the surrounding environment (e.g., the Earth). If the upper roller is the die roller, then the lower roller is the support roller. If the upper roller is the support roller, then the lower roller is the die roller. Although the die roller is shown stacked above the support roller, it may be located below the support roller relative to the gravity vector 1690. In this embodiment, the lower roller 1602 is coupled to a device 1601 that can realize rotation of the roller and / or control such rotation. The device 1601 can realize a change in the height of the lower roller. The device 1601 is operatively coupled to an actuator 1604 (e.g., a motor). Rollers 1602 and 1603. The upper roller 1603 is coupled to an actuator 1605, for example, to actuate the rotation of the upper roller 1603. Rollers 1602 and 1603 are held by a frame including a bridging portion 1606 and opposing sides 1607a and 1607b. Sides 1607a and 1607b are held together by support structures such as 1608a and 1608b. Four support structures may be present coupling sides 1607a and 1607b, for example, two support structures 1608a and 1608b and two similar support structures located at the rear. Each roller can be accessed from the front and rear, for example, to allow the roller and / or any embossed structure (e.g., a die) coupled to the roller to be replaced, depending at least in part on the design to be cut and / or the sharpness of the embossed portion (e.g., a cutter). Dashed arrow 1610 indicates an optional direction from which the user can access the die. The user can be living or non-living, such as a robot or a human.

[0181] Example 1630 illustrates a target starting material processed by two rollers, such as a die roller and a support roller, coupled to a detection system configured to measure the width of the gap between the rollers. Example 1630 is shown relative to a gravity vector 1690. The detection system includes a light generator 1634a, i.e., an emitter that emits light in one direction. The light is directed to illuminate the gap between rollers 1632 and 1633. The light emitted from the gap is detected by a sensor 1634b (i.e., a light receiver). The detection system can detect the gap with varying degrees of precision, for example, optically. For the distance between the emitter and receiver depicted in 1650, the gap can be measured with the corresponding precision listed in 1651. For example, at a receiver-emitter distance of approximately 20 mm, the gap can be detected with a precision of approximately 1 micrometer. For example, at a receiver-emitter distance of approximately 100 mm, the gap can be detected with a precision of approximately 2.5 micrometers. For example, at a receiver-transmitter distance of approximately 500 mm, the gap can be detected with an accuracy of approximately 5 micrometers. The longer the distance between the transmitter and the receiver, the less accurate the gap measurement becomes. The target starting material can be pulled into the gap between rollers 1632 and 1633 along the transverse direction 1631b and discharged along the vertical direction 1631a. The target starting material can be pulled into the gap between rollers 1632 and 1633 along the vertical direction 1631a and discharged along the transverse direction 1631b. The rollers can be any two rollers of the rotary cutting machine, for example, the die roller and the support roller.

[0182] In some embodiments, the rotary cutter includes a support roller and a die roller. As shown, the two rollers can be operatively coupled via a system such that when one roller rotates in one direction and at one speed, the second roller rotates at an equal speed in the opposite direction to that of the inner roller via the system. In some embodiments, the system is a gear system. As shown, the rotary cutter can receive sheets under tension to perform the cutting function and possibly calendering function described herein.

[0183] Figure 17A textured (e.g., flexible) sheet or "die" 1710, shown in unfolded sheet form, includes die sub-units 1701 for cutting and an exploded view 1720 of such die sub-units. The die sheet 1710 is converted into a bent form 1730 at 1760, such that the endpoints of each die contact, e.g., to couple with the inner roller of the die roller. The die 1710 is patterned with cutting edges, such as blade 1705, to form a textured cutting edge (e.g., a cutting tool). The die 1710 and cutting edge 1705 can be fabricated using mask etching techniques (e.g., photolithography) disclosed herein. The cutting edge can be further processed, e.g., to sharpen or round it, e.g., rounding angular structures such as right angles or acute angles. In some embodiments, laser processing techniques can be used to sharpen the cutting edge 1705. In some embodiments, the cutting edge 1705 may be rounded to reduce adhesion during the cutting process. The mold may typically be designed to reduce adhesion of the target starting material and / or the resulting cut and residue during the cutting process, for example, based on the target starting material. The mold 1701 is designed to cut an electrode having a current collector and active material coupled thereto. The mold subunit 1701 includes mold alignment structures 1701a and 1701b. The alignment structures may be configured to allow the cut to be aligned relative to each other and / or relative to another component of the resulting device (e.g., stacked battery cells). The mold includes sections for tabs 1704a and 1704b, located at the distal edge of a mold portion 1703, which is designated to cut the active material of the electrode in a central region of the mold. The mold sheet 1701 is rectangular and has a long side 1761 (length) and a short side 1762 (width). The mold roller includes a portion configured to receive the mold sheet, the portion being a central portion. The long side of the mold sheet is (e.g., substantially) equal to the perimeter of one side of the mold roller portion configured to receive the mold sheet. The short side of the mold sheet is (e.g., substantially) equal to the lateral length of the mold roller portion configured to receive the mold sheet.

[0184] Figure 18 Examples of independent rollers, such as die rollers, are depicted, each comprising a roller and a shaft designed to couple with a frame, actuation system, and / or control system, as disclosed herein. The roller may include materials suitable for the structure of a rotary cutter, such as those described herein. In some embodiments, the roller comprises a single metal, a metal alloy, or any material disclosed herein. The roller may include materials configured to enable it to perform its intended purpose in the rotary cutter. The metal alloy may include stainless steel or an Inco nickel alloy. Figure 18The roller depicted herein may be a die roller. The roller has a shaft showing its side 1803, a central portion 1801 configured to receive the die sheet, and side portions 1802a and 1802b adjacent to a distal section of the central portion. A gear 1804 is coupled to the die roller. The die roller comprises two concentric cylinders; for example, the first cylinder includes the shaft 1803, and the second cylinder includes the portion 1801. The die may be wound around the outer surface of the roller and may be held flush with the surface of the roller by any of the techniques disclosed herein (e.g., adhesives (e.g., epoxy resin), fasteners (e.g., screws), attractive forces (e.g., magnetism), or any combination thereof).

[0185] Figure 19 A photograph depicts a rotary cutting machine with a cutting die 1940 mounted around a die roller positioned above a support roller 1932. Both rollers are coupled to a frame including a bridging section 1934, two opposing sides such as side sections 1933, and a support structure such as 1931. The rotary cutting machine is located on a tabletop and includes gear systems such as gears 1936 and 1934, each operatively coupled to a corresponding roller. The support roller is coupled to gear system 1934 and an electronic actuation system section 1934. The support roller 1932 is also coupled to a manual rotation system with a handle 1939, for example, for operation, safety, and / or maintenance purposes. The die roller 1940 is coupled to gear system 1936 and actuator 1938. When the target starting material is placed between the rollers, the rollers can be compressed relative to each other. The rollers can be separated from each other by a gap. The separation can be achieved using manual and / or electronic means. The separation can be achieved using one or more lead screws. Figure 19 An example of a rotary cutting machine with gaps separated by lead screws such as lead screw 1941 is shown. Figure 19 In the example, the mold roller is coupled to a mold having a lateral length of 105 mm. Figure 19 Shown according to scale.

[0186] In some embodiments, the rotary cutter is coupled to a die sheet / foil. The die sheet may have a width configured to couple with the lateral length of a die receiving portion of the die roller. The lateral length of the receiving portion may be at least about 5 mm, 10 mm, 50 mm, 100 mm, 150 mm, or 200 mm. The lateral length of the receiving portion may be at most about 10 mm, 50 mm, 100 mm, 150 mm, 200 mm, 500 mm, or 1000 mm. The lateral length of the receiving portion may be any value between the foregoing values, for example, from about 5 mm to about 1000 mm, or from about 50 mm to about 150 mm. The lateral length of the receiving portion of the die roller may be equal to (e.g., substantially) the width of the die sheet.

[0187] The circumference of the cylindrical receiving portion can be at least about 50 mm, 100 mm, 250 mm, 500 mm, 600 mm, 800 mm, 1000 mm, 1500 mm, or 2000 mm. The circumference of the cylindrical receiving portion can be at most about 100 mm, 250 mm, 500 mm, 600 mm, 800 mm, 1000 mm, 1500 mm, 2000 mm, or 3000 mm. The circumference of the cylindrical receiving portion can be between any of the aforementioned values, for example, from about 100 mm to about 3000 mm, or from about 400 mm to about 800 mm. The circumference of the receiving portion of the mold roller can be approximately equal to the length of the mold sheet (e.g., substantially).

[0188] Figure 20 An image of the die roller of the rotary cutting machine is shown, on which a die 2001 is mounted. The die is etched and processed to form a sharp, patterned embossed surface comprising repeating rectangular units according to a scale. Figure 20Each rectangle is shown to be approximately 4.77 mm wide. The die roller is coupled to a frame, and a support structure 2020 is shown in the figure. The die includes a line structure 2002 for cutting (e.g., elongated) battery cell components, including electrodes, separators, spacers, and / or end plates. The die includes a joining structure 2003, for example, to engage a busbar with the cut battery cell portion in the joining structure. The die includes an alignment structure 2004, for example, to align the battery cell components relative to each other, for example, in a battery cell and / or a stack of battery cells. The alignment structure may be cut by the die or dented by the die relative to the target starting material. The joining structure may be cut by the die or dented by the die relative to the target starting material. The dented structure may be processed by other methods to create (e.g., smaller) cut portions in the resulting cuts.

[0189] In some embodiments, at least one roller of the rotary cutter rotates during use. The rotational speed can be at least about 10 revolutions per minute (RPM), 20 RPM, 30 RPM, 33 RPM, 40 RPM, 47 RPM, or 50 RPM. The rotational speed can be at most about 20 RPM, 30 RPM, 33 RPM, 40 RPM, 47 RPM, 50 RPM, or 100 RPM. The rotational speed of the roller can be between the aforementioned values, for example, from about 10 RPM to about 100 RPM, or from about 20 RPM to about 50 RPM. The rotary cutter is configured to process the target starting material at a certain speed. The speed can be at least about 5 meters per minute (m / min), 10 m / min, 15 m / min, 20 m / min, 25 m / min, 30 m / min, or 50 m / min. The speed can be up to about 10 m / min, 15 m / min, 20 m / min, 25 m / min, 30 m / min, 50 m / min or 55 m / min. The speed can be any speed value between the foregoing values, for example, from about 5 m / min to about 55 m / min, or from about 10 m / min to about 25 m / min.

[0190] Figure 21 An exemplary photograph is shown of a die portion processed by a rotary cutter according to the process described herein. The die is mounted on a die roller with a diameter of approximately 143 mm. The die is clearly etched and includes shallow etched patterns indicating blades for piercing and cutting through the target starting material intended to pass through the rotary cutter. Figure 21The die depicted successfully cut cathode and anode cell components at roller speeds up to approximately 33 revolutions per minute (RPM). The die also successfully cut the cathode and anode cell components at a speed of 15 meters per minute (m / min) of target starting material (e.g., sheet material). The die manufactured a cathode component comprising an LCO-based active material layer on an aluminum current collector. The anode components manufactured by the die comprise either a Si-C composite active material layer or a SiO2 active material layer. x Active material layers, each deposited separately on a separate copper current collector. In some embodiments of the mold disclosed herein, as... Figure 21 The mold of the rotary cutter can act on the diaphragm sheet. In one example, the (e.g., anode) active material includes SiO₂. x And Si-C. In Figure 21 In the figure, the mold portion is configured as: (a) a cutting / denting alignment structure or bonding structure; (b) a cutting / denting tab portion (e.g., a tab portion of a current collector); and (c) a cutting / denting active material portion of the target starting material. Molds associated with the bonding or alignment structure are indicated by reference numerals 2101 and 2105. The tab mold structure is shown at 2102. The active material portion mold is shown at 2103. A portion without a tab mold is shown at 2104, for example, which may cut material to form a diaphragm, or may process the target starting material including an active material portion of an electrode deposited on a charge carrier fluid. The mold may be located on one distal end (e.g., Figure 17 1704a and 1704b) include a splice portion mold, include a splice portion mold on one of its distal ends, or do not include a splice portion mold on either of its distal ends.

[0191] Photos 19 to 21 illustrate examples of a rotary cutting machine and its corresponding mold.

[0192] In some embodiments, the rotary cutter is configured to cut and / or indent (e.g., compress or press) the target starting material. The die can be configured to cut in a region parallel to the longitudinal axes of the die roller and the support roller, the region comprising the area of ​​the target starting material compressed by the die roller and the support roller. This processing area can be smaller than the area required to cut the entire design to be cut, for example, as in stamping cuts. The arrangement of the shape to be cut in the die can be configured to minimize the force required to cut and / or indent the desired shape. The force required to cut and / or indent the desired shape can be dynamically adjusted, for example, according to the extent of the shape to be cut when the relevant portion of the die engages with the target starting material. The dynamic adjustment can be performed at least partially automatically using the controller, for example. The dynamic adjustment can be pre-performed, for example, using open-loop control. The dynamic adjustment can be made at least in part by considering the following: (a) one or more material properties of the material to be cut; (b) the rotational speed of the die; (c) the complexity of the design (e.g., acute angles and / or the dimensions of the portion to be cut); and (d) one or more properties of the die (e.g., material, blade sharpness, angle of the blade relative to the plane, for example, ...). Figure 17 (e) the gap between the die roll and the support roll; or (f) any combination thereof. The dynamic adjustment may include the use of physical simulations, for example, including consideration of force, dynamics, and / or material composition. The control system may be configured to control the calendering of the target starting material, for example, the control system may set a height and force the target starting material to reach a desired height. The control system may be configured to maintain the height of the target starting material, for example, configured to maintain the height of the active material used as an electrode on the current collector. The control system may be configured to control pressure, for example, maintaining pressure regardless of the resulting height. The control system (e.g., during the calendering) may not have pressure control. The control system (e.g., during the slitting) may include pressure control. The control system may control one or more attributes at least in part based on the action of the components (e.g., devices) it controls.

[0193] In some embodiments, the electrode is separated from the counter electrode by a gap. The gap may include a diaphragm. The diaphragm may include a polymer, resin, or ceramic. The ceramic may include alumina (Al₂O₃), zirconium oxide (ZrO₂), magnesium oxide (MgO), boron nitride (BN), mullite, boehmite, or silicon carbide (SiC, for example, in pure form), boehmite (AlO(OH)), or any combination thereof. The diaphragm may include a central layer of polymer and / or resin, which may be coupled to a portion of the ceramic on its two opposite sides. The ceramic body may be in the form of a layer. The ceramic body may include a binder such as those disclosed herein.

[0194] In some embodiments, the mold is configured to cut one or more components of a battery cell. The mold may be configured to cut at least two distinct components of the battery cell, such as an anode and a cathode, in separate cutting stages. The mold may also be configured to cut one component of the battery cell, such as an electrode and a separator, while not cutting other components of the battery cell, for example.

[0195] Figure 22An example of a process flow for manufacturing multiple battery components using a rotary cutting machine such as those disclosed herein is illustrated. In one embodiment, three separate rotary cutting machines each include a die, each die being etched with a custom pattern, and three separate battery components are manufactured via the functions disclosed herein. For example, at 2202, a cathode structure sheet is fed in roll-to-roll to a first rotary cutting machine equipped with a first die, which has been processed using a pattern for the cathode structure component intended to manufacture an electrode assembly. The cathode structure battery component is manufactured and stored for subsequent electrode assembly. In this example, at 2203, an anode structure sheet is fed in roll-to-roll to a second rotary cutting machine equipped with a second die, which has been processed using a pattern for the anode structure component intended to manufacture an electrode assembly. The anode structure battery component is manufactured and stored for subsequent electrode assembly. Finally, in this example, at 2204, the membrane structure sheet is fed in roll-to-roll form into a third rotary cutter equipped with a third die that has been patterned using the membrane structure components intended for manufacturing the electrode assembly. The membrane structure battery component is manufactured and transported together with the previously manufactured cathode and anode structure components to any downstream process that assembles the three components into an electrode assembly. This implementation of the technique would allow each of the three rotary dies to operate in a separate environment suitable for manufacturing its respective battery component. For example, two rotary cutters dedicated to manufacturing the cathode and anode structures could operate in a controlled drying chamber environment to minimize the exposure of sensitive pre-dried active materials on the surfaces of the cathode and anode structures to moisture, while the third rotary cutter dedicated to manufacturing the membrane structure could operate outside the drying chamber environment. This processing decision depends on the manufacturer's judgment.

[0196] In another embodiment, a rotary cutter can be used three times, each time with a different die, to manufacture three different battery components. For example, at start 2201, a die specifically for manufacturing the cathode structure component can be fitted to the rotary cutter. At 2202, the rotary cutter with the die can manufacture the cathode structure component. Manufacturing can be stopped, the cathode structure can be collected, the die can be replaced with a die specifically for manufacturing the anode structure component, the rotary cutter can receive roll-to-roll anode structure sheet, and operation can resume. At 2203, the rotary cutter is now fitted with a die for manufacturing the anode structure component and is now receiving anode structure sheet; the rotary cutter can manufacture the anode structure component. Manufacturing can then be stopped, the anode structure can be collected, the die can subsequently be replaced with a die specifically for manufacturing the diaphragm structure component, the rotary cutter can subsequently receive roll-to-roll anode structure sheet, and finally operation can resume. At point 2204, the rotary cutter is now equipped with a mold for manufacturing the diaphragm structure component and is receiving the diaphragm structure sheet. The rotary cutter can manufacture the diaphragm structure component. Finally, the rotary cutter can stop operating at point 2205 and the diaphragm structure can be collected. In this embodiment, the rotary cutter can operate in the same environment and location to manufacture different battery components.

[0197] like Figure 12 , Figure 17 , Figure 18 , Figure 21 and Figure 22As shown and discussed herein (e.g., above), this document discloses systems and methods employing rotary die-cutting technology, for example, for mechanically cutting secondary battery electrodes to at least partially replace laser cutting of secondary battery electrodes. The systems and methods disclosed herein enable faster, more precise, and / or cleaner cutting, for example, while allowing roll-to-roll continuous processing of (e.g., secondary) battery electrodes. The cutting process is fundamental to (e.g., secondary) battery manufacturing processes because it is responsible for defining individual electrodes by R2R (roll-to-roll) coated electrode materials. Rotary die-cutting is used, for example, in the conversion processing industry, where it is primarily used to form custom parts from various rolls of material. One challenge in adopting this technology in the battery industry is the target starting material, for example, which may include, for example, loosely bonded particulate materials. These bonded particulate materials can withstand (e.g., by the rotary cutter) cutting without causing (e.g., substantial) damage to the active material. The substantial damage refers to measurable damage that would prevent the active material from functioning as required and / or designed in the final product in which it is intended. Materials that can be cut using rotary cutting range from soft metals to plastics, adhesives, and / or paper. The thickness ranges from tens of micrometers to several millimeters. A schematic diagram of an exemplary rotary die assembly is shown in... Figure 12 As shown in the image.

[0198] In some embodiments, the mold (the portion of the mold assembly that performs the cutting) is made of ferrous metal and is flexible, for example, due to its thickness. The cutting features are first defined by etching (e.g., for accuracy), followed by machining in a secondary process to fully define the cutting edge. Exemplary rotary molds and magnetic rotary chucks are respectively... Figure 17 and Figure 18 As shown in the diagram. Raw material (in roll form) is fed between the die assembly and a support roller (e.g., anvil roller), the material is pressed against the cutting edge of the die and cleaved as it moves, for example, along the cutting edge in a straight line. The rotational shape of the die ensures that a cutting edge is always present, interacting with the workpiece. This differs from press systems that require both lateral actuation of the workpiece and vertical actuation of the press. An exemplary die section is shown in... Figure 21 As shown in the figure. The mold can be used to manufacture the cathode component, anode component, and / or separator component of a secondary battery.

[0199] In one aspect, the systems and methods disclosed herein include processes for manufacturing electrodes for (e.g., secondary) batteries using rotary die assemblies. Figure 22As shown, the process begins by manufacturing the cathode component of the electrode assembly of the secondary battery using a first mold of the rotary mold assembly. The process continues by manufacturing the anode component of the electrode assembly of the secondary battery using a second mold of the rotary mold assembly. The process ends by manufacturing the separator component of the electrode assembly of the secondary battery using a third mold of the rotary mold assembly.

[0200] In another aspect, the systems and methods disclosed herein include a rotary die assembly for manufacturing electrodes for a secondary battery. The rotary die assembly includes a first die, a second die, and a third die. The rotary die assembly is configured to manufacture a cathode component of the electrode assembly of the secondary battery using the first die of the rotary die assembly. The rotary die assembly is also configured to manufacture an anode component of the electrode assembly of the secondary battery using the second die of the rotary die assembly. The rotary die assembly is further configured to manufacture a separator component of the electrode assembly of the secondary battery using the third die of the rotary die assembly.

[0201] The systems and methods discussed herein allow for faster processing of electrode components, for example, compared to laser cutting. The systems and methods discussed herein enable the arrangement of cutters in groups, allowing for the cutting of more than one electrode width at a time. The systems and methods discussed herein allow for reduced heat-affected zone (HAZ) occurrence (e.g., no HAZ), minimal to no debris, and / or minimal to no re-deposition.

[0202] The systems and methods discussed herein can be modified, at least in part, by adjusting the size and shape of the die and the cutting height of the die relative to the electrode material, for example, to allow stepped cutting. Furthermore, the systems and methods discussed herein can be used in hybrid methods, in which the laser is used to process some electrode components but not others. The stepped cutting can include sequential cutting. The die rollers can be configured to sequentially cut and / or imprint the target starting material.

[0203] In some embodiments, the systems, apparatuses, and / or devices disclosed herein include control systems. A control system may include one or more controllers. The control system may include, or be operatively coupled to, one or more apparatuses, devices, and / or systems of the entities disclosed herein (e.g., systems, apparatuses, or devices), including any components of said apparatus(s), devices(s), and / or systems(s). The controller(s) may include, or be operatively coupled to, a hierarchical control system. A hierarchical control system may include at least three, four, or five control levels. In some embodiments, at least two operations are performed or directed by the same controller. In some embodiments, at least two operations are performed or directed by different controllers. A control system may include a control system. A control system may include a laser control system. A controller may include a feedback control scheme. A feedback control scheme may include an open-loop control scheme. A feedback loop control scheme may include a closed-loop feedback control scheme. A feedback control scheme may include hardware compensation. A feedback control scheme may include software compensation. A control system may include, or be operatively coupled to, a metrology system and configured to receive measurement data from the metrology system. A control system may be configured to generate control signals in response to measurement data acquired by the metrology system.

[0204] In some embodiments, the systems, devices, apparatuses, and / or components thereof disclosed herein include one or more controllers. One or more controllers may include one or more central processing units (CPUs), input / output (I / O), and / or communication modules. A CPU may include electronic circuitry that executes computer program instructions by performing arithmetic, logic, control, and I / O operations specified by the instructions. A controller may include suitable software (e.g., an operating system). A control system may optionally include feedback control loops and / or feedforward control loops. A controller may be shared among one or more systems or devices. Each device or system may have its own controller. Two or more systems and / or components thereof may share a controller. A controller may monitor and / or direct changes in the operating conditions (e.g., physical) of the devices, software, and / or methods described herein. A controller may be manual or non-manual. A controller may be automatic. A controller may operate on request. A controller may be programmable. A controller may be programmable. A controller may include a processing unit (e.g., a CPU or GPU). A controller may receive input (e.g., from a sensor). A controller may deliver output. A controller may include multiple controllers. The controller can receive multiple inputs. The controller can generate multiple outputs. The control system may include a single-input single-output (SISO) controller or a multiple-input multiple-output (MIMO) controller. The controller can interpret the received input signals. The controller can acquire data from one or more sensors. Acquisition may include receiving or extracting. Data may include measurement, estimation, determination, generation, or any combination thereof. The controller may include feedback control. The controller may include feedforward control. Control may include switching control, proportional control, proportional-integral (PI) control, or proportional-integral-derivative (PID) control. Control may include open-loop control or closed-loop control. The controller may include closed-loop control. The controller may include open-loop control. The controller may include a user interface. The user interface may include a keyboard, keypad, mouse, touchscreen, microphone, voice recognition component, camera, imaging system, or any combination thereof. Outputs may include a display (e.g., a screen), speaker, or printer.

[0205] Figure 23A schematic example of process 2320 controlled using a control system in a feedback loop control scheme (e.g., in a closed-loop control scheme) is shown. The control system provides a setpoint 2305 to a comparator 2306 that generates an error signal, which is fed to a controller 2340 via a signal path 2345. In other control systems, the comparator may be part of the controller. The controller 2340 generates a control signal that is fed to a control element 2330. The control element may include mechanisms for its control functions to control process 2320. The control element 2330 provides inputs to process 2320. The mechanisms may cause physical and / or chemical changes that are inputs to process 2320. Physical changes may include mechanical, magnetic, electromagnetic, piezoelectric, electrical, pressure, or temperature changes. Chemical changes may include changes in chemical gradients or changes in chemical entities. Process 2320 may be any process disclosed herein, such as any method, like a making (e.g., manufacturing) method. Process 2320 generates an output detected by measuring element 2310, for example, using its sensors (one or more). The output provided by process 2320 may be a process response to an input provided by control element 2330. Measuring element 2310 generates a variable amplitude signal, which is fed back to comparator 2306 and compared again with a setpoint. Measuring element 2310 optionally also generates a controlled variable 2381. Control element 2330 optionally also receives a manipulated variable 2382, for example, from an external source, such as a processor and / or communication system. Sensors (one or more) may be used by measuring element 2310 to measure parameters of the process, such as parameters of process 2320. Sensor measurements may be, for example, the determination of the amplitude of parameters of materials as disclosed herein. In the example, the measured values ​​are consistent and repeatable. The sensors (one or more) may convert physical parameters (e.g., repeatedly and reliably) into a form usable by the control system, for example, into electrical signals, such as digital electrical signals. A comparator can perform error detection, for example, by determining the difference between the amplitude of the measured variable and a set reference point (e.g., setpoint 2305), which is the error signal. The error signal can be amplified and / or conditioned, for example, filtered. Signal amplification and / or conditioning can be performed by an external component of the controller (e.g., 2340) or within the controller. The reference point (e.g., the setpoint) can be stored in the controller's memory or in memory operatively coupled to the controller. The controller can be a processor-based (e.g., micro) system that determines the next action to be taken in a process. The process can be sequential. The controller can evaluate the error signal in a continuous process control system, for example, to determine what action to take. The controller (e.g., 2340) can condition the signal or be operatively coupled to a unit that conditions the signal.Signal conditioning may include noise filtering. Signal conditioning may include correcting for nonlinearities in the sensor. The controller may include parameters of process input control elements. The controller may condition error signals to guide control elements, such as 2330. The controller may monitor input signals (one or more). Input signals may be correlated. The controller may be configured to coordinately guide at least two control elements. The controller may be configured to simultaneously guide at least two control elements. The controller may be configured to sequentially control at least two control elements. A control element (e.g., 2330) may be a means of controlling the feed to the process or any other property of the process that includes physical or chemical properties. Physical properties may include mechanical, magnetic, piezoelectric, electromagnetic, electrical, pressure, or temperature properties. Chemical properties may include chemical gradients or chemical entities. The control element may be a flow control element. The control element may be a temperature control element. The control element may have switching (e.g., on / off) characteristics. The control element may provide linear or nonlinear control. The control element may be used to regulate inputs to the process, for example, bringing an output variable to a setpoint. The measuring element (e.g., 2310) may consist of a sensor (one or more), a transducer, and / or a transmitter, wherein the sensor measures the physical properties of a variable, the transducer converts the sensor signal into an electrical signal, and the transmitter amplifies the electrical signal. Signal amplification may be achieved with minimal loss (e.g., no measurement loss). The control element may include an actuator that converts an electrical signal from a controller into a signal for operating and / or controlling a physical device (e.g., a valve). The controller may include or be operatively coupled to a memory. The control system may include a summing circuit, for example, for comparing a setpoint with a sensed signal so that it can generate an error signal. The summing circuit may be part of a comparator. The controller may use the error signal to generate a correction signal to control the control element. In the example, the controller controls the valve via an actuator and an input variable. The sensor of the measuring element may include an optical sensor, a temperature sensor, a pressure sensor, a chemical sensor, a proximity sensor, a viscosity sensor, or any other sensor disclosed herein. The chemical sensor may sense materials containing oxygen, water, or any other reactive reagent (one or more) herein. The sensor can be configured to sense one or more properties of the methods disclosed herein (e.g., manufacturing methods).

[0206] Control can include regulation, modulation, adjustment, maintenance, alteration, modification, control, management, restriction, constraint, guidance, instruction, supervision, management, maintenance, continuation, inhibition, harmonization, or change.

[0207] In some embodiments, the apparatus, system, and / or device disclosed herein includes a processor. A processor may be a processing unit. A controller may include a processing unit. A processing unit may be a central processing unit (CPU). A controller or control mechanism (e.g., including a computer system) may be programmed to implement the methods of this disclosure. A processor may be programmed to implement the methods of this disclosure. A controller may control at least one component of the system and / or device disclosed herein. Figure 24An exemplary schematic diagram of a computer system 2400 programmed or otherwise configured to facilitate the performance of any of the methods provided herein is shown. The computer system 2400 may control (e.g., direct, monitor, and / or regulate) various features of the methods, apparatuses, devices, and / or systems disclosed herein. The computer system 2400 may be part of, or communicate with, the apparatuses, systems, and / or devices disclosed herein. The computer may be coupled to one or more of the mechanisms and / or any parts thereof disclosed herein. The computer system 2400 may include a processing unit 2406 (also used herein as “processor,” “computer,” and “computer processor”). The computer system may include memory or memory location 2402 (e.g., random access memory, read-only memory, flash memory), electronic storage unit 2404 (e.g., hard disk), communication interface 2403 for communicating with one or more other systems (e.g., network adapter), and peripheral devices 2405, such as cache, other memory, data storage, and / or electronic display adapters. Memory 2402, data storage unit 2404, interface 2403, and peripheral device 2405 communicate with processing unit 2406 via a communication bus (solid line), such as a motherboard. The storage unit may include a data storage unit (or data repository) for storing data. The computer system may be operatively coupled to a computer network (“network”) 2401, for example, via a communication interface. The network may be the Internet, the Internet and / or an extranet, or an intranet and / or extranet communicating with the Internet. In some cases, the network is a telecommunications network and / or a data network. The network may include one or more computer servers that can enable distributed computing, such as cloud computing. In some cases, the network may enable a peer-to-peer network via the computer system, where devices coupled to the computer system can act as clients or servers. The processing unit can execute machine-readable instruction sequences, which may be embodied in a program or software. The instructions may be stored in a storage location, such as memory 2402. The instructions may be directed to the processing unit, which may then be programmed or otherwise configured to implement the methods of this disclosure. Examples of operations performed by the processing unit may include instruction fetching, decoding, execution, and write-back. The processing unit can interpret and / or execute instructions. Processing unit 2406 may include a microprocessor, data processor, central processing unit (CPU), graphics processing unit (GPU), system-on-a-chip (SoC), coprocessor, network processor, application-specific integrated circuit (ASIC), application-specific instruction set processor (ASIP), controller, programmable logic device (PLD), chipset, field-programmable gate array (FPGA), or any combination thereof. Processing unit 2406 may be part of a circuit, such as an integrated circuit. One or more other components of the system (e.g., 2400) may be included in the circuit.

[0208] In some embodiments, the storage unit (e.g., 2404) stores files, such as drivers, libraries, and saved programs. The storage unit may store user data (e.g., user preferences and user programs). In some cases, the computer system may include one or more additional data storage units located outside the computer system, such as on a remote server communicating with the computer system via an intranet or the Internet. The processor may be configured to process control protocols, such as using control protocols to communicate with one or more components of the entities disclosed herein (e.g., apparatuses, devices, and / or systems). The control protocol may be one or more of the Internet Protocol suite, such as Transmission Control Protocol (TCP) or Transmission Control Protocol / Internet Protocol (TCP / IP). The control protocol may be one or more serial communication protocols. The control protocol may be one or more of Controller Area Network (CLAN) or another message-based protocol, such as for communicating with microcontrollers and devices. The control protocol may interface with one or more serial bus interfaces to communicate with the entities disclosed herein, such as communicating with any components of the entities disclosed herein. The control protocol may be any control protocol disclosed herein.

[0209] In some embodiments, the systems, apparatuses, and / or devices disclosed herein include those that communicate via a network. A computer system can communicate with one or more remote computer systems via a network. For example, a computer system can communicate with a user's (e.g., an operator's) remote computer system. Examples of remote computer systems include personal computers (e.g., portable PCs), tablet PCs (e.g., Apple® iPad, Samsung® Galaxy Tab), telephones, smartphones (e.g., Apple® iPhone, Android devices, Blackberry®), or personal digital assistants. A user (e.g., a client) can access the computer system via a network.

[0210] In some embodiments, the computer system utilizes program instructions to perform one or more operations, or to direct the execution of said operations. The program instructions may be recorded in machine-executable code. The methods described herein can be implemented using machine-executable code stored on an electronic storage location in the computer system (e.g., memory 2402 or electronic (e.g., data) storage unit 2404). The machine-executable or machine-readable code may be provided in software form. In use, a processor (e.g., 2406) can execute the code. In some cases, the code can be retrieved from a storage unit and stored in memory for quick processor access. In some cases, an electronic storage unit may be excluded, and the machine-executable instructions are stored in memory. The code may be pre-compiled and configured for use on a machine with a processor adapted to execute the code, or it may be compiled at runtime. The code may be provided in a programming language, which may be selected to enable the code to be executed in a pre-compiled or just-in-time (JIT) compiled manner.

[0211] In some embodiments, the computer system utilizes a machine-readable medium / media to perform one or more operations, or to direct the execution of said operations. Program instructions may be recorded in machine-executable code. Machine-readable media / media (such as computer-executable code) may take many forms, including but not limited to tangible storage media / media, carrier media, or physical transmission media. Non-volatile storage media / media include, for example, optical discs or disks, any processor-dependent storage device such as any computer(s), for example, a storage device that can be used to implement a database. Volatile storage media / media may include dynamic memory, for example, the main memory of such a computer platform. Tangible transmission media may include coaxial cables, wires (e.g., copper wires), and / or optical fibers, including wires that form a bus in a computer system. Carrier transmission media may take the form of electrical or electromagnetic signals, or sound waves or light waves, such as those generated during radio frequency (RF) and infrared (IR) data communications. Therefore, common forms of computer-readable media include, for example: floppy disks, flexible disks, hard disks, magnetic tapes, any other magnetic media, CD-ROMs, DVDs or DVD-ROMs, any other optical media, punched cards, paper tapes, any other physical storage media / mediums with a perforated pattern, RAM, ROM, PROM and EPROM, FLASH-EPROM, any other memory chips or cartridges, carrier waves for transmitting data or instructions, cables or links for transmitting such carrier waves, any other media from which a computer can read program code and / or data, or any combination thereof. Memory and / or data storage can include external and / or removable storage devices, such as Universal Serial Bus (USB) memory sticks and / or hard disks. Many of these forms of computer-readable media can be involved in transmitting one or more sequences of instructions to a processor for execution.

[0212] In some embodiments, the apparatus, systems, and / or devices disclosed herein include, or are operatively coupled to, communication technologies, such as those other than optical fibers disclosed herein. Communication may include wired or wireless communication. For example, the system, device, and / or part thereof may include Bluetooth, Wi-Fi, Global Positioning System (GPS), or radio frequency (RF) technology. RF technology may include ultra-wideband (UWB) technology. The system, device, and / or part thereof may include a communication port. The communication port may be a serial port or a parallel port. The communication port may be a Universal Serial Bus port (i.e., USB). The system, device, and / or part thereof may include a USB port. USB may be a micro USB or mini USB. Surface identification mechanisms may include plugs and / or receptacles, such as electrical plugs / receptacles, AC power plugs / receptacles, and DC power plugs / receptacles. The system, device, and / or part thereof may include a power adapter (e.g., an AC power adapter and / or a DC power adapter). The system, device, and / or part thereof may include a power connector. The power connector may be a power connector. The power connector may include a magnetic power connector. The power connector may be a base connector. The connector may be a data and power connector. The connector may include pins. The connector may include at least about 10, 15, 18, 20, 22, 24, 26, 28, 30, 40, 42, 45, 50, 55, 80 or 100 pins.

[0213] In some embodiments, the energy control device (e.g., a battery) is used to provide energy to an electrical device. The energy control device (one or more) may include smartphones, tablets, wearable electronics (watches, glasses, health trackers), power banks (e.g., for mobile devices), miniature portable devices (drones, cameras, smart cards), mobile Wi-Fi, Bluetooth headsets, smart home-related devices (IoT), electric toothbrushes, precision grooming tools, small gardening equipment, robots (e.g., service robots), medical devices (e.g., compact medical devices), such as chest compression devices, beauty devices, fitness devices (e.g., compact fitness devices), other health devices, learning tools, UAVs (unmanned aerial vehicles) for short-range operations, such as racing drones, short-range drones, and military drones, torpedoes, and missiles. The energy control device may also include helicopters and other industrial equipment, online banking tools (e.g., bank Ukeys), Bluetooth-enabled devices, EVs (e.g., consumer vehicles, bicycles, racing cars, scooters), wearable vests, heaters, coolers, cameras, Internet of Things (IoT), wearable devices, watches, e-cigarettes, augmented reality (AR) glasses, virtual reality (VR) glasses, sensors, hearing devices, smart glasses, or any combination thereof. The energy control device can be used with any battery-powered electronic product. The robot may be a service robot for cargo, for example, for handling. The cargo handling may be within or between facilities. The robot may include warehouse robots. The EV may include cargo UAVs. The EV may include UAVs. The energy control device may be used for control. The energy control device may be used for video streaming, for example, for an MP3 player. The drone may be an underwater drone and / or an aerial drone.

[0214] In some embodiments, the energy manipulation device is manufactured. The energy manipulation device may be manufactured (e.g., fabricated). The environment may or may not be the surrounding environment. The environment may include one or more environmental characteristics different from those of the surrounding environment. These characteristics may include lower concentrations of reactive reagents, higher temperatures, or higher pressures. The reactive reagents may react with one or more components of the energy manipulation device, for example, during use, storage, transport, maintenance, and / or fabrication of the energy manipulation device. The battery cell may be fabricated according to any configuration disclosed herein and appropriately using any materials disclosed herein. The tabs may be folded, welded, adhered to adhesive connectors, and / or adhered to solid busbars. The manufacturing process (e.g., the manufacturing process of any component disclosed herein) may suitably include printing, stencil forming, applying heat, heat transfer, any combination thereof, or any combination thereof. The application may include deposition. The printing may include stencil printing, direct printing, or sublimation printing. One or more operations of the manufacturing process may be controlled by a control system, for example, a control system including at least one controller (such as any control system disclosed herein). The calendering may include temperature regulation, for example, heating. The operation of the rotary cutter may include temperature regulation, for example, as disclosed herein. One or more manufacturing conditions may require temperature regulation, for example, by appropriately using any temperature regulation system disclosed herein. The control system may be configured to automatically control the temperature during the temperature regulation. The temperature regulation may be manually and / or automatically controlled, for example, using a control system such as those disclosed herein.

[0215] In some embodiments, the battery cell is manufactured, for example, to form a battery. An insulator and / or adhesive (e.g., an adhesive material) may be applied, for example, at the glass transition temperature or melting temperature of at least one component of the adhesive, for example, at a temperature of at least about 100°C, 150°C, 200°C, or 250°C. The adhesive and / or insulator may be applied at at least ambient pressure or above ambient pressure, for example, at a pressure of at least about 14.5 psi, 14.7 psi, 20 psi, or 25 psi. The adhesive and / or insulator may be hardened. The adhesive and / or insulator may have a thickness of at least about 50 µm, 100 µm, or 150 micrometers (µm). The adhesive and / or insulator may have a resistance of, for example, at most about 0.1 milliohms (mΩ), 0.2 mΩ, 0.5 mΩ, 1 mΩ, or 2 ohms (Ω).

[0216] The processes discussed above are intended to be illustrative and not restrictive. Those skilled in the art will understand that the operations (e.g., steps) of the processes discussed herein can be omitted, modified, combined, and / or rearranged, and any additional operations (e.g., steps) can be performed without departing from the scope of the invention. More generally, the above disclosure is intended to be exemplary and not restrictive. Furthermore, it should be noted that the features and limitations described in any embodiment can be applied to any other embodiment herein, and flowcharts or examples associated with one embodiment can be combined with any other embodiment in a suitable manner, performed in a different order, or performed in parallel. Moreover, the systems and methods described herein can be performed in real time. It should also be noted that the above systems and / or methods can be applied to other systems and / or methods, or used according to other systems and / or methods.

[0217] While preferred embodiments of the invention have been shown and described herein, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. This disclosure is not intended to be limited to the specific examples provided herein. Although this disclosure has been described with reference to the foregoing description, the description and illustration of embodiments herein are not intended to be construed as limiting. Numerous variations, modifications, and substitutions can be made by those skilled in the art without departing from this disclosure. Furthermore, it should be understood that all aspects of this disclosure are not limited to the specific descriptions, configurations, or relative proportions presented herein, which depend on various conditions and variables. It should be understood that various alternatives to the embodiments described herein can be used to practice this disclosure. Therefore, this disclosure is contemplated to also cover any such alternatives, modifications, variations, or equivalents. The following claims are intended to define the scope of this disclosure and are intended to cover methods and structures falling within the scope of these claims and their equivalents.

Claims

1. An apparatus for processing target starting materials of one or more battery cells, the apparatus comprising: frame; An inner roller having a first transverse axis, the inner roller being operatively coupled to the frame, the inner roller being configured to be operatively coupled to a mold to form a mold roller, the inner roller being configured to be coupled to the mold such that, as the inner roller rotates (e.g., turns), the mold remains (e.g., substantially) stationary relative to the inner roller. as well as A support roller having a second transverse axis parallel to the first transverse axis (e.g., substantially), the support roller being separated from the inner roller by a gap, the support roller and the inner roller being configured to rotate relative to each other such that during their rotation, (i) the target starting material is drawn into the gap, (ii) the target starting material interacts with the mold, the interaction of the mold with the target starting material causing a pattern of the mold to be pressed onto the target starting material to cut, press in, or cut and press in the target starting material, thereby generating a product according to the pattern of the mold, or (iii) any combination of (i) and (ii), the product being a component of the one or more battery cells, and: (a) The apparatus is configured to process the target starting material comprising a planar material operatively coupled to a particulate material body, the planar material comprising a foil or sheet, without causing (e.g., substantially) deformation of the particulate material body; (b) The device is configured to dynamically change the gap; (c) The device is configured to dynamically change the compression of the mold on the target starting material; (d) The mold is optimized to reduce the variation in the force required to press the mold onto the target starting material, the variation being at least in part dependent on the design layout of the mold; (e) The inner roller is configured to be at least partially coupled to the mold by means of an attractive force; (f) The device is configured to operate in an enclosed space having an internal environment different from the surrounding environment outside the enclosed space, and the product is susceptible to one or more reactive reagents present in the surrounding environment; (g) At least one component of the device is configured for temperature regulation; (h) The mold includes at least one coating, the at least one coating being configured to reduce the adhesion of a portion of the target starting material to the mold after processing the target starting material; (i) The mold and the target starting material comprise at least one common material type; or (j) Any combination thereof.

2. The apparatus according to claim 1, wherein, The apparatus is configured to process the target starting material comprising a planar material operatively coupled to the particulate material body; optionally, wherein the particulate material body is an anolyl active material and the planar material is a current collector coupled to the anolyl active material; optionally, wherein the anolyl active material includes a protective material configured to be removed from the product; and optionally, wherein the protective material includes an adhesive or coating.

3. The apparatus according to claim 1, wherein, The apparatus is configured to process the particulate material body without causing (e.g., substantially) deformation of the particulate material body; optionally, wherein deforming the particulate material body includes introducing one or more defects, the one or more defects including cracks, dislocations, separation of the particulate material from its coupled structure (e.g., sheet / foil), undesired growth centers, any type thereof, or any combination thereof; and optionally, wherein the undesired growth centers include (a) crystallization centers, (b) metallurgical phases, (c) growth centers formed by the accumulation of reduced phases of charge carriers, (d) any of the types thereof, or (e) any combination thereof.

4. The apparatus according to claim 1, wherein, The device is configured to dynamically change the gap; optionally, the dynamic change of the gap depends at least in part on the target starting material, the relative rotation of the mold roller with respect to the support roller, the design of the mold, the required fidelity of the product, or any combination thereof; optionally, (I) the higher the fidelity, the lower the rotation speed; (II) the more fragile the material, the lower the rotation speed; optionally, a control system is used at least in part to change the gap; and optionally, (a) a feedback control scheme, (b) a feedforward control scheme, (c) a lookup table, (d) historical measurements, or (e) any combination thereof to change the gap.

5. The apparatus according to claim 1, wherein, The device is configured to dynamically change the compression of the mold on the target starting material; optionally, the dynamic change in compression depends at least in part on the target starting material, the relative rotation of the mold rollers relative to the support rollers, the design of the mold, the required fidelity of the product, or any combination thereof; optionally, (I) the higher the fidelity, the lower the rotation speed; (II) the more fragile the material, the lower the rotation speed; optionally, a control system is used at least in part to change the gap; and optionally, (a) a feedback control scheme, (b) a feedforward control scheme, (c) a lookup table, (d) historical measurements, or (e) any combination thereof to change the gap.

6. The apparatus according to claim 1, wherein, The mold is optimized to reduce the variation in the force required to press the mold onto the target starting material during the interaction, the variation being at least in part dependent on the design (e.g., design layout) of at least one of the mold's ridges. Optionally, the design of the at least one ridge is minimized such that (A) the mold cuts a minimum range of the target starting material each time it interacts with the target starting material while the device is in operation, and / or (B) the mold cuts a similar range of the target starting material each time it interacts with the target starting material while the device is in operation.

7. The apparatus according to claim 1, wherein, The inner roller is configured to be at least partially operatively coupled to the mold by means of the attractive force; optionally, the attractive force includes magnetic force, mechanical force, hydraulic force, gas force, or any combination thereof; optionally, the gas force includes pneumatic force or vacuum; and optionally, the attractive force includes magnetic force.

8. The apparatus according to claim 1, wherein, The device is configured to operate in a closed space, the internal environment of which differs from the surrounding environment outside the closed space, and the product is susceptible to one or more reactive reagents present in the surrounding environment; optionally, the one or more reactive reagents include oxygen, water, alcohol, thiol, sulfuric acid, phosphoric acid, carboxylic acid, hydrogen sulfide, any combination thereof; optionally, the internal environment includes argon, nitrogen, clean dry air, or any combination thereof; and optionally, the temperature, pressure, and / or one or more reactive reagents in the internal environment differ from the temperature, pressure, and / or one or more reactive reagents in the surrounding environment.

9. The apparatus according to claim 1, wherein, The at least one component of the apparatus is configured for temperature regulation; optionally, the at least one component includes the inner roller, the support roller, the frame, or any combination thereof; optionally, the temperature regulation is controlled; optionally, the temperature regulation includes heating; optionally, the temperature regulation includes cooling; optionally, the at least one component is operatively coupled to, or includes, one or more channels configured to change the temperature of the at least one component; optionally, the one or more channels are configured for fluid flow; optionally, the fluid includes gas, liquid, semi-solid, or any combination thereof; wherein the at least one component includes a rod configured for heat transfer; and optionally, the rod includes a single metal or metal alloy; optionally, the rod includes silver, copper, aluminum, graphene, gold, aluminum nitride, or boron arsenide; optionally, the temperature of the at least one component is changed during the production of the product using the apparatus; optional The temperature of the at least one component is controlled, at least in part, by a control system; optionally, the temperature regulation is active; optionally, the temperature regulation is; optionally, the temperature regulation includes heating; optionally, the temperature regulation includes cooling; optionally, the temperature regulation helps to improve the accuracy, fidelity, and / or integrity of the product; optionally, the temperature regulation helps to reduce deformation relative to the target starting material; optionally, the deformation is deformation of a particulate material body that is part of the target starting material; optionally, the deformation includes the introduction of one or more defects, the one or more defects including cracks, dislocations, undesired growth centers, any type thereof, or any combination thereof; and optionally, the undesired growth centers include (a) crystallization centers, (b) metallurgical phases, (c) growth centers formed by the accumulation of reduced phases of charge carriers, (d) any of the types thereof, or (e) any combination thereof.

10. The apparatus according to claim 1, wherein, The mold includes at least one coating configured to reduce the adhesion of a portion of the target starting material to the mold after processing; and optionally, the coating includes polytetrafluoroethylene, polyfluoroalkyl substances, perfluoroalkyl substances, anti-stick ceramic coatings, carbon steel, stainless steel, silicone, Gore-Tex, siloxanes, silanes, oxidized regenerated cellulose, any combination thereof, or any combination thereof.

11. The apparatus according to claim 1, wherein, The apparatus is configured to be integrated with one or more other processes and / or mechanisms to produce a required product, a system including the product, or a system including the required product from the product; optionally, wherein the other processes include deposition, compression, calendering, roll-to-roll, cutting, forming, machining, welding, stamping, encapsulation, deposition, drying, spraying, 3D printing, calendering, compression, ablation, slitting, adhesion (e.g., glue bonding), soldering, any combination thereof; and optionally, wherein producing the required product from the product includes manufacturing.

12. The apparatus according to claim 1, wherein, The device is configured to deliver the product using at least partially attractive and / or repulsive forces; optionally, the attractive force includes magnetic, mechanical, hydraulic, gaseous, electrostatic, or any combination thereof; and optionally, the gaseous force includes pneumatic or vacuum forces; optionally, the mechanical force may include a scraper, shovel, loader, fork, gripper, mover, broom, or any combination thereof; optionally, the mechanical force is part of a robotic system; and optionally, the attractive force includes gravity of the surrounding environment.

13. The apparatus according to claim 1, wherein, The mold and the target starting material include at least one common material type; optionally, the target starting material includes a current collector, and the at least one material type is the material type of the current collector; and optionally, the target starting material includes an end plate, and the at least one material type is the material type of the end plate.

14. The apparatus according to claim 1, wherein, The mold comprises at least one material harder than the target starting material; optionally, the mold comprises a high-performance metal; optionally, the target starting material does not contain a high-performance metal; optionally, the high-performance metal comprises stainless steel (e.g., 316), Inco nickel alloy, titanium, tungsten, tool steel, platinum, rhodium, aluminum alloy, rhenium, carbon composite material, any combination thereof; and optionally, the carbon composite material comprises an allotrope of elemental carbon.

15. The apparatus according to claim 1, wherein, The support roller comprises (I) a material harder than the material of the mold and / or (III) a self-healing material.

16. The apparatus according to claim 1, wherein, The relative rotation of the mold roller with respect to the support roller includes the rotation of the mold roller along a first direction, which is opposite to the second direction along which the support roller rotates.

17. The apparatus according to claim 1, wherein, (a) The absolute value of the rotation of the mold roller is the same as the absolute value of the rotation of the support roller (e.g., substantially), (b) The lateral length of the mold roller is the same as the lateral length of the support roller (e.g., substantially), (c) The diameter of the mold roller is the same as the diameter of the support roller (e.g., substantially), and (d) The first lateral length of the joint portion of the mold roller with the target starting material is the same as the second lateral length of the joint portion of the support roller with the target starting material (e.g., substantially).

18. The apparatus according to claim 1, wherein, (a) the absolute value of the rotation of the mold roller is the same as (e.g., substantially) the absolute value of the rotation of the support roller; (b) the lateral length of the mold roller is different from the lateral length of the support roller; (c) the diameter of the mold roller is different from the diameter of the support roller; and (d) the first lateral length of the joint portion of the mold roller with the target starting material is different from the second lateral length of the joint portion of the support roller with the target starting material; optionally, the difference is smaller; and optionally, the difference is larger.

19. The apparatus according to claim 1, wherein, The mold includes an outer surface and an inner surface opposite to the outer surface, the inner surface of the mold being operatively coupled to the inner roller to form the mold roller.

20. The apparatus according to claim 1, wherein, The mold is configured to generate one or more components of an energy manipulation device (e.g., the energy manipulation device disclosed herein); optionally, the energy manipulation device includes a battery (e.g., the battery disclosed herein); and optionally, the battery is a rechargeable battery (e.g., the rechargeable battery disclosed herein).

21. The apparatus according to claim 1, wherein, The product includes electrodes, counter electrodes, separators, or spacers for one or more battery cells; and optionally, the product comprises a plurality of units having a length-to-width ratio of at least about 1:1, 2:1, 4:1, 5:1, 8:1, 10:1, 15:1, 20:1, 50:1, 100:1, 1000:1, or higher; and optionally, the product comprises a plurality of units having a length-to-height ratio of at least about 1:1, 2:1, 4:1, 5:1, 8:1, 10:1, 15:1, 20:1, 50:1, 100:1, 1000:1, or higher; and optionally, the battery cell comprises at least 1, 2, 10, 20, 50, 100, 150, 200, 250, or 500 battery cells.

22. The apparatus according to claim 1, wherein, The mold is configured to cut individual battery cell components.

23. A method of manufacturing, the method comprising: The target starting material is processed by performing one or more operations, at least in part, using the apparatus according to any one of claims 1 to 22; Optionally, the use of the apparatus to process the target starting material is at least part of the manufacturing process that includes the product.

24. An apparatus for manufacturing, the apparatus comprising: At least one controller, the at least one controller being configured to: (a) be operatively coupled to the device according to any one of claims 1 to 22; (b) performing one or more operations related to the fabrication, or directing at least one component of the device to perform the one or more operations; optionally, wherein the at least one controller is configured to be operatively coupled to a power supply and / or communication platform; optionally, wherein the fabrication includes manufacturing; optionally, wherein the manufacturing includes roll-to-roll manufacturing; optionally, wherein the fabrication is the fabrication of a system comprising the product; optionally, wherein the system includes an energy control device; and optionally, wherein the energy control device is a battery.

25. One or more non-transitory computer-readable media, the one or more non-transitory computer-readable media comprising program instructions physically recorded thereon, the program instructions being configured, when read by one or more processors operatively coupled to the apparatus according to any one of claims 1 to 22, to: (I) perform one or more operations related to the manufacture of the product, or to direct the execution of the one or more operations; (II) the one or more operations comprising directing at least one component of the apparatus to perform the one or more operations; optionally, wherein, The manufacturing includes production; optionally, the production includes roll-to-roll production; optionally, the manufacturing is the production of a system including the product; optionally, the system includes an energy control device; and optionally, the energy control device is a battery.

26. A method comprising: (a) Providing an apparatus according to any one of claims 1 to 22; (b) manufacturing, testing, storing, transporting and / or using the device to produce the product.

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