MULTI-POWERED ELECTRODES

Abstract

Systems and procedures are provided for electrodes having multiple current paths. In an exemplary approach, a battery is provided comprising: a first electrode layer including a first positive flag and a first negative flag; and a second electrode layer including a second positive flag and a second negative flag, the second electrode layer being stacked on top of the first electrode layer, with the second positive flag misaligned with the first positive flag and the second negative flag misaligned with the first negative flag.

Description

field of technology

[0001] The present disclosure relates to solid-state batteries. General state of the art

[0002] A solid-state battery (SSB) is a type of battery that uses a solid electrolyte for ion conduction between the electrodes, instead of the liquid or gel polymer electrolytes found in conventional batteries. In some examples, solid-state batteries can use metallic lithium for the anode and oxides or sulfides for the cathode, thereby increasing energy density. The solid electrolyte can act as a separator, allowing only lithium ions to pass through. Solid-state batteries can potentially have a higher energy density and may, for example, function differently than typical lithium-ion or lithium-polymer batteries. Solid-state batteries can be used in a variety of devices and machines, including, but not limited to, pacemakers, RFID and wearable devices, and electric or hybrid electric vehicles.

[0003] In some designs, single-phase battery (SSB) electrode cells can be stacked to form a stack of cells known as a pouch cell. A pouch cell can consist of multiple layers of positive and negative electrodes with metal electrode tabs located on the sides of the cells. During manufacturing, the electrode tabs can be welded to an aluminum or nickel conductor, providing a current path from the battery cell to external circuitry. The fabrication of some SSB cell configurations may involve a process to laminate layers to form an electrode stack. The laminated electrode stack can then be vacuum-sealed within a pouch bag or similar container. Brief description

[0004] This document discloses systems and methods for electrodes, such as electrodes in a solid-state pouch cell battery, which have multiple current paths. In an exemplary approach, a battery is provided comprising: a first electrode layer comprising a first positive flag and a first negative flag; and a second electrode layer comprising a second positive flag and a second negative flag, wherein the second electrode layer is stacked on top of the first electrode layer, the second positive flag being misaligned with the first positive flag and the second negative flag being misaligned with the first negative flag.

[0005] This and other approaches described herein introduce novel electrode designs that incorporate multiple current paths capable of distributing current flow, resulting in a reduction of heat loads that can occur during battery charging and discharging. These multiple current paths can be achieved, for example, by distributing the positions of the electrodes. In addition to other advantages described herein, such approaches can reduce the overall thermal load on the battery pack by minimizing the accumulation of localized heat.

[0006] It is understood that the foregoing summary is provided to present, in simplified form, a selection of concepts that are described in greater detail in the detailed description. It is not intended to identify important or decisive features of the claimed subject matter, the scope of which is defined solely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that remedy any of the disadvantages mentioned above or in any part of this disclosure. Brief description of the characters Fig. Figure 1 shows an example electric vehicle with one battery. Fig. Figure 2 shows a perspective view of an example single-layer battery cell. Fig. Figure 3 shows exemplary current densities and temperature profiles after charging exemplary electrodes. Fig. Figure 4 shows exemplary current densities after charging exemplary electrodes with different flag positions. Fig. Figure 5 shows exemplary current densities and temperature profiles after charging exemplary electrodes with different flag positions. Fig. Figure 6 shows exemplary implementations of multi-stream path designs. Fig. Figure 7 shows additional exemplary implementations of multi-stream path designs. Fig. Figure 8 shows an exemplary method for manufacturing a solid-state pouch cell battery. Detailed description

[0007] As noted above, solid-state batteries can potentially have a higher energy density and can be more consistent than typical lithium-ion or lithium-polymer batteries, for example. Solid-state batteries can be used in a variety of devices and machines, including, but not limited to, pacemakers, RFID and wearable devices, and electric or hybrid electric vehicles. In electric or hybrid electric vehicles, long-lasting solid-state battery packs, such as pouch cells, can provide high power, enable fast charging, and meet the needs of the vehicle's driver. For example, such battery packs can provide enough power to propel a vehicle from 0 to 60 miles per hour (mph) in a short period of time.However, these characteristics can pose significant thermal challenges during battery charging and discharging, such as localized heat near battery flag areas where the current is concentrated. Such localized heat generation within the battery can, for example, lead to a loss of performance due to heat exposure.

[0008] Solid-state batteries used in electric vehicles (and other applications) can comprise a large number of individual battery cells stacked together. Localized heat generation near the battery tabs can occur in each individual battery cell, causing heat to accumulate within a stack of cells. As described above, such stacks of cells can be referred to as pouch cells. A pouch cell may consist of multiple layers of positive and negative electrodes with metal electrode tabs located on the sides of the cells; for example, in some examples, the tabs may be located on the shorter sides of the cells. During manufacturing, the electrode tabs may be welded to an aluminum or nickel conductor, which provides a current path from the battery cell to external circuitry.

[0009] During charging and discharging, current flows through the conductors and battery flags; thus, heat generation and associated material degradation can be localized in areas surrounding the flags. Heat can be localized near the flag in each battery cell layer, and each layer can influence the others, for example, if they are in a stacked formation. Heat can be transferred from one layer to another, causing heat to accumulate and further increasing the overall temperature of the pouch cell. The generated heat can also affect the stability of the battery materials. Although positive and negative electrode materials may be thermally stable in their pure state, they can become less stable due to phase transitions over charge / discharge cycles, making the materials more susceptible to performance loss due to heat exposure.Furthermore, in some cases, the materials used in the battery can readily react with the surrounding electrolyte, thereby increasing electrolyte consumption and generating reactive gases, which can, for example, lead to a rapid reduction in the lifespan of a battery cell. Additionally, these localized thermal effects can become more significant under harsh conditions, such as high-power, fast-charging, or extended operating times.

[0010] This paper describes novel electrode designs that incorporate multiple current paths to distribute current flow. The approaches described herein can result in a reduction or mitigation of thermal effects. As detailed below, multiple current paths can be achieved by distributing the positions of the electrodes within battery cell stacks. Such approaches can, for example, reduce the overall thermal load of a battery pack by minimizing the accumulation of localized heat.

[0011] It is understood that the specific assemblies and systems illustrated in the accompanying drawings and described in the description are exemplary embodiments of the concepts of the invention defined herein. For the purpose of discussion, the drawings may be described together. Thus, identical elements herein may be generally designated by the same reference numerals and need not be introduced again.

[0012] With reference to the figures now shown Fig. Figure 1 shows a schematic representation of an exemplary vehicle system 106 that can derive drive power from an electric motor 154 (e.g., a traction motor). In the sense used herein, the terms "electric vehicle" or "EV" are intended to denote any suitable vehicle that is at least partially configured to be driven using electrical power, e.g., via one or more electric motors installed in the vehicle. For example, the vehicle system 106 can be considered an electric vehicle (EV). Although Fig. Figure 1 shows a single electric motor 154. It is understood that the vehicle system 106 can include any suitable number of electric motors to propel the vehicle and / or to provide power to various components and systems within the system 106. In some examples, the electric motor 154 may be a traction motor, but other types of electric motors are also considered. The electric motor 154 can draw electrical power from a battery 158 to provide torque to the vehicle's rear wheels 155. The electric motor 154 can also be operated as a generator to provide electrical power for charging the battery 158, for example, during wheel brake caliper application operation. In some examples, the battery 158 may comprise a solid-state battery (SSB), as described below.

[0013] It goes without saying that, while Fig. Figure 1 depicts an electric motor 154 mounted in a rear-wheel drive configuration; however, other configurations are possible, such as using the electric motor 154 in a front-wheel drive configuration or in a configuration where an electric motor is mounted on both the vehicle's rear wheels 155 and the vehicle's front wheels 156. Furthermore, additional electric motors can be included in the system 106.

[0014] The electric motor 154 can include an integrated gearbox and / or, together with other electric motors, provide input power to a transmission system. Additionally or alternatively, the electric motor 154 can be coupled to the outside of a gearbox / transmission housing. The integrated gearbox can include one or more input speed reduction gear sets. The electric motor 154 can also include at least one clutch. Additionally or alternatively, multiple batteries can be present, configured to provide power to different driven wheels, with the power to the wheels being predicted based on wheel traction, driver requirements, and other conditions.

[0015] With reference to Fig. Figures 2-7 show different views of an exemplary battery 200 and an exemplary battery cell stack (e.g., pouch cells). An axis system 206 is shown in Fig. Figures 2-7 are provided for reference. In one example, the z-axis may be parallel to a vertical axis (e.g., parallel to a gravitational axis), the y-axis may be a lateral axis (e.g., a horizontal axis), and / or the x-axis may be a longitudinal axis. In other examples, however, the axes may have different orientations.

[0016] Fig. Figure 2 shows a perspective view of an exemplary single-layer battery cell 200. The battery cell 200 can comprise a solid-state battery and can be a stack (e.g., the one shown in Figure 2). Fig. The solid-state battery cell 200 (stack 230 shown in Figure 2) comprises various components, such as anode and cathode layers, electrode coatings, current collectors, solid electrolyte separators, etc. The solid-state battery cell 200 can have any suitable configuration, e.g., bipolar or monopolar (as shown in Figure 2). Fig. (2 shown). One or more flags, e.g., a negative flag 204 and a positive flag 206, can be included in the battery cell 200. The flags can be in electrical communication with electrode current collectors in the cell.

[0017] The exemplary single-layer battery cell 200, which is in Fig. Figure 2 shows a monopolar cell structure; however, it is understood that any suitable cell structure is considered and included within the scope of this disclosure. For example, the single-layer battery cell may comprise a bipolar cell structure or any other suitable cell structure. The exemplary monopolar stack 230 shown in Figure 230 is a monopolar cell structure. Fig. Figure 2 shows an anode layer 218 (negative electrode layer) and a cathode layer 220 (positive electrode layer). The anode layer 218 can be separated from the cathode layer 220 by a solid electrolyte separator 210. In this example, the anode layer 218 comprises anode coatings 214 positioned on an upper and a lower surface of an anode current collector 208. In this example, the cathode layer 220 comprises cathode coatings 216 positioned on an upper and a lower surface of a cathode current collector 212. In this example, the electrode layers, e.g., the anode layer and the cathode layer, comprise double-sided coated electrodes.

[0018] As noted above, the battery cell 200 can include a solid-state battery cell. A solid-state battery is an electric battery that uses a solid electrolyte for ion conduction between the electrodes instead of the liquid or gel polymer electrolytes found in conventional batteries. Solid-state batteries can provide a higher energy density than typical lithium-ion or lithium-polymer batteries. The cathode layers (i.e., positive electrodes) can be made with the same compounds as a lithium-ion battery (e.g., LFP, NMC, LMO, etc.). The anode layers (i.e., negative electrodes) can, in some examples, be made of lithium metal (e.g., pure lithium).In some examples, a negative electrode can be formed by coating both surfaces of a negative electrode current collector made of copper, nickel, a copper alloy, other potentially conductive materials, or any combination thereof with an active negative electrode material, such as lithium metal, a lithium alloy, carbon, petroleum coke, activated carbon, graphite, silicon, silicon oxide, a silicon composite, a titanium-based material, or the like. Furthermore, a positive electrode can be formed by coating both surfaces of a positive electrode current collector made of aluminum, nickel, other potentially conductive materials, or a combination thereof with an active positive electrode material, such as lithium manganese oxide, lithium cobalt oxide, lithium nickel oxide, or the like.

[0019] Separator 210 can consist of a general ceramic (e.g., oxides, sulfides, phosphates) or a solid polymer, which also functions as the electrolyte. It thus becomes the medium through which the ions move and also exhibits electrically insulating properties, acting as a mechanical separator between the anodes and cathodes. The solid electrolyte can function as a separator that allows only lithium ions to pass through. For this reason, solid-state batteries can potentially address various problems, such as limited voltage, solid electrolyte interface formation, cycle performance, and strength. The separators can be made of a material generally used in the prior art.For example, a multilayer film made of polyethylene, polypropylene or a combination thereof, which has a microporous structure, may be produced, or a polymer film for a gel-type polymer electrolyte or a solid polymer electrolyte, such as polyvinylidene fluoride, polyethylene oxide, polyacrylonitrile or polyvinylidene fluoride-hexafluoropropylene copolymer, may be used.

[0020] As mentioned above, a negative flag 204 and a positive flag 206 can be included in the battery cell 200. The flags can be in electrical communication with corresponding electrode current collectors in the cell. For example, the positive flag 206 can be coupled to the cathode current collector 212, and the negative flag 204 can be coupled to the anode current collector 208. In some examples, the flags can protrude axially from the electrode layer, such that the flags extend a distance beyond an edge of the electrode layers. For example, in Fig. As shown in Figure 2, the negative electrode 204 extends beyond the edge 240 of cell 200 by a non-zero distance, and the positive electrode 206 extends beyond the edge 242 of cell 200 by a non-zero distance.

[0021] In some examples, the positive and negative flags can extend beyond the edges of the electrodes on opposite sides of the electrodes, as in Fig. Figure 2 illustrates this. However, in other examples, the flags may extend from the same side or edge, or in a different configuration. In some examples, the flags may be located on the shorter sides of the cells (as in Figure 2). Fig. (2 illustrated); in other examples, however, the flags may extend from longer sides of the cells or a combination of different sides of the cells. During manufacturing, the electrode flags may be welded to an Al or Ni (or another suitable metal) conductor, which provides a current path from the battery cell to, for example, external circuits. The positive and negative flags may form a current path; for example, the positive and negative flags together may form a single current path in which current flows between the two flags. For example, current may flow from the negative flag to the positive flag.

[0022] The various components in the Fig. The two stacks of 230 shown can be laminated together to fix all components. Lamination is a technique / process for manufacturing a material in multiple layers. A laminate is a layered object or material that can be assembled using heat, pressure, welding, or adhesives. Various coating machines, presses, and / or calendering equipment can be used to laminate the layers in the stack of 230.

[0023] In some examples, several single-layer battery cells, such as cell 200, which are used in Fig. As shown in Figure 2, the cells are stacked on top of each other and sealed in a pouch to form a pouch cell. As noted above, pouch cells can consist of multiple layers of positive and negative electrodes with metal electrode tabs located on the sides of the cells. For example, a pouch cell can comprise at least two single-layer cells stacked together; however, in other examples, any suitable number of single-layer cells can be stacked to form a pouch cell. For example, a pouch cell can comprise more than one single-layer cell. For example, a pouch cell can comprise two, three, four, five, twenty, or any suitable number of single-layer cells stacked together. In some examples, the stacked cells can be laminated together. These cell stacks can be vacuum-sealed in a pouch to form, for example, a pouch cell.The pouch can, for example, comprise a bag or other suitable container that is vacuum-sealed around the electrode stack. The pouch can form a container, pocket, or cavity in which the electrode assembly, containing the electrode stack, is housed. In some examples, the pouch can comprise a porous plastic tube or sleeve made of any suitable material.

[0024] As noted above, during charging and discharging, heat generation and corresponding material degradation can be localized in areas surrounding the flags. Heat can be localized near the flag in any battery cell layer, and each layer can affect the others if they are in a stacked formation. For example, heat can be transferred from one layer to another, causing heat to accumulate and further increasing the overall temperature of the pouch cell. The generated heat can also affect the stability of the battery materials.

[0025] Fig. Figure 3 shows exemplary current densities and temperature profiles after charging exemplary electrodes, such as the single-layer cell 200, which is in Fig. 2 is shown. In particular, it shows Fig. 3 (a) Current density vectors in a cathode current collector 302 and current density vectors in an anode current collector 304. The current vectors that are in Fig. The current density vectors shown in Figure 3(a) occur, for example, at the end of the current collector charge at a 4C rate. The flag shown on the bottom side is connected to the cathode current collector 302, and the flag on the top side is connected to the anode current collector 304. The arrows shown indicate the direction and magnitude of the current density vectors. In this example, the magnitude of the current density vectors has been scaled proportionally by a factor of 2E⁻⁹ for visual purposes. Fig. 3 (b) shows a temperature distribution over the current collector at the same charging step as in Fig. 3(a). In Fig. 3 (b) Lighter colors indicate higher temperatures. Fig. Figures 3(c) and (d) show exemplary temperature profiles during a constant current-constant voltage (CC-CV) cycle at (c) a 1C rate (charging in one hour) and at a 4C rate (charging in 15 minutes). The average, maximum, and minimum temperatures in a single cell were evaluated, showing that heat generation is localized near the flags.

[0026] Fig. Figure 4 shows exemplary current densities after charging exemplary electrodes with different flag positions in a battery cell, such as cell 200, which is in Fig. 2 is shown. In particular, it shows Fig. Four exemplary current density vectors in a cathode current collector 408 and an anode current collector 410 at the end of a current collector charge at a 4C rate in three different flag positions: a first flag position shown at 402, a second flag position shown at 404, and a third flag position shown at 406. The arrows indicate the direction and magnitude of the current density vectors, and the magnitude of the current density vectors has been scaled proportionally by a factor of 2E-9 for visual purposes.

[0027] The approaches described herein include the design of multiple stream paths by diversifying the positions of flags, as in the different flag configurations at 402, 404 and 406 in Fig. Figure 4 shows that, in particular, the flags can be positioned at different locations along the edges of a single-layer battery cell, such as battery cell 200, which is shown in Fig. 2 is shown. The diversified positions that are in Fig. Figure 4 is provided as an example, and various alternative flag positions can be used. In conventional pouch cells, battery cell layers with only one type of flag configuration can be stacked in a pouch cell. For example, all single-layer cells shown at 408 in Fig. The configuration shown in Figure 4 is used and then stacked so that the flags in the stack are essentially aligned on top of each other. With such an approach, the localized heat in each layer can accumulate in the same region (e.g., near the aligned flags) throughout the stack of layers, potentially leading to a temperature increase in that region. The position of the localized heat can be distributed by stacking single-layer cells with different flag configurations, e.g., stacking cells with the different configurations shown in Figures 402, 404, and 406. Fig. 4 are shown (or some other flag configurations that do not overlap or align when stacked together). In some examples, single-layer cells with different flag configurations can be stacked alternately within a pouch cell, thus diversifying or spreading the location of heat generation to different points, resulting in reduced temperature effects on the pouch cell. Examples of such alternative stackings are shown in Fig. Figure 6 illustrates the description below.

[0028] Fig. Figure 5 shows exemplary current densities and temperature profiles after charging exemplary electrodes with different flag positions. In particular, Figure 5 shows Fig. 5. Comparisons of the level of heat generated depending on the different C rates and flag points. Fig. Figures 5 (a) and (b) show exemplary temperature distributions of the different flag configurations 402, 404 and 406 at the end of a current collector charge at a 1C rate (a) and a 4C rate (b). Fig. 5(a) and (b) show the overall heat distribution in each design and the maximum heat generated at different positions under three configurations (lighter colors indicate higher temperatures). Fig. Figures 5(c)-(f) show the temperature profiles of flag configurations 402 and 406 at different c-rates. The maximum temperature is shown in the lines labeled 504 in the graphs and indicates that it changes during the cycle and varies depending on the flag configuration. The temperature difference in different configurations is not significant if the c-rate is constant. In particular, Fig. 5 (c) and (d) Temperature profiles during a CC-CV cycle at a 1C rate (c) and a 4C rate (d) with the flag configuration 402, where the flags are located on the left side of the battery cell. Fig. Figures 5(e) and (f) show exemplary temperature profiles during a CC-CV cycle at a 1C rate (c) and a 4C rate (d) using the 406 flag configuration, where the flags are located in the center of the battery cell. At the lower c-rate (1C), the difference in maximum temperature between different configurations is within 3°C. At the higher c-rate (4C), the difference can increase to approximately 5°C. The average, maximum, and minimum temperatures in a single cell were evaluated, demonstrating how heat can be distributed by positioning the flags at different locations within the cells to reduce the accumulation of localized heat in a pouch cell.

[0029] Fig. Figure 6 shows exemplary implementations of multi-stream path designs, including single-layer cells, such as a Cell 200, which are in Fig. Figure 2 shows that the flags, which have different configurations, are stacked in such a way that the different configurations are misaligned. In particular, Figure 2 shows that the flags have different configurations and are stacked in such a way that the different configurations are misaligned. Fig. 6 (a) Single-layer cells with a configuration having multiple flags, wherein the flags are located at different positions in different single-layer cells, so that when they are stacked together, as in e.g. Fig. Figure 6(b) shows that the flags in the stack are misaligned or offset from each other. Two exemplary ways of implementing the multi-stream path design are shown in Figure 6(b). Fig. 6 illustrates this. For example, it shows Fig. 6 (b) an alternating stacking of each configuration, wherein different flag configurations are alternately stacked together such that adjacent flags do not substantially overlap or are not substantially aligned with each other. Fig. Figure 6(c) shows another exemplary approach in which segments (e.g., 2 or more single-layer cells) of layers with the same flag configuration are formed, and then different segments with different flag configurations are stacked together so that the flags in each segment are not aligned with (i.e., misaligned with) the flags in an adjacent segment in the stack.

[0030] The approaches described herein can be applied in manufacturing processes in two exemplary ways, as shown in Fig. Figure 6 is shown (however, other stacking approaches may be used that misalign adjacent flags). In some examples, single-layer cells can be prepared with a multi-flag layout, and the number of flags included may vary depending on the cell size, as shown in Figure 6. Fig. 6(a) shown. For example, the layers of each configuration can be stacked alternately, as in Fig. 6 (b) shown. In this approach, the heat can be well distributed throughout the entire stack; however, it can still be susceptible to misalignment. In another approach, each configuration can be stacked together in segments, as shown in Fig. 6 (c) shown. This approach may be advantageous due to the simplicity of stacking during manufacturing, and such an approach may reduce possible misalignments.

[0031] Fig. Figure 7 shows additional exemplary implementations of multi-stream path designs. In particular, it shows Fig. Seven different exemplary designs are shown, which can be manufactured using exactly one notching die and two notching dies with different flag widths. Design strategies can be implemented to further reduce potential manufacturing complexity and increase compatibility with existing cell / terminal designs. First, the presence of multiple flag locations implies that multiple notching die designs can be used in the manufacturing process. To minimize the complexity resulting from designs with multiple notching dies, double-sided coated electrodes can be used, allowing, for example, the production of two symmetrical, off-center electrodes with only one notching die by simply reversing the electrode. Fig. Figure 7 shows examples of exactly one notching die and two notching dies. With exactly one notching die, two different flag positions can be achieved. With two notching dies, four different flag positions can be used. Such approaches can reduce manufacturing complexity. Additionally, such approaches can be compatible with existing electrode-to-cell connections.

[0032] Fig. Figures 1-7 are drawn approximately to scale, except for the schematically depicted components. In other embodiments, however, the components may have different relative dimensions. The figures show exemplary configurations with a relative positioning of the various components. If they are shown to be directly touching or directly coupled, such elements may be described as directly touching or directly coupled, at least in one example. Similarly, elements shown to be connected or adjacent to each other may be connected or adjacent, at least in one example. As an example, components that are in surface-dividing contact with each other may be described as being in surface-dividing contact.As another example, elements positioned separately, with only a space between them and no other components, can be described in this way in at least one example. As yet another example, elements shown above / below each other, on opposite sides of each other, or left / right of each other can be described in this way relative to each other. Furthermore, as shown in the figures, a topmost element or the highest point of an element can be described in at least one example as the "top" of the component, and a bottommost element or the lowest point of the element can be described as the "bottom" of the component. In the sense used here, top / bottom, upper / lower, and above / below can refer to a vertical axis of the figures and can be used to describe the arrangement of elements of the figures in relation to each other.Thus, in one example, elements shown above other elements are positioned vertically above them. As another example, the shapes of elements depicted within figures can be described as having those shapes (such as circular, straight, planar, curved, rounded, chamfered, angled, or the like). Additionally, in one example, elements that are coaxial with each other can be described as such. Furthermore, elements shown intersecting each other can be described, in at least one example, as intersecting elements or intersecting each other. Even further, an element shown within another element or shown outside another element can be described, in one example, as such. In other examples, elements that are offset from each other can be described as such.Furthermore, elements that are coaxial or parallel to each other can be described as such.

[0033] Fig. Figure 8 shows an exemplary process 800 for manufacturing a solid-state pouch cell battery formed from a stack of single-layer cells, such as the cell 200 described in Fig. Figure 2 shows different flag configurations designed to distribute heat generated during battery charging and discharging. Multiple current paths can be achieved, for example, by distributing the flag positions. Such approaches can reduce the overall thermal load on the battery pack by minimizing localized heat buildup.

[0034] In 802, the process involves 800 fabricating electrode layers with offset flags. For example, several different electrode layers or single-layer cells can be produced that have different flag configurations, so that when stacked, they are misaligned. For example, fabricating electrode layers with offset flags can involve fabricating a first electrode layer comprising a first positive flag extending beyond one edge of the first electrode layer and a first negative flag extending beyond an opposite edge of the first electrode layer; and fabricating a second electrode layer comprising a second positive flag extending beyond one edge of the second electrode layer and a second negative flag extending beyond an opposite edge of the second electrode layer.In some examples, the first and second electrode layers can each comprise double-sided coated electrodes; and the first and second electrode layers can be produced using a single notching die configuration. In other examples, the first and second electrode layers can be produced using two different notching die configurations. As described above, different notching dies can be used to minimize the complexity of multi-notching die designs. For example, double-sided coated electrodes can be used, which can produce two symmetrical, off-center electrodes with exactly one notching die by simply flipping the electrode. In some examples, the flags can be welded into a corresponding current collector in different flag configurations.

[0035] In 804, method 800 involves stacking the electrode layers. For example, in 804, method 800 may involve stacking the second electrode layer onto a top face of the first electrode layer, wherein the second electrode layer is substantially aligned with the first electrode layer; and wherein the second positive flag is misaligned with the first positive flag, and the second negative flag is misaligned with the first negative flag. Arranging electrodes in a stack may involve positioning a plurality of electrodes, current collectors, solid electrolyte layers, and the like in a substantially aligned stack, but with adjacent flags being misaligned. For example, the layers of each flag may be stacked alternately, as in Fig. 6 (b) shown. In another approach, each configuration can be stacked together in segments, as in Fig.6 (c) shown. The stacked electrode layers can be laminated together within the stack. For example, a suitable lamination process can be carried out to fix the electrode and other components, such as solid electrolyte separators, current collectors, and the like, together within the stack.

[0036] In 806, the process involves sealing the stacked electrodes in a pouch. For example, the stacked first and second electrode layers (along with any other electrode layers) can be sealed in a pouch. These cell stacks can be vacuum-sealed in a pouch to form, for example, a pouch cell. The pouch can comprise a bag or other suitable container that is vacuum-sealed around the electrode stack. The pouch can form a container, pocket, or cavity that houses the electrode assembly containing the electrode stack.

[0037] The invention is further described in the following paragraphs. In one aspect, a battery is provided comprising: a first electrode layer comprising a first positive flag and a first negative flag; and a second electrode layer comprising a second positive flag and a second negative flag, wherein the second electrode layer is stacked on top of the first electrode layer, the second positive flag being misaligned with the first positive flag and the second negative flag being misaligned with the first negative flag. In some examples, the battery may comprise a pouch cell battery. In some examples, the battery may comprise a solid-state battery. In further examples, the first electrode layer and the second electrode layer may each comprise double-sided coated electrodes.In some examples, the first electrode layer may comprise a first anode, a first anode current collector, a first cathode, a first cathode current collector, and a first solid electrolyte positioned between the first anode and the first cathode; and the second electrode layer may comprise a second anode, a second anode current collector, a second cathode, a second cathode current collector, and a second solid electrolyte positioned between the second anode and the second cathode. In some aspects, the first positive terminal may be coupled to the first cathode current collector, and the first negative terminal may be coupled to the first anode current collector; and the second positive terminal may be coupled to the second cathode current collector, and the second negative terminal may be coupled to the second anode current collector.In some examples, the first positive flag and the first negative flag may be offset from a central axis of the first electrode layer. In some examples, the second electrode layer may be an inverted version of the first electrode layer. In some aspects, the first electrode layer and the second electrode layer may be produced using exactly one notching matrix configuration. In other aspects, the first positive flag and the first negative flag may protrude axially from the first electrode layer. In some aspects, the first positive flag and the first negative flag may form a first current path, and the second positive flag and the second negative flag may form a second current path.

[0038] In additional aspects, a solid-state pouch cell battery is provided comprising: a first electrode layer comprising a first positive flag extending beyond one edge of the first electrode layer and a first negative flag extending beyond an opposite edge of the first electrode layer; and a second electrode layer comprising a second positive flag extending beyond one edge of the second electrode layer and a second negative flag extending beyond an opposite edge of the second electrode layer; wherein the second electrode layer is stacked on and aligned with an upper surface of the first electrode layer; and wherein the second positive flag is misaligned with the first positive flag and the second negative flag is misaligned with the first negative flag.In some examples, the first electrode layer and the second electrode layer can each comprise double-sided coated electrodes. In some aspects, the first electrode layer comprises a first anode, a first anode current collector, a first cathode, a first cathode current collector, and a first solid electrolyte positioned between the first anode and the first cathode; and the second electrode layer comprises a second anode, a second anode current collector, a second cathode, a second cathode current collector, and a second solid electrolyte positioned between the second anode and the second cathode.In some examples, the first positive flag may be coupled to the first cathode current collector, and the first negative flag may be coupled to the first anode current collector; and the second positive flag may be coupled to the second cathode current collector, and the second negative flag may be coupled to the second anode current collector. In some examples, the first positive flag and the first negative flag may be offset from a central axis of the first electrode layer.

[0039] In additional aspects, a method for manufacturing a solid-state pouch cell battery is provided, comprising: producing a first electrode layer comprising a first positive flag extending over one edge of the first electrode layer and a first negative flag extending over an opposite edge of the first electrode layer; and producing a second electrode layer comprising a second positive flag extending over one edge of the second electrode layer and a second negative flag extending over an opposite edge of the second electrode layer; stacking the second electrode layer onto a top surface of the first electrode layer, the second electrode layer being substantially aligned with the first electrode layer;and wherein the second positive flag is misaligned with the first positive flag and the second negative flag is misaligned with the first negative flag. In some examples, the method may further include sealing the stacked first and second electrode layers in a pouch. In some examples, the first electrode layer and the second electrode layer may each comprise double-sided coated electrodes; and the first and second electrode layers may be produced using a single notching die configuration. In other examples, the first and second electrode layers may be produced using two different notching die configurations.

[0040] Although various embodiments have been described above, it is understood that these are presented as examples and not to limit the scope of the disclosure. It is evident to the person skilled in the art that the disclosed subject matter can be implemented in other specific forms without deviating from its essence. The embodiments described above are to be regarded in every respect as illustrative and not limiting. Therefore, the configurations and routines disclosed herein are exemplary in nature, and these specific examples are not to be understood as limiting, since numerous variations are possible. The subject matter of this disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations, as well as other features, functions, and / or properties disclosed herein.

[0041] The following claims highlight certain combinations and subcombinations that are considered novel and not obvious. These claims may refer to "one" element, "a first" element, or the equivalent thereof. Such claims are to be understood as including one or more such elements and neither requiring nor excluding two or more such elements. Other combinations and subcombinations of the disclosed features, functions, elements, and / or properties may be claimed by amending the present claims or by filing new claims in this or a related application.Such patent claims, regardless of whether they have a broader, narrower, the same or different scope compared to the original patent claims, are also considered to be included in the subject matter of the present disclosure.

Claims

[1] Battery (158), comprising: a first electrode layer (402) comprising a first positive flag and a first negative flag; and a second electrode layer (404) comprising a second positive flag and a second negative flag, wherein the second electrode layer (404) is stacked on top of the first electrode layer (402), wherein the second positive flag is misaligned with the first positive flag and the second negative flag is misaligned with the first negative flag. [2] Battery according to claim 1, wherein the battery comprises a pouch cell battery. [3] Battery according to claim 1, wherein the battery comprises a solid-state battery. [4] Battery according to claim 1, wherein the first electrode layer (402) and the second electrode layer (404) each comprise double-sided coated electrodes. [5] Battery (158) according to claim 1, wherein the first electrode layer (402) comprises a first anode, a first anode current collector, a first cathode, a first cathode current collector and a first solid electrolyte positioned between the first anode and the first cathode; and wherein the second electrode layer (404) comprises a second anode, a second anode current collector, a second cathode, a second cathode current collector and a second solid electrolyte positioned between the second anode and the second cathode. [6] Battery (158) according to claim 5, wherein the first positive flag is coupled to the first cathode current collector and the first negative flag is coupled to the first anode current collector; and wherein the second positive flag is coupled to the second cathode current collector and the second negative flag is coupled to the second anode current collector. [7] Battery (158) according to claim 1, wherein the first positive flag and the first negative flag are offset from a central axis of the first electrode layer. [8] Battery (158) according to claim 1, wherein the second electrode layer is an inverted version of the first electrode layer. [9] Battery (158) according to claim 8, wherein the first electrode layer and the second electrode layer are produced using exactly one notching matrix configuration. [10] Battery (158) according to claim 1, wherein the first positive flag and the first negative flag protrude axially from the first electrode layer. [11] Battery (158) according to claim 1, wherein the first positive flag and the first negative flag form a first current path and wherein the second positive flag and the second negative flag form a second current path. [12] Method (800) for manufacturing a solid-state pouch cell battery (158) comprising the following: Producing a first electrode layer (402) comprising a first positive flag extending beyond one edge of the first electrode layer (402) and a first negative flag extending beyond an opposite edge of the first electrode layer (402); Producing a second electrode layer (404) comprising a second positive flag extending beyond one edge of the second electrode layer (404) and a second negative flag extending beyond an opposite edge of the second electrode layer (404); Stacking the second electrode layer (404) onto an upper surface of the first electrode layer (402), wherein the second electrode layer (404) is substantially aligned with the first electrode layer (402); and wherein the second positive flag is misaligned with the first positive flag and the second negative flag is misaligned with the first negative flag. [13] Method according to claim 12, further comprising sealing the stacked first and second electrode layers in a pouch. [14] Method according to claim 12, wherein the first electrode layer (402) and the second electrode layer (404) each comprise double-sided coated electrodes; and wherein the first and the second electrode layer are produced using a single notching matrix configuration. [15] Method according to claim 12, wherein the first and second electrode layers are produced using two different notching matrix configurations.

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