Battery assembly with protective layer and method for manufacturing the battery assembly

Abstract

The secondary battery assembly includes an electrode assembly having mutually perpendicular lateral, longitudinal, and vertical axes corresponding to the X, Y, and Z axes, respectively. The constraint is disposed on an outer surface of the electrode assembly. At least one of the electrode assembly or the constraint has a protrusion extending in an XY plane defined by the X and Y axes and having a first radius of curvature in the XY plane. The battery housing encapsulates the electrode assembly and the constraint. The housing protection layer is disposed over at least a portion of the protrusion and between the protrusion and the battery housing. The housing protection layer defines a second radius of curvature that overlaps the first radius of curvature in the XY plane. The second radius of curvature is greater than the first radius of curvature, thereby reducing the possibility that the protrusion will cause damage to the battery housing.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63 / 168,392, filed March 31, 2021, which is incorporated by reference in its entirety.

[0002] The field of the disclosure relates generally to energy storage technology, such as battery technology. More specifically, the field of the disclosure relates to protective layers, systems, and methods for battery components, such as electrochemical battery components, for example lithium-based secondary batteries. [Background technology]

[0003] Lithium-based secondary batteries have become a desirable energy source due to their relatively high energy density, power, and shelf life. Examples of lithium secondary batteries include non-aqueous batteries such as lithium ion batteries and lithium polymer batteries.

[0004] Known energy storage devices, such as batteries, fuel cells, and electrochemical capacitors, typically have two-dimensional laminate structures, such as planar or spirally wound (i.e., jelly-roll) laminate structures, where the surface area of ​​each laminate is approximately equal to its geometric footprint (neglecting porosity and surface roughness).

[0005] Three-dimensional secondary batteries can offer increased capacity and extended life compared to layered secondary batteries, however, fabrication of such three-dimensional secondary batteries presents manufacturing and cost challenges.

[0006] During the manufacturing process of secondary batteries, sharp edges, corners, or other features can create areas that are vulnerable to damage and can impair the functionality, safety, or power output of the battery. Therefore, it would be desirable to manufacture three-dimensional batteries while addressing the problems of the known art. Summary of the Invention

[0007] In one embodiment, a secondary battery assembly comprises an electrode assembly having mutually perpendicular lateral, longitudinal, and vertical axes corresponding, respectively, to the X-, Y-, and Z-axes of a three-dimensional Cartesian coordinate system; a constraint disposed on an outer surface of the electrode assembly, where at least one of the electrode assembly or the constraint includes a protrusion extending in an XY plane defined by the X- and Y-axes, the protrusion having a first radius of curvature in the XY plane; a battery housing enclosing the electrode assembly and the constraint; and a housing protection layer disposed over at least a portion of the protrusion and between the protrusion and the battery housing, where the housing protection layer defines a second radius of curvature that overlaps the first radius of curvature in the XY plane, the second radius of curvature being greater than the first radius of curvature, thereby reducing a likelihood that the protrusion will cause damage to the battery housing.

[0008] In yet another embodiment, a secondary battery comprises: an electrode assembly having mutually perpendicular lateral, longitudinal, and vertical axes corresponding, respectively, to the X-, Y-, and Z-axes of a three-dimensional Cartesian coordinate system; a constraint defining a volume within which the electrode assembly is contained, wherein at least one of the electrode assembly or the constraint defines at least one protrusion extending in an XY plane defined by the X- and Y-axes, the protrusion having a first radius of curvature in the XY plane; and a housing protection layer disposed over at least a portion of the protrusion and between the protrusion and a battery housing, the housing protection layer defining a second radius of curvature that overlaps the first radius of curvature in the XY plane, the second radius of curvature being greater than the first radius of curvature, thereby reducing a likelihood that the protrusion will cause damage to the battery housing, wherein the battery housing encapsulates the electrode assembly, the constraint, and the housing protection layer, and at least a portion of the battery housing is in direct contact with the housing protection layer.

[0009] In yet another embodiment, a method of making a battery assembly for use with a secondary battery includes making an electrode assembly having mutually perpendicular lateral, longitudinal, and vertical axes corresponding to the X-, Y-, and Z-axes, respectively, of a three-dimensional Cartesian coordinate system, and disposing the electrode assembly within a volume defined by the constraint such that the constraint is disposed on an outer surface of the electrode assembly, wherein at least one of the electrode assembly or the constraint has at least one protruding portion extending in an XY plane defined by the X- and Y-axes. the protrusion having a first radius of curvature in the XY plane; adhering a housing protection layer over at least a portion of the protrusion, the housing protection layer defining a second radius of curvature that overlaps the first radius of curvature in the XY plane, the second radius of curvature being greater than the first radius of curvature, thereby reducing a likelihood that the protrusion will cause damage to the battery housing; and encapsulating the electrode assembly, the constraint, and the housing protection layer within the battery housing such that the housing protection layer is disposed between the constraint and the battery housing.

[0010] In yet another embodiment, a method of manufacturing a secondary battery includes creating an electrode assembly having mutually perpendicular lateral, longitudinal, and vertical axes corresponding to the X-, Y-, and Z-axes, respectively, of a three-dimensional Cartesian coordinate system, and disposing the electrode assembly within a volume defined by the constraint such that the constraint is disposed on an outer surface of the electrode assembly, wherein at least one of the electrode assembly or the constraint defines at least one protrusion extending in an XY plane defined by the X- and Y-axes, the protrusion defining a first curvature in the XY plane. the at least one protrusion having a first radius of curvature in the XY plane, the second radius of curvature being greater than the first radius of curvature, thereby reducing a likelihood that the protrusion will cause damage to the battery housing; encapsulating the electrode assembly, the constraint, and the housing protection layer within the battery housing such that the housing protection layer is disposed between the constraint and the battery housing; and vacuum sealing the battery housing. [Brief description of the drawings]

[0011] [Figure 1] FIG. 2 is a front perspective view of one preferred embodiment of a battery assembly having a cut portion prior to application of a protective layer according to the present disclosure. [Diagram 2] 2 is a cross-sectional view of the electrode assembly of FIG. 1 taken from section line DD. [Diagram 3] FIG. 2 is an enlarged partial perspective view of a battery assembly within the constraints of the present disclosure. [Figure 3A] FIG. 1 is a perspective view of one embodiment of a constraint according to the present disclosure. [Figure 4] FIG. 2 is a perspective view of a battery assembly including a housing protective layer according to an embodiment of the present disclosure. [Figure 4A] Photograph of the face of the battery assembly before a housing protective layer is applied on top. [Figure 4B] 4B is a photograph of the face of the battery assembly of FIG. 4A after application of a housing protection layer according to the present disclosure. [Figure 4C] Photograph of the face of the battery assembly before a housing protective layer is applied on top. [Figure 4D] 4D is a photograph of the face of the battery assembly of FIG. 4C after application of a housing protection layer according to the present disclosure. [Figure 4E] FIG. 2 is a schematic profile view of a battery assembly prior to attachment of a housing protective layer according to the present disclosure. [Figure 4F] FIG. 4F is a schematic profile view of the battery assembly of FIG. 4E after application of a housing protective layer according to the present disclosure. [Diagram 5] FIG. 2 is a perspective view of a battery assembly partially disposed within a battery housing. [Figure 6] FIG. 6 is a perspective view of the battery assembly of FIG. 5 including a second cover of the battery housing. [Figure 7] FIG. 2 is a profile view of the completed battery after it has been sealed into the battery housing. [Figure 8] FIG. 2 is a perspective view of a portion of a web of a housing protective layer. [Figure 9] FIG. 2 is a perspective view of one embodiment of a housing protective layer on a battery assembly of the present disclosure. [Figure 10] 1 is a schematic diagram of a method of making a battery assembly including a housing protective layer according to the present disclosure.

[0012] definition As used herein, "A," "an," and "the" (i.e., singular) refer to plural referents unless the context clearly dictates otherwise. For example, in one instance, reference to an "electrode" includes both a single electrode and a plurality of similar electrodes.

[0013] As used herein, "about" and "approximately" refer to plus or minus 10%, 5%, or 1% of the stated value. For example, in one case, about 250 μm includes 225 μm to 275 μm. As a further example, in one case, about 1,000 μm includes 900 μm to 1,100 μm. Unless otherwise indicated, all numbers expressing quantities (e.g., measurements, etc.) and the like used in the specification and claims should be understood to be modified in all cases by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and the appended claims are approximations. Each numerical parameter should be construed, at least in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0014] "Anode" as used herein in the context of a secondary battery refers to the negative electrode of the secondary battery.

[0015] As used herein, "anode material" or "anode active" means a material suitable for use as the negative electrode of a secondary battery.

[0016] "Cathode" as used herein in the context of a secondary battery refers to the positive electrode of the secondary battery.

[0017] As used herein, "cathode material" or "cathode active" means a material suitable for use as the positive electrode of a secondary battery.

[0018] "Conversion chemical active material" or "conversion chemical" refers to a material that undergoes a chemical reaction during the charge-discharge cycle of a secondary battery.

[0019] As used herein, a "counter electrode" may refer to the electrode opposite the negative or positive electrode (anode or cathode) of a secondary battery, unless the context explicitly indicates otherwise.

[0020] As used herein in the context of cycling a secondary battery between a charging state and a discharging state, "cycling" refers to charging and / or discharging the battery to move the battery from a first state, either a charging state or a discharging state, to a second state that is the opposite of the first state (i.e., the charging state if the first state was discharging, or the discharging state if the first state was charging), and then returning the battery to the first state to complete the cycle. For example, a single cycle of a secondary battery between a charging state and a discharging state can include charging the battery from the discharging state to the charging state, as in a charging cycle, and then discharging back to the discharging state to complete the cycle. A single cycle can also include discharging the battery from the charging state to the discharging state, as in a discharging cycle, and then charging back to the charging state to complete the cycle.

[0021] As used herein, "electrochemically active material" means an anode active material or a cathode active material.

[0022] As used herein, an "electrode" may refer to either the negative or positive electrode (anode or cathode) of a secondary battery, unless the context explicitly indicates otherwise.

[0023] As used herein, an "electrode current collector layer" may refer to an anode (e.g., negative) current collector layer or a cathode (e.g., positive) current collector layer.

[0024] As used herein, "electrode material" may refer to either anodic or cathodic materials, unless the context explicitly indicates otherwise.

[0025] As used herein, "electrode structure" may refer to an anode structure (e.g., a negative electrode structure) or a cathode structure (e.g., a positive electrode structure) suitable for use in a battery, unless the context explicitly indicates otherwise.

[0026] As used herein, "longitudinal axis", "transverse axis", and "vertical axis" refer to mutually perpendicular axes (i.e., each is orthogonal to the other). For example, "longitudinal axis", "transverse axis", and "vertical axis" as used herein are analogous to a Cartesian coordinate system used to define three-dimensional aspects or orientations. As such, the description of the elements of the subject matter disclosed herein is not limited to the particular axes used to describe the three-dimensional orientation of the elements. Alternatively stated, the axes may be interchangeable when referring to the three-dimensional aspects of the subject matter disclosed. "Weakened region" refers to a portion of a web that has been subjected to a processing operation, such as, for example, scoring, cutting, or perforating, such that the localized breaking strength of the weakened region is lower than the breaking strength of the non-weakened region. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] Embodiments of the present disclosure relate to protective layers for components of batteries, such as secondary batteries, to reduce the occurrence of damage to the components in order to maintain the functionality, safety and / or power output of the battery.

[0028] A preferred embodiment of a battery assembly 100, prior to attachment of a protective layer, is described with reference to FIG. 1. As shown in FIG. 1, the battery assembly 100 includes a group of adjacent electrode subunits 102. Each electrode subunit 102 has dimensions along an X-axis, a Y-axis, and a Z-axis, respectively. The X, Y, and Z axes are each mutually perpendicular, similar to a Cartesian coordinate system. As used herein, the dimension of each electrode subunit 102 along the Z-axis may be referred to as the "height", the dimension along the X-axis may be referred to as the "length", and the dimension along the Y-axis may be referred to as the "width". The electrode subunits may be combined into one or more unit cells 200 (FIG. 2). Each electrode unit cell 200 includes at least one anode active material layer 104 and at least one cathode active material layer 106. The anode active material layer 104 and the cathode active material layer 106 are electrically insulated from each other by a separator layer 108. It should be understood that in preferred embodiments of the present disclosure, any number of electrode subunits 102 may be used, such as 1 to 200 or more subunits in a single battery assembly 100.

[0029] Still referring to FIG. 1 , the battery assembly 100 includes bus bars 110 and 112 that are in electrical contact with the anode active layer 104 and the cathode active layer 106 of each electrode subunit 102, respectively, via electrode tabs (or current collector tabs) 120. Thus, the bus bar 110 shown in FIG. 1 may be referred to as an anode bus bar, and the bus bar 112 may be referred to as a cathode bus bar. In one embodiment, a casing 116, which may be referred to as a constraint, may be attached on one or both of the XY surfaces of the battery assembly 100. In the embodiment shown in FIG. 1 , the casing 116 includes a group of perforations 118 to facilitate the distribution or flow of electrolyte solution once the battery assembly 100 is fully assembled.

[0030] In one embodiment, each of the anode active layer 104 and the cathode active layer 106 can be a multi-layer material including, for example, an electrode current collector layer (i.e., an anode current collector layer or a cathode current collector layer) on at least one major surface thereof, and an electrochemically active material layer (i.e., a layer of anode active material or a layer of cathode active material), while in other embodiments, one or more of the anode active layer and cathode active layer can be a single layer of a suitable material.

[0031] Referring to FIG. 2, the individual layers of an electrode unit cell 200 are described, which may be the same as or similar to the electrode subunit 102. For each of the unit cells 200, in some embodiments, the separator layer 108 is an ion-permeable woven polymeric material suitable for use as a separator in a secondary battery. A cross-sectional view of one embodiment of a unit cell 200 is shown in FIG. 2. In this embodiment, the electrode subunit 200 comprises a central anode current collector layer 206, an anode active material layer 104, a separator 108, a cathode active material layer 106, and a cathode current collector layer 210 in a stacked formation. In an alternative embodiment, the position of the cathode active material layer 106 and the anode active material layer 104 may be swapped, with the cathode active material layer 106 toward the center and the anode active material layer distal to the cathode active material layer 106. In one embodiment, unit cell 200A includes a cathode current collector 210, a cathode active material layer 106, a separator 108, an anode active material layer 104, and an anode current collector 206, stacked sequentially from left to right in the view of Figure 2. In an alternative embodiment, unit cell 200B includes a separator 108, a first layer of cathode active material layer 106, a cathode current collector 210, a second layer of cathode active material layer 106, a separator 108, a first layer of anode active material layer 104, an anode current collector 206, a second layer of anode active material layer 104, and a separator 108, stacked sequentially from left to right in the view of Figure 2.

[0032] In one embodiment, the anode current collector layer 206 may include a conductive metal such as copper, a copper alloy, carbon, nickel, stainless steel, or any other material suitable as an anode current collector layer. The anode active material layer 104 may be formed as a first layer on a first surface of the anode current collector layer 206 and a second layer on a second opposing surface of the anode current collector layer 206. In another embodiment, the anode current collector layer 206 and the anode active material layer 104 may be intermixed. The first surface and the second opposing surface may be referred to as the major surfaces, or the front and back surfaces, of the layer. A major surface, as used herein, refers to a surface defined by a plane formed by the length of the material in the X-axis direction (not shown in FIG. 2) and the height of the material in the Z-axis direction.

[0033] In one embodiment, the anode active material layers 104 may each have a thickness of at least about 10 um. For example, in one embodiment, the anode active material layers 104 have a width in the Y-axis direction of (each) at least about 40 um. By way of further example, in one such embodiment, the anode active material layers 104 have a width in the Y-axis direction of (each) at least about 80 um. By way of further example, in one such embodiment, the anode active material layers 104 each have a width of at least about 120 um. Typically, however, the anode active material layers 104 each have a width of less than about 60 um, or even less than about 30 um. As used herein, the terms "thickness" and "width" may be used interchangeably to refer to measurements in the Y-axis direction.

[0034] In general, the negative electrode active material (e.g., anode active material) may be selected from the group consisting of: (a) silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (Co), and cadmium (Cd); (b) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, or Cd with other elements; and (c) Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Fe. , oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Ni, Co, V, or Cd, and mixtures, composites, or lithium-containing composites thereof; (d) salts and hydroxides of Sn; (e) lithium titanate, lithium manganate, lithium aluminate, lithium-containing titanium oxides, lithium transition metal oxides, ZnCo2O4; (f) graphite and carbon particles; (g) lithium metal; and (h) combinations thereof.

[0035] Exemplary anode active materials include graphite and soft or hard carbon, or carbon materials such as graphene (e.g., single-walled or multi-walled carbon nanotubes), or any of a range of metals, metalloids, alloys, oxides, nitrides, and compounds that can intercalate or form alloys with lithium. Specific examples of metals or metalloids that can constitute the anode material include graphite, tin, lead, magnesium, aluminum, boron, gallium, silicon, Si / C composites, Si / graphite blends, silicon oxide (SiOx), porous Si, intermetallic Si alloys, indium, zirconium, germanium, bismuth, cadmium, antimony, silver, zinc, arsenic, hafnium, yttrium, lithium, sodium, graphite, carbon, lithium titanate, palladium, and mixtures thereof. In one exemplary embodiment, the anode active material includes aluminum, tin, or silicon, or oxides thereof, nitrides thereof, fluorides thereof, or other alloys thereof. In another exemplary embodiment, the anode active material comprises silicon, or an alloy or oxide thereof.

[0036] In one embodiment, the anode active material is microstructured to provide a significant void volume fraction to accommodate volume expansion and contraction as lithium ions (or other carrier ions) are introduced into or removed from the anode active material during charge and discharge processes. Generally, the void volume fraction of each of the anode active material layers 104 is at least 0.1. Typically, however, the void volume fraction of each of the anode active material layers is 0.8 or less. For example, in one embodiment, the void volume fraction of each of the anode active material layers 104 is from about 0.15 to about 0.75. As a further example, in one embodiment, the void volume fraction of (each of) the anode active material layers 104 is from about 0.2 to about 0.7. As a further example, in one embodiment, the void volume fraction of each of the anode active material layers 104 is from about 0.25 to about 0.6.

[0037] Depending on the composition of the microstructured anode active material and the method of its formation, the microstructured anode active material may include macroporous, microporous, or mesoporous material layers, or combinations thereof, such as a combination of microporous and mesoporous, or a combination of mesoporous and macroporous. Microporous materials are typically characterized by pore dimensions of less than 10 nm, wall dimensions of less than 10 nm, pore depths of 1 to 50 micrometers, and pore morphologies generally characterized by a "spongy" and irregular appearance, non-smooth walls, and branched pores. Mesoporous materials are typically characterized by pore dimensions of 10 to 50 nm, wall dimensions of 10 to 50 nm, pore depths of 1 to 100 micrometers, and pore morphologies generally characterized by somewhat well-defined branched or dendritic pores. Macroporous materials are typically characterized by pore dimensions greater than 50 nm, wall dimensions greater than 50 nm, pore depths between 1 and 500 micrometers, and pore morphologies that can be linear, branched, or dendritic, and smooth or rough-walled. Furthermore, the void volume can include open or closed porosity, or a combination thereof. In one embodiment, the void volume includes open porosity, i.e., the anode active material includes porosity with openings in the sides of the anode active material through which lithium ions (or other carrier ions) can enter or leave the anode active material, e.g., lithium ions can enter the anode active material through the porosity openings after leaving the cathode active material. In another embodiment, the void volume includes closed porosity, i.e., the anode active material includes porosity that is enclosed by the anode active material. In general, open porosity can provide a greater interfacial surface area for carrier ions, while closed porosity tends to be less susceptible to solid electrolyte interfaces, while each provides room for expansion of the anode active material upon ingress of carrier ions. Thus, in certain embodiments, it is preferred that the anode active material include a combination of open and closed porosity.

[0038] In one embodiment, the anode active material comprises porous aluminum, tin or silicon, or alloys, oxides, or nitrides thereof. The porous silicon layer can be formed, for example, by anodization, by etching (e.g., by depositing a precious metal such as gold, platinum, silver, or gold / palladium on the surface of the single crystal silicon and etching the surface with a mixture of hydrofluoric acid and hydrogen peroxide), or by other methods known in the art, such as patterned chemical etching. Furthermore, the porous anode active material generally has a porosity of at least about 0.1, but less than 0.8, and a thickness of about 1 to about 100 micrometers. For example, in one embodiment, the anode active material comprises porous silicon, has a thickness of about 5 to about 100 micrometers, and has a porosity of about 0.15 to about 0.75. As a further example, in one embodiment, the anode active material comprises porous silicon, has a thickness of about 10 to about 80 micrometers, and has a porosity of about 0.15 to about 0.7. By way of further example, in one such embodiment, the anode active material comprises porous silicon, has a thickness of about 20 to about 50 micrometers, and has a porosity of about 0.25 to about 0.6. By way of further example, in one embodiment, the anode active material comprises a porous silicon alloy (e.g., nickel silicide), has a thickness of about 5 to about 100 micrometers, and has a porosity of about 0.15 to about 0.75.

[0039] In another embodiment, the anode active material comprises aluminum, tin or silicon fibers, or alloys of tin or silicon. The individual fibers may have a diameter (thickness dimension) of about 5 nm to about 10,000 nm, and a length generally corresponding to the thickness of the anode active material. The silicon fibers (nanowires) may be formed by, for example, chemical vapor deposition or other techniques known in the art, such as vapor-liquid-solid (VLS) growth and solid-liquid-solid (SLS) growth. Additionally, the anode active material generally has a porosity of at least about 0.1, but less than 0.8, and a thickness of about 1 to about 200 micrometers. For example, in one embodiment, the anode active material comprises silicon nanowires, has a thickness of about 5 to about 100 micrometers, and has a porosity of about 0.15 to about 0.75. As a further example, in one embodiment, the anode active material comprises silicon nanowires, has a thickness of about 10 to about 80 micrometers, and has a porosity of about 0.15 to about 0.7. By way of further example, in one such embodiment, the anode active material comprises silicon nanowires, has a thickness of about 20 to about 50 micrometers, and has a porosity of about 0.25 to about 0.6. By way of further example, in one embodiment, the anode active material comprises silicon alloy (such as nickel silicide) nanowires, has a thickness of about 5 to about 100 micrometers, and has a porosity of about 0.15 to about 0.75.

[0040] In yet other embodiments, the negative electrode (i.e., electrode or counter electrode, depending on the context) or anode active material layer 104 is coated with a particulate lithium material selected from the group consisting of stabilized lithium metal particles, e.g., lithium carbonate stabilized lithium metal powder, lithium silicate stabilized lithium metal powder, or other sources of stabilized lithium metal powder or ink. The particulate lithium material is in an amount of about 0.05-5 mg / cm. 2 , for example, about 0.1 to 4 mg / cm 2 , or even about 0.5-3 mg / cm 2 The lithium particulate material may be applied to the anode active material layer 104 (e.g., the negative electrode) by spraying, packing, or otherwise disposing the lithium particulate material in the negative electrode active material layer at a loading of 0.1 to 0.5 μm. 50The average particle size (D) can be 5 to 200 μm, for example, about 10 to 100 μm, 20 to 80 μm, or even about 30 to 50 μm. 50 ) can be defined as the particle size corresponding to 50% in the cumulative volume-based particle size distribution curve. 50 ) can be measured, for example, using laser diffraction methods.

[0041] Generally, the anode current collector 206 has a thickness of at least about 10 3 For example, in one such embodiment, the anode current collector has an electrical conductivity of at least about 10 4 By way of further example, in one such embodiment, the anode current collector has a conductivity of at least about 10 Siemens / cm. 5 It has a conductivity of Siemens / cm. Exemplary electrically conductive materials suitable for use as the anode current collector 206 include metals such as copper, nickel, stainless steel, carbon, cobalt, titanium, and tungsten, and alloys thereof.

[0042] Referring again to FIG. 2, in another preferred embodiment, the unit cell 200 includes one or more cathode current collector layers 210 and one or more cathode active material layers 106. The cathode current collector layer 210 of the cathode material may include aluminum, an aluminum alloy, titanium, or any other material suitable for use as a cathode current collector layer 210. The cathode active material layer 106 may be formed as a first layer on a first surface of the cathode current collector layer 210 and a second layer on a second opposing surface of the cathode current collector layer 210. The cathode active material layer 106 may be coated on one or both sides of the cathode current collector layer 210. Similarly, the cathode active material layer 106 may be coated on one or both major surfaces of the cathode current collector layer 210. In another embodiment, the cathode current collector layer 210 may be mixed with the cathode active material layer 106.

[0043] In one embodiment, the cathode active material layers 106 each have a thickness of at least about 20 um. For example, in one embodiment, the cathode active material layers 106 each have a thickness of at least about 40 um. By way of further example, in one such embodiment, the cathode active material layers 106 each have a thickness of at least about 60 um. By way of further example, in one such embodiment, the cathode active material layers 106 each have a thickness of at least about 100 um. Typically, however, the cathode active material layers 106 each have a thickness of less than about 90 um, or even less than about 70 um.

[0044] In one embodiment, the positive electrode (eg, cathode) material can include or be an intercalation-type chemically active material, a conversion chemically active material, or a combination thereof.

[0045] Exemplary conversion chemical materials useful in the present disclosure include S (or the lithiated form LiS), LiF, Fe, Cu, Ni, FeF, FeO d F 3.2d , FeF3, CoF3, CoF2, CuF2, and NiF2, where 0≦d≦0.5.

[0046] Exemplary cathode active materials also include any of a wide range of intercalation type cathode active materials. For example, in the case of a lithium ion battery, the cathode active material may include a cathode active material selected from transition metal oxides, transition metal sulfides, transition metal nitrides, lithium transition metal oxides, and lithium transition metal sulfides, 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 an 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(Nix Co y Al z )O2, LiFePO4, Li2MnO4, V2O5, molybdenum oxysulfide, phosphates, silicates, vanadates, sulfur, sulfur compounds, oxygen (air), Li(Ni x Mn y Co z ) O2, and combinations thereof.

[0047] Generally, the cathode current collector 210 has a thickness of at least about 10 3 For example, in one such embodiment, the cathode current collector 210 has an electrical conductivity of at least about 10 4 By way of further example, in one such embodiment, the cathode current collector 210 has a conductivity of at least about 10 5 It has a conductivity of Siemens / cm. Exemplary electrically conductive materials suitable for use as the cathode current collector 210 include metals such as aluminum, nickel, cobalt, titanium, and tungsten, and alloys thereof.

[0048] 2, in one embodiment, the electrically insulating separator layer 108 is adapted to electrically insulate the components of the anode active material layer 104 from the components of the cathode active material layer 106. The electrically insulating separator layer 108 typically comprises a microporous separator material that can be permeated with a non-aqueous electrolyte, for example, in one embodiment the microporous separator material comprises pores having diameters of at least 50 Å, more typically in the range of about 2,500 Å, and a porosity in the range of about 25% to about 75%, more typically in the range of about 35 to 55%.

[0049] In one embodiment, the electrically insulating separator material layers 108 each have a thickness of at least about 4 um. For example, in one embodiment, the electrically insulating separator material layers 108 each have a thickness of at least about 8 um. By way of further example, in one such embodiment, the electrically insulating separator material layers 108 each have a thickness of at least about 12 um. By way of further example, in one such embodiment, the electrically insulating separator material layers 108 each have a thickness of at least about 15 um. In another embodiment, the electrically insulating separator material layers 108 each have a thickness of at least about 25 um. In another embodiment, the electrically insulating separator material layers 108 each have a thickness of at least about 50 um. Typically, however, the electrically insulating separator material layers 108 each have a thickness of less than about 12 um, or even less than about 10 um.

[0050] In general, the separator material for separator layer 108 can be selected from a wide variety of separator materials capable of conducting carrier ions between the positive and negative active materials of the unit cells. For example, the separator material can include a microporous separator material that can be permeated with a liquid non-aqueous electrolyte. Alternatively, the separator material can include a gel or solid electrolyte that can conduct carrier ions between the positive and negative electrodes of the unit cells.

[0051] In one embodiment, the separator material may include a polymer-based electrolyte. Exemplary polymer electrolytes include PEO-based polymer electrolytes, polymer ceramic composite electrolytes, polymer ceramic composite electrolytes, and polymer ceramic composite electrolytes.

[0052] In another embodiment, the separator material may include an oxide-based electrolyte. Exemplary oxide-based electrolytes include lithium lanthanum titanate (Li 0.34 La 0.56 TiO3), Al-doped lanthanum zirconate lithium (Li 6.24 La3Zr2Al 0.24 O 11.98 ), Ta-doped lithium lanthanum zirconate (Li 6.4La3Zr 1.4 Ta 0.6 O 12 ), and lithium aluminum titanium phosphate (Li 1.4 Al 0.4 Ti 1.6 (PO4)3).

[0053] In another embodiment, the separator material may include a solid electrolyte. Exemplary solid electrolytes include lithium tin sulfide (Li 10 SnP2S 12 ), lithium phosphorus sulfide (β-Li3PS4) and lithium phosphorus sulfide chloride iodide (Li6PS5Cl 0.9 I 0.1 ) and other sulfide-based electrolytes.

[0054] In one embodiment, the separator material comprises a microporous separator material including a particulate material and a binder, and having a porosity (void fraction) of at least about 20% by volume. The pores of the microporous separator material have a diameter of at least 50 Å, typically in the range of about 250-2500 Å. The microporous separator material typically has a porosity of less than about 75%. In one embodiment, the microporous separator material has a porosity (void fraction) of at least about 25% by volume. In one embodiment, the microporous separator material has a porosity of about 35-55%.

[0055] Binders for the microporous separator material may be selected from a wide range of inorganic or polymeric materials. For example, in one embodiment, the binder is an organic material selected from the group consisting of silicates, phosphates, aluminates, aluminosilicates, and hydroxides, such as magnesium hydroxide, calcium hydroxide, etc. For example, in one embodiment, the binder is a fluoropolymer derived from monomers including vinylidene fluoride, hexafluoropropylene, and tetrafluoropropene, etc. In another embodiment, the binder is a polyolefin, such as polyethylene, polypropylene, or polybutene, having any of a variety of molecular weight and density ranges. In another embodiment, the binder is selected from the group consisting of ethylene-diene propene terpolymer, polystyrene, polymethyl methacrylate, polyethylene glycol, polyvinyl acetate, polyvinyl butyral, polyacetal, and polyethylene glycol diacrylate. In another embodiment, the binder is selected from the group consisting of methyl cellulose, carboxymethyl cellulose, styrene rubber, butadiene rubber, styrene butadiene rubber, isoprene rubber, polyacrylamide, polyvinyl ether, polyacrylic acid, polymethacrylic acid, and polyethylene oxide. In another embodiment, the binder is selected from the group consisting of acrylates, styrenes, epoxies, and silicones. In another embodiment, the binder is a copolymer or blend of two or more of the foregoing polymers.

[0056] The particulate material comprised by the microporous separator material may also be selected from a wide range of materials. Generally, such materials have relatively low electronic and ionic conductivity at operating temperatures and do not corrode under the operating voltages of the battery electrodes or current collectors that contact the microporous separator material. For example, in one embodiment, the particulate material has a molecular weight of 1×10 -4 By way of further example, in one embodiment, the particulate material has a conductivity for carrier ions (e.g., lithium) of less than 1×10 -5 By way of further example, in one embodiment, the particulate material has a conductivity for carrier ions of less than 1×10 -6Exemplary particulate materials include particulate polyethylene, polypropylene, TiO2-polymer composite, silica aerogel, fumed silica, silica gel, silica hydrogel, silica cellogel, silica sol, colloidal silica, alumina, titania, magnesia, kaolin, talc, diatomaceous earth, calcium silicate, aluminum silicate, calcium carbonate, magnesium carbonate, or combinations thereof. For example, in one embodiment, the particulate material is TiO 2、 SiO 2、 Particulate materials include particulate oxides or nitrides such as Al2O3, GeO2, B2O3, Bi2O3, BaO, ZnO, ZrO2, BN, Si3N4, Ge3N4, etc. (See, for example, P. Arora and J. Zhang, "Battery Separators," Chemical Reviews 2004, 104, 4419-4462). In one embodiment, the particulate material has an average particle size of about 20 nm to 2 micrometers, more typically 200 nm to 1.5 micrometers. In one embodiment, the particulate material has an average particle size of about 500 nm to 1 micrometer.

[0057] In alternative embodiments, the particulate materials comprised by the microporous separator material may be bound together by techniques such as, for example, sintering, bonding, curing, etc., while maintaining a desired void fraction for electrolyte ingress to provide ionic conductivity for the function of the battery.

[0058] In an assembled energy storage device, such as the battery assembly 100, the microporous separator material is permeated with a non-aqueous electrolyte suitable for use as a secondary battery electrolyte. Typically, the non-aqueous electrolyte comprises a lithium salt and / or mixture of salts dissolved in an organic solvent and / or solvent mixture. Exemplary lithium salts include inorganic lithium salts such as LiClO4, LiBF4, LiPF6, LiAsF6, LiCl, and LiBr, as well as inorganic lithium salts such as LiB(CH5)4, LiN(SO2CF3)2, LiN(SO2CF3)3, LiNSO2CF3, LiNSO2CF5, LiNSO2C4F9, LiNSO2C5F11 , LiNSO2C6F 13 , and LiNSO2C7F 15 Exemplary organic solvents for dissolving lithium salts include cyclic esters, chain esters, cyclic ethers, and chain ethers. Specific examples of cyclic esters include propylene carbonate, butylene carbonate, γ-butyrolactone, vinylene carbonate, 2-methyl-γ-butyrolactone, acetyl-γ-butyrolactone, and γ-valerolactone. Specific examples of chain esters include dimethyl carbonate, diethyl carbonate, dibutyl carbonate, dipropyl carbonate, methyl ethyl carbonate, methyl butyl carbonate, methyl propyl carbonate, ethyl butyl carbonate, ethyl propyl carbonate, butyl propyl carbonate, alkyl propionates, dialkyl malonates, and alkyl acetates. Specific examples of cyclic ethers include tetrahydrofuran, alkyltetrahydrofuran, dialkyltetrahydrofuran, alkoxytetrahydrofuran, dialkoxytetrahydrofuran, 1,3-dioxolane, alkyl-1,3-dioxolane, and 1,4-dioxolane.Specific examples of chain ethers include 1,2-dimethoxyethane, 1,2-diethoxyethane, diethyl ether, ethylene glycol dialkyl ether, diethylene glycol dialkyl ether, triethylene glycol dialkyl ether, and tetraethylene glycol dialkyl ether.

[0059] In one embodiment, the microporous separator layer 108 can be permeated with a non-aqueous organic electrolyte comprising a mixture of a lithium salt and a high purity organic solvent. Additionally, the electrolyte can be a polymer using a polymer electrolyte or a solid electrolyte.

[0060] 1 and 2, in one embodiment, the bus bars 110 and 112 are disposed through bus bar openings (not shown) of the respective electrodes or counter electrodes (e.g., anodes or cathodes, as the case may be) to connect the anode current collectors 206 in parallel with each other (in a battery including multiple electrode subunits), and the other of the bus bars connects the cathode current collectors 210 in parallel with each other in a battery including multiple unit cells 200. In one embodiment, the bus bars 110, 112 are welded or otherwise electrically coupled to the current collector tabs 120 that are respectively folded over prior to welding. In one embodiment, the bus bar 110 is a copper bus bar and is welded to the anode tab of the anode current collector layer 206, and the bus bar 112 is an aluminum bus bar and is welded to the cathode tab of the cathode current collector layer 210. However, in other embodiments, the bus bars 110, 112 may be any suitable conductive material to enable the battery assembly 100 to function as described herein. The welding may be performed using a laser welder, friction welding, ultrasonic welding, or any suitable welding method for welding the bus bars 110 and 112 to the electrode tabs 120. In one embodiment, each of the bus bars 110 and 112 makes electrical contact with all of the electrode tabs 120 for the anodes and cathodes, respectively.

[0061] As referred to herein, the anode group unit includes at least the anode current collector 206 and the anode active material layer 104. In some embodiments, the anode group unit includes the anode current collector 206 and the anode active material layer 104 disposed on each major surface of the anode current collector 206. The length of the anode group unit varies depending on the energy storage device and its intended use. However, in general, the anode group unit typically has a length in the range of about 5 mm to about 500 mm. For example, in one such embodiment, the anode group unit has a length of about 10 mm to about 250 mm. As a further example, in one such embodiment, the anode group unit has a length of about 25 mm to about 100 mm.

[0062] The width of the anode group unit (Y-axis range) also varies depending on the energy storage device and its intended use. In general, however, each anode group unit typically has a width in the range of about 0.01 mm to 2.5 mm. For example, in one embodiment, the width of each anode group unit is in the range of about 0.025 mm to about 2 mm. As a further example, in one embodiment, the width of each anode group unit is in the range of about 0.05 mm to about 1 mm.

[0063] The height (Z-axis range) of the anode group constituent units also varies depending on the energy storage device and its intended use. In general, however, the anode group constituent units typically have a height in the range of about 0.05 mm to about 25 mm. For example, in one embodiment, the height of each anode group constituent unit is in the range of about 0.05 mm to about 5 mm. As a further example, in one embodiment, the height of each anode group constituent unit is in the range of about 0.1 mm to about 1 mm. According to one embodiment, the anode group constituent units include one or more first electrode constituent units having a first height and one or more second electrode constituent units having a second height other than the first height. In yet another embodiment, the different heights of the one or more first electrode constituent units and the one or more second electrode constituent units can be selected to accommodate a predetermined shape of the electrode assembly, such as a shape of the electrode assembly having different heights along one or more of the longitudinal axis and / or the lateral axis, and / or to provide a predetermined performance characteristic of the secondary battery. According to another embodiment, the anode group unit includes one or more first electrode units having a first width and one or more second electrode units having a second width other than the first width. In yet another embodiment, the different widths of the one or more first electrode units and the one or more second electrode units can be selected to accommodate a predetermined shape of the electrode assembly, such as an electrode assembly shape having different widths, and / or to provide a predetermined performance characteristic of the secondary battery. According to yet another embodiment, the anode group unit includes one or more first electrode units having a first length and one or more second electrode units having a second length other than the first length. In yet another embodiment, the different lengths of the one or more first electrode units and the one or more second electrode units can be selected to accommodate a predetermined shape of the electrode assembly, such as an electrode assembly shape having different lengths, and / or to provide a predetermined performance characteristic of the secondary battery.

[0064] In general, an anode group unit has a length (X-axis extent) that is substantially greater than each of its width and its height. For example, in one embodiment, the ratio of each of the length to width and height is at least 5:1, respectively, for each anode group unit (i.e., the ratio of the length to width is at least 5:1, respectively, and the ratio of the length to height is at least 5:1, respectively). By way of further example, in one embodiment, the ratio of each of the length to width and height is at least 10:1. By way of further example, in one embodiment, the ratio of each of the length to width and height is at least 15:1. By way of further example, in one embodiment, the ratio of each of the length to width and height is at least 20:1, respectively, for each anode group unit.

[0065] In one embodiment, the height to width ratio of each of the constituent units of the anode group is at least 0.4:1. For example, in one embodiment, the height to width ratio is at least 2:1 for each of the constituent units of the anode group. By way of further example, in one embodiment, the height to width ratio is at least 10:1 for each of the constituent units of the anode group. By way of further example, in one embodiment, the height to width ratio is at least 20:1 for each of the constituent units of the anode group. However, typically, the height to width ratio is generally less than 1,000:1 for each of the constituent units of the anode group. For example, in one embodiment, the height to width ratio is less than 500:1 for each of the constituent units of the anode group. By way of further example, in one embodiment, the height to width ratio is less than 100:1 for each of the constituent units of the anode group. By way of further example, in one embodiment, the height to width ratio is in the range of about 2:1 to about 100:1 for each of the constituent units of the anode group.

[0066] As referred to herein, the cathode group unit includes at least a cathode current collector 210 and a cathode active material layer 106. The length of the cathode group unit varies depending on the energy storage device and its intended use. In general, however, each cathode group unit typically has a length in the range of about 5 mm to about 500 mm. For example, in one such embodiment, each cathode group unit has a length of about 10 mm to about 250 mm. As a further example, in one such embodiment, each cathode group unit has a length of about 25 mm to about 100 mm.

[0067] The width (Y-axis range) of the cathode group constituent units also varies depending on the energy storage device and its intended use. In general, however, the cathode group constituent units typically have a width in the range of about 0.01 mm to 2.5 mm. For example, in one embodiment, the width of each cathode group constituent unit is in the range of about 0.025 mm to about 2 mm. As a further example, in one embodiment, the width of each cathode group constituent unit is in the range of about 0.05 mm to about 1 mm.

[0068] The height (Z-axis range) of the cathode group constituent units also varies depending on the energy storage device and its intended use. In general, however, the cathode group constituent units typically have a height in the range of about 0.05 mm to about 25 mm. For example, in one embodiment, the height of each of the cathode group constituent units is in the range of about 0.05 mm to about 5 mm. As a further example, in one embodiment, the height of each of the cathode group constituent units is in the range of about 0.1 mm to about 1 mm. According to one embodiment, the cathode group constituent units include one or more first cathode constituent units having a first height and one or more second cathode constituent units having a second height other than the first height. In yet another embodiment, the different heights of the one or more first cathode constituent units and the one or more second cathode constituent units can be selected to accommodate a predetermined shape of the electrode assembly, such as a shape of the electrode assembly having different heights along one or more of the longitudinal axis and / or the lateral axis, and / or to provide a predetermined performance characteristic of the secondary battery. According to another embodiment, the cathode group of constituent units includes one or more first electrode units having a first width and one or more second electrode units having a second width other than the first width. In yet another embodiment, the different widths of the one or more first electrode units and the one or more second electrode units can be selected to accommodate a predetermined shape of the electrode assembly, such as an electrode assembly shape having different widths, and / or to provide a predetermined performance characteristic of the secondary battery. According to yet another embodiment, the cathode group of constituent units includes one or more first electrode units having a first length and one or more second electrode units having a second length other than the first length. In yet another embodiment, the different lengths of the one or more first electrode units and the one or more second electrode units can be selected to accommodate a predetermined shape of the electrode assembly, such as an electrode assembly shape having different lengths, and / or to provide a predetermined performance characteristic of the secondary battery.

[0069] In general, each of the cathode group units has a length (X-axis extent) that is substantially greater than its width and substantially greater than its height. For example, in one embodiment, the ratio of each of the length to width and height is at least 5:1 for each of the cathode group units (i.e., the ratio of the length to width is at least 5:1 and the ratio of the length to height is at least 5:1). As a further example, in one embodiment, the ratio of each of the length to width and height is at least 10:1 for each of the cathode group units. As a further example, in one embodiment, the ratio of each of the length to width and height is at least 15:1 for each of the cathode group units. As a further example, in one embodiment, the ratio of each of the length to width and height is at least 20:1 for each of the cathode group units.

[0070] In one embodiment, the height to width ratio of each of the cathode group units is at least 0.4:1. For example, in one embodiment, the height to width ratio is at least 2:1 for each of the cathode group units. By way of further example, in one embodiment, the height to width ratio is at least 10:1 for each of the cathode group units. By way of further example, in one embodiment, the height to width ratio is at least 20:1 for each of the cathode group units. Typically, however, the height to width ratio is generally less than 1,000:1 for each of the anode group units. For example, in one embodiment, the height to width ratio is less than 500:1 for each of the cathode group units. By way of further example, in one embodiment, the height to width ratio is less than 100:1 for each of the cathode group units. By way of further example, in one embodiment, the height to width ratio is less than 10:1 for each of the cathode group units. By way of further example, in one embodiment, the height to width ratio is within the range of about 2:1 to about 100:1, respectively, for each unit of the cathode group.

[0071] In one embodiment, the anode current collector 206 also has an electrical conductivity that is substantially greater than the electrical conductivity of the negative electrode active material layer 104. It should be noted that the negative electrode active material layer 104 can be the same as or similar to the anode active material layer 104. For example, in one embodiment, the ratio of the electrical conductivity of the anode current collector 206 to the electrical conductivity of the anode active material layer 104 is at least 100:1 when there is an applied current to store energy in the device or an applied load to discharge the device. By way of further example, in some embodiments, the ratio of the electrical conductivity of the anode current collector 206 to the electrical conductivity of the anode active material layer 104 is at least 500:1 when there is an applied current to store energy in the device or an applied load to discharge the device. By way of further example, in some embodiments, the ratio of the electrical conductivity of the anode current collector 206 to the electrical conductivity of the negative electrode active material layer 104 is at least 1000:1 when there is an applied current to store energy in the device or an applied load to discharge the device. By way of further example, in some embodiments, the ratio of the electrical conductivity of the anode current collector 206 to the electrical conductivity of the anode active material layer 104, when subjected to an applied current to store energy in the device or an applied load to discharge the device, is at least 5000:1. By way of further example, in some embodiments, the ratio of the electrical conductivity of the anode current collector 206 to the electrical conductivity of the anode active material layer 104, when subjected to an applied current to store energy in the device or an applied load to discharge the device, is at least 10,000:1.

[0072] In general, the cathode current collector layer 210 may comprise a metal such as aluminum, carbon, chromium, gold, nickel, NiP, palladium, platinum, rhodium, ruthenium, alloys of silicon and nickel, titanium, or combinations thereof (see "Current collectors for positive electrodes of lithium-based batteries" by A.H. Whitehead and M. Schreiber, Journal of the Electrochemical Society, 152(11) A2105-A2113 (2005)). By way of further example, in one embodiment, the cathode current collector layer 210 comprises gold or an alloy thereof, such as gold silicide. By way of further example, in one embodiment, the cathode current collector layer 210 comprises nickel or an alloy thereof, such as nickel silicide.

[0073] Reference is now made to Figure 3, which is an enlarged, partially detailed perspective view of a battery assembly 300 (which may be the same as or similar to battery assembly 100) before a housing protective layer or outer packaging is placed thereon. Battery assembly 300 includes an electrode assembly 301 including a group of electrode subunits 302 (which may be the same as or similar to subunits 102) configured in a stacked arrangement along a Y-axis. Each of electrode subunits 302 includes at least an electrode current conductor layer, an electrode layer including an electrode active material (e.g., an anode active material layer), a separator layer, a counter electrode layer including a counter electrode active material (e.g., a cathode active material layer), and a counter electrode current collector layer.

[0074] In a preferred embodiment, the electrode assembly 301 is enclosed within a volume defined by a constraint 316 (which in some embodiments may be the same as or similar to the casing 116). In one embodiment, the constraint 316 comprises stainless steel, such as SS316, 440C, or 440C hard. In other embodiments, the constraints are made of aluminum (e.g., aluminum 7075-T6, hard H18, etc.), titanium (e.g., 6Al-4V), beryllium, beryllium copper (hard), copper (O2 free, hard), nickel, other metals or metal alloys, composites, polymers, ceramics (e.g., alumina (e.g., sintered or Coorstek AD96), zirconia (e.g., Coorstek YZTP), yttria stabilized zirconia (e.g., ENrG E-Strate®), glass, tempered glass, polyetheretherketone (PEEK) (e.g., Aptiv 1102), carbon filled PEEK (e.g., Victrex 90HMF40 or Xycomp 1000-04), carbon filled polyphenylene sulfide (PPS) (e.g., Tepex Dynalite 207), 30% glass filled polyetherketone (PEEK), (e.g., Victrex 90 HMF 40 or Xycomp 1000-04), Polyimide (e.g., Kapton®), E Glass Std Fabric / Epoxy, 0°, E Glass UD / Epoxy, 0°, Kevlar Std Fabric / Epoxy, 0°, Kevlar UD / Epoxy, 0°, Carbon Std Fabric / Epoxy, 0°, Carbon UD / Epoxy, 0°, Toyobo Zylon® HM Fiber / Epoxy, Kevlar 49 Aramid Fiber, S Glass Fibers, Carbon Fibers, Vectran UM LCP Fibers, Dyneema, Zylon, or other suitable materials.

[0075] The constraint 316 comprises a first cover 320 (i.e., a first primary growth constraint) generally aligned along the XY plane, and a second cover (i.e., a second primary growth constraint) (not shown in FIG. 3 but substantially similar to the first cover 320 and generally indicated at 322) on the opposite side of the battery assembly 300 separated in the Z-axis direction from the first cover 320 and also generally aligned along the XY plane and having a thickness t1 (FIG. 3A) measured in the Z-axis direction. The thickness (t1) of the constraint 316 may depend on a variety of factors including, for example, the material of construction of the constraint 316, the overall dimensions of the electrode assembly 301, and the composition of the electrodes and counter electrodes. In some embodiments, for example, the constraint 316 comprises a sheet having a thickness t1 in the range of about 10 to about 100 micrometers. For example, in one such embodiment, the constraint 316 comprises a stainless steel sheet (e.g., SS316) having a thickness of about 30 μm. By way of further example, in another embodiment, the constraint 316 comprises an aluminum sheet (e.g., 7075-T6) having a thickness of about 40 μm. By way of further example, in another embodiment, the constraint 316 comprises a zirconia sheet (e.g., Coorstek YZTP) having a thickness of about 30 μm. By way of further example, in another embodiment, the constraint 316 comprises an E Glass UD / Epoxy 0 degree sheet having a thickness of about 75 μm. By way of further example, in another such embodiment, the constraint 316 comprises 12 μm carbon fiber at a packing density of greater than 50%. The first cover 320 and the second cover 322 may each comprise one or more features 315, which may be formed as indentations, through cuts, holes, or the like. In one embodiment, the features 315 facilitate lithiation of the battery assembly 300, for example, from an external lithium foil electrode (not shown). In such an embodiment, the features 315 allow lithium to diffuse therethrough to facilitate prelithiation. In one embodiment, there is a third cover 324 (i.e., a first secondary growth constraint) extending in the XZ plane and an opposing third cover separated in the Y axis direction, and a fourth cover 326 (e.g., a second secondary growth constraint) extending in the XZ plane and an opposing fourth cover separated in the Y axis direction.In the embodiment shown, the third cover 324 is defined by a folded portion of the first cover 320 folded at a first corner 328, and the fourth cover 326 is defined by a folded portion of the second cover 322 folded at a second corner 329. The first and second corners 328 and 329 can be radius or angled corners. In one embodiment, the first and second corners 328 and 329 are at an angle of 90 degrees to 100 degrees. In other embodiments, the third and fourth covers can be a single cover. In one embodiment, the first secondary growth constraint 324 or the first primary growth constraint 320 is connected to a surface (e.g., a top surface) of the electrode or counter electrode structure of the subset of unit cells, and the second primary growth constraint 322 or the second secondary growth constraint 326 is connected to another surface (e.g., a bottom surface) of the electrode or counter electrode structure of the subset of unit cells.

[0076] In one embodiment, the casing edge gap 338 is defined between the third constraint 324 and the fourth constraint 326 with the gap distance defined in the Z-axis direction. In one embodiment, the gap distance of the casing edge gap 338 in the Z-axis direction between the third constraint 324 and the fourth constraint 326 is less than or equal to 50% of the Z-axis thickness of the battery assembly 300. Note that the opposite side of the battery assembly 300 may include constraints similar to the third and fourth constraints 324 and 326. The third constraint includes a flap edge 330 defined along the X-axis and the Z-axis, and the fourth constraint includes a second flap edge 332 defined along the X-axis and the Z-axis.

[0077] Each of the first cover 320 and the second cover 322 may include one or more notches 334 or lands 336 formed along an edge generally aligned with the Y-axis. In an embodiment, one or more of the size, shape, spacing, and amount of the notches 334 or lands 336 are determined based on manufacturing conditions or limitations. In an embodiment, the notches 334 or lands 336 may facilitate manufacturability by facilitating machining, stamping processes, or cutting of the first cover 320 or the second cover 322 from the material stock used in the manufacturing process of the first cover 320 and the second cover 322. In addition, the battery assembly 300 includes a bus bar 310 electrically coupled to one of the electrode subunits 302. Due to the material thickness t1 used for the constraint 316, the constraint includes an edge surface 340 that protrudes from the electrode structure 301 in the Z-axis direction. Similarly, one or more of the flap edges 330 and 332 protrude from the battery assembly 300 in the Y-axis direction. Additionally, the busbars 310 protrude from the sides 344 of the battery in the X-axis direction at busbar edges 342. The protruding edges may potentially create areas of friction or high stress that could puncture the battery's battery package 700 (FIG. 7). These protruding areas may be referred to as potential puncture points because they are more likely to cause a puncture through the outer casing than non-protruding portions.

[0078] To facilitate reducing or eliminating the possibility of a puncture point causing a rupture or puncture of the housing (e.g., outer casing or pouch), a housing protective layer 450 is described with reference to FIG. 4. In one embodiment, a housing protective layer (PPL) 450 is disposed around at least a portion of the periphery of the battery assembly 400 (when moving along the X and Y axes). The battery assembly 400 may be the same as or similar to the battery assembly 300. The PPL 450 has a height PL H and width PL W Prior to attachment to the periphery of the battery assembly 400, the PPL 450 generally has a width PL W Length and height significantly greater than PL HIn an embodiment, the PPL 450 may comprise a polymer such as one or more of polyvinylidene fluoride (PVDF), polyethylene (PE), ethylene acrylic acid (EAA), ethylene methacrylic acid (EMAA), or functional derivatives or copolymers, or combinations thereof. In one embodiment, the polymer used in the PPL 450 is an elastic material. In one embodiment, the PPL height PL H is the height B of the battery assembly 400 in the Z-axis direction H 8, it is noted that the PPL 450 has a thickness t2 in the range of 25 μm to 500 μm, such as 25 μm, 50 μm, 75 μm, 100 μm, 125 μm, 150 μm, 175 μm, 200 μm, 225 μm, 250 μm, 275 μm, 300 μm, 325 μm, 350 μm, 375 μm, 400 μm, 425 μm, 450 μm, 475 μm, 500 μm, etc., prior to attachment to the battery assembly 400.

[0079] With further reference to FIG. 4, the battery assembly 400 has four minor faces F 1~4 and two principal surfaces F 5、6 4, it is noted that major surface F6 is located on the underside of battery assembly 400. In one embodiment, PPL 450 is attached to at least two of minor surfaces F1 and F2 in a manner that covers substantially the entirety of minor surfaces F1 and F2 in the Y-axis and Z-axis directions. In this manner, PPL 450 covers flap edges 330 and 332. Referring to FIGS. 4A and 4B, FIG. 4A is a photograph of surface F1 before attachment of PPL 450, and FIG. 4B is a photograph of the same surface F1 after attachment of PPL 450. In this embodiment, PPL 450 is a transparent layer that includes a polymer.

[0080] 4C and 4D, FIG. 4C is a photograph of surface F2 before application of PPL 450, and FIG. 4D is a photograph of the same surface F2 after application of PPL 450. In this embodiment, PPL 450 is a transparent layer comprising a polymer. In this embodiment, battery assembly 400 includes electrode assembly 401, which may be the same as or similar to electrode assembly 301, and bus bar 410, which may be the same as or similar to bus bars 110, 112.

[0081] The PPL 450 is attached to face F of the battery assembly 400 to cover any of the protrusions 415 that are potential puncture points. 1~6 4E and 4F, the PPL 450 may be attached to one or more of the puncture points PP 1-X 415, thus increasing the radius of curvature on the protrusions 415. Each protrusion 415 is shown to have a puncture point PP 1-x 4F, by covering the puncture point of the protrusion 415 with the PPL 450, the second radius of curvature R2 across the puncture point in the XY plane can be effectively increased compared to the first radius R1, thus reducing the pressure exerted by the puncture point of the protrusion against the housing (e.g., housing layers 500, 600), and thus facilitating the reduction or elimination of punctures into the housing. For example, a series of puncture points PP1-PP X may be a corner, such as an edge of the busbar 110, 112, the current collector tab 120, or the constraint 316.

[0082] In one embodiment, the PPL 450 is initially aligned at a height PL H , thickness t2, and length PL L The battery assembly 400 of the PPL 450 is in the form of an elongated web having a surface F 1~6 Before attachment to the surface, the PPL450 is 1~6For example, in one embodiment, PPL 450 has a length PL substantially equal to the length of face F1 in the Y-axis direction. L After cutting, PPL 450 is placed on face F1 and adhered to face F1 using one or more of heat, pressure, and time. In one preferred embodiment, the use of a heat staking device is utilized to heat stake PPL 450 in the desired location along face F1. In one embodiment, PPL 450 is heat staked to at least 80% or more of the length of face F1. However, in other embodiments, PPL 450 may be heat staked any amount, such as 1%-100% of the length of face F1. In still other embodiments, PPL 450 is heat staked at one or more distinct points along the length of face F1. In some embodiments, depending on the material comprising PPL 450, PPL 450 may be heat staked to face F1 or otherwise adhered without the use of any additional adhesive. However, in other embodiments, an adhesive layer is used between face F1 and PPL 450 to adhere PPL 450 to face F1. In yet another embodiment, PPL 450 is a multi-layer material having at least one adhesive layer adjacent face F1. In a similar manner, PPL 450 may be cut and any or all of faces F1 may be removed using the same or a similar process. 1~6 In yet another embodiment, the PPL 450 may be attached to surface F. 1~4 (e.g., the circumference of the battery assembly 400), and the PPL 450 is then wrapped around the circumference (e.g., the surface F 1~4 Each of which is then glued to such a surface).

[0083] In one embodiment, the height PL H is the height B of the surface of the battery assembly 400 to which the PPL 450 is attached H However, in other embodiments, the height PL H is the height B of the surface of the battery assembly 400 to which it is attached H However, typically, the height PL Hshould be high enough to cover any potential puncture points on such surfaces. In yet another embodiment, the height PL H is the height B of the surface of the battery assembly 400 to which it is attached H In this embodiment, distal edges 801, 802 (FIG. 8) of PPL 450 may cover and contact additional faces of battery assembly 400. For example, in one embodiment, PPL 450 may be adhered to face F1 as described above, but then distal edges 801, 802 are rolled or folded such that they are adhered to at least a portion of faces F5 and F6, respectively (FIG. 9).

[0084] Reference is now made to Figures 5-7. Following attachment of the PPL 450, the battery assembly 400 is placed into a battery package 700 to form a complete battery 760. In an embodiment, the battery package comprises a first housing layer 500 and a second housing layer 600. Each of the first and second housing layers may comprise a flexible or semi-flexible material, such as, for example, aluminum, or a polymer. In one embodiment, one or more of the first and second housing layers 500, 600 comprises a multi-layer aluminum polymer material, plastic, or the like. In one embodiment, one or more of the first and second housing layers 500, 600 comprises a polymer material laminated onto a metal substrate, such as aluminum.

[0085] In the embodiment shown in FIG. 5, the battery assembly 400 is disposed on the first housing layer 500 such that the main surface F6 of the constraint 316 contacts the first housing layer 500. In one embodiment, the battery assembly 400 is disposed in a recess 502 formed in the first housing layer 500. The recess 502 is sized and shaped to match the outer size and shape of the battery assembly 400. In one embodiment, the second housing layer 600 is disposed on top of the battery assembly 400 such that the main surface F5 of the constraint 316 contacts the second housing layer 600. The second housing layer 600 can be positioned (e.g., by movement in the arrangement direction P1) to cover the entire main surface F5 and the recess 502. The conductive terminals 705 and 707 remain uncovered by the first and second housing protective layers 500, 600. After the second housing protective layer 600 is properly positioned, the first and second housing protective layers 500, 600 are sealed along the sealing edge S1 (shown by the dotted line in FIG. 7). In one embodiment, excess material of the first and second housing protective layers 500, 600 may be trimmed before or after sealing. The first and second housing protective layers 500, 600 may be sealed along the sealing edge S1, such as by welding, heat sealing, adhesive, or a combination thereof. In another embodiment, the first and second housing protective layers 500, 600 may be sealed along three sides of the sealing edge S1 to create a pocket therein. In such an embodiment, the battery assembly 400 may be placed in the pocket, and the final edge of the sealing edge S1 is then sealed. In one embodiment, the sealing edge S1 is sealed using a heat press, which applies controlled temperature and pressure to the sealing edge S1 to bond or fuse the first and second housing layers 500, 600 together along the sealing edge S1. In another embodiment, a vacuum is applied to the battery assembly 400 during the sealing process to evacuate any excess volume occupied by air or other gases. The amount of time the sealing edge is exposed to the hot press can be controlled and depends on the materials selected for the first and second housing layers 500, 600. Once sealed onto the battery assembly 400, the sealed first and second housing layers 500, 600 form the battery package 700.Once sealed, the battery package 700 is liquid-tight and / or air-tight, depending on the desired application. Terminals 705, 707 are left exposed and uncovered by the battery package 700 to allow a user to connect the terminals to a powered device or a battery charger.

[0086] The method of the present disclosure (e.g., method 1000 shown in FIG. 10) will be described with reference to FIGS. 1-10. Initially, at 1002, a battery assembly, such as battery assembly 400, including a fabricated electrode assembly is provided. At 1004, a constraint, such as constraint 316, is provided on the electrode assembly, as previously described herein. The electrode assembly and the constraint together define one or more puncture points. To facilitate reducing or eliminating the possibility that the puncture points cause rupture or puncture of the outer casing, a housing protection layer 450 is provided on the puncture points. In one embodiment, a housing protection layer (PPL) 450 is disposed / adhered on at least a portion of the periphery of the battery assembly 400 (moving along the X-axis and Y-axis). The battery assembly 400 may be the same as or similar to the battery assembly 300. Prior to attachment to the periphery of the battery assembly 400, the PPL 450 is attached to the outer casing at a width PL W Length and height significantly greater than PL H The adhesive may be in the form of an elongated web or tape having a

[0087] In one embodiment, the PPL 450 is attached to at least two of the minor surfaces F1 and F2 in a manner that covers substantially the entire Y-axis and Z-axis minor surfaces F1 and F2. The PPL 450 may be attached manually or using an automated machine. In one embodiment, the PPL 450 may be attached to cover the flap edges 330 and 332 of the constraint.

[0088] In an embodiment, the PPL 450 is disposed on face F of the battery assembly 400. 1~6 4E and 4F, the PPL 450 may be attached in such a way that it covers, and thus, the puncture point PP1-X As shown in FIG. 4F, by covering the puncture point with PPL 450, the radius of curvature on the puncture point can be effectively increased, thus reducing the pressure exerted by the puncture point on the housing (e.g., housing layers 500, 600), and thus facilitating the reduction or elimination of punctures on the housing. For example, a series of puncture points PP1-PP X may be a corner, such as an edge of the busbar 110, 112, the current collector tab 120, or the constraint 316.

[0089] In one embodiment, the method 1000 first determines the height PL H , thickness t2, and length PL L In this embodiment, the PPL 450 is attached to one or more faces F of the battery assembly 400. 1~6 Before attaching to the surface, the PPL450 is 1~6 To cover a desired portion of the PPL 450, the PPL 450 may be cut at 1006 to a desired length and / or height by any suitable means, such as using a mechanical device (e.g., a knife), a laser, or a water jet, etc. For example, in one embodiment, the PPL 450 has a length PL substantially equal to the length of the face F1 in the Y-axis direction. LAfter cutting, at 1008, PPL 450 is placed on face F1 and adhered to face F1 using one or more of heat, pressure, and time. In one preferred embodiment, the use of a heat staking device is utilized to heat stake PPL 450 in the desired location along face F1. In one embodiment, PPL 450 is heat staked to at least 80% or more of the length of face F1. However, in other embodiments, PPL 450 may be heat staked any amount, such as 1%-100% of the length of face F1. In still other embodiments, PPL 450 is heat staked at one or more distinct points along the length of face F1. In some embodiments, depending on the material comprising PPL 450, PPL 450 may be heat staked to face F1 or otherwise adhered without the use of any additional adhesive. However, in other embodiments, an adhesive layer is used between face F1 and PPL 450 to adhere PPL 450 to face F1. In a similar manner, PPL450 may be cut and any or all of the faces F removed using the same or similar processes. 1~6 In yet another embodiment, the PPL 450 may be attached to surface F. 1~4 (e.g., the circumference of the battery assembly 400), and the PPL 450 is then cut to a length equal to the sum of the lengths of the 1~4 In yet another embodiment, the PPL 450 comprises a stretchable material and surface F 1~4 4, the PPL 450 is then cut to a length equal to or less than the sum of the lengths of the 1~4 Each of the first and second electrodes is stretch-wrapped around the first and second electrodes and then glued to such surface.

[0090] In one embodiment of the method 1000, the height PL H is the height B of the surface of the battery assembly 400 to which the PPL 450 is attached H However, in other embodiments, the height PL H is the height B of the surface of the battery assembly 400 to which it is attached H However, typically, the height PL Hshould be high enough to cover any potential puncture points on such surfaces. In yet another embodiment, the height PL H is the height B of the surface of the battery assembly 400 to which it is attached H In this embodiment, distal edges 801, 802 (FIG. 8) of PPL 450 may be rolled to contact additional faces of battery assembly 400. For example, in one embodiment, PPL 450 is adhered to face F1 as described above, but then distal edges 801, 802 are rolled or folded such that they are adhered to at least a portion of faces F5 and F6, respectively (FIG. 9).

[0091] Following attachment of the PPL 450, at 1010, the battery assembly 400 is placed into a battery package 700 (e.g., a battery housing) to form a complete battery 760. In an embodiment, the battery package 700 includes a first housing layer 500 and a second housing layer 600. Each of the first and second housing layers may include a flexible or semi-flexible material, such as, for example, aluminum, or a polymer. In one embodiment, one or more of the first and second housing layers 500, 600 includes a multi-layer aluminum polymer material, or plastic, or the like.

[0092] In one embodiment of the method 1000, the battery assembly 400 is placed on the first housing layer 500 such that the main surface F6 of the constraint 316 contacts the first housing layer 500. In one embodiment, the battery assembly 400 is placed in a recess 502 formed in the first housing layer 500. The recess 502 is sized and shaped to match the outer size and shape of the battery assembly 400. In one embodiment, the second housing layer 600 is placed on top of the battery assembly 400 such that the main surface F5 of the constraint 316 contacts the second housing layer 600. The second housing layer 600 can be positioned (e.g., by movement in the placement direction P1) to cover the entire main surface F5 and the recess 502. The conductive terminals 705 and 707 remain uncovered by the first and second housing protection layers 500, 600. After the second housing protective layer 600 is properly positioned, the first and second housing protective layers 500, 600 are sealed along sealing edge S1 (shown by the dotted line in FIG. 7). In one embodiment, excess material of the first and second housing protective layers 500, 600 may be trimmed off before or after sealing.

[0093] In one embodiment, the first and second housing protective layers are then sealed along the sealing edge S1, such as by welding, heat sealing, adhesive, or a combination thereof. In another embodiment, the first and second housing protective layers 500, 600 are sealed along three sides of the sealing edge S1 to create a pocket therein. In such an embodiment, the battery assembly 400 is placed into the pocket, and the final edge of the sealing edge S1 is then sealed. When sealed onto the battery assembly 400, the sealed first and second housing layers 500, 600 define the battery package 700. When sealed, the battery package 700 is liquid-tight and / or air-tight, depending on the desired application. The terminals 705, 707 remain exposed and are not covered by the battery package 700 to allow a user to connect the terminals to a powered device or a battery charger.

[0094] The following embodiments are provided to illustrate aspects of the disclosure, but the embodiments are not intended to be limiting and other aspects and / or embodiments may be provided.

[0095] Embodiment 1. A secondary battery assembly comprising: an electrode assembly having mutually perpendicular lateral, longitudinal, and vertical axes corresponding, respectively, to the X-, Y-, and Z-axes of a three-dimensional Cartesian coordinate system; a constraint disposed on an outer surface of the electrode assembly, wherein at least one of the electrode assembly or the constraint includes a protrusion extending in an XY plane defined by the X- and Y-axes, the protrusion having a first radius of curvature in the XY plane; a battery housing enclosing the electrode assembly and the constraint; and a housing protection layer disposed over at least a portion of the protrusion and between the protrusion and the battery housing, the housing protection layer defining a second radius of curvature that overlaps the first radius of curvature in the XY plane, the second radius of curvature being greater than the first radius of curvature, thereby reducing the likelihood that the protrusion will cause damage to the battery housing.

[0096] Embodiment 2. A secondary battery assembly as described in embodiment 1, wherein the electrode assembly has a rectangular prism shape.

[0097] Embodiment 3. A secondary battery assembly as described in any preceding embodiment, wherein the electrode assembly is enclosed within a volume defined by a constraint, the constraint including a first primary growth constraint in contact with at least one surface of an electrode or counter-electrode of the electrode assembly, the first primary growth constraint defining a protrusion.

[0098] Embodiment 4. A secondary battery assembly as described in any preceding embodiment, wherein the constraint further comprises a second primary growth constraint spaced apart from the first primary growth constraint, the second primary growth constraint in contact with a different surface of an electrode or counter-electrode of the electrode assembly.

[0099] Embodiment 5. A secondary battery assembly as in any preceding embodiment, wherein the constraint further comprises a first secondary growth constraint in contact with a second surface of the electrode or counter-electrode of the electrode assembly.

[0100] Embodiment 6. A secondary battery assembly as described in any preceding embodiment, wherein the constraint further comprises a second secondary growth constraint spaced apart from the first secondary growth constraint and in contact with a third surface of the electrode or counter-electrode of the electrode assembly.

[0101] Embodiment 7. The secondary battery assembly of any preceding embodiment, further comprising a first busbar and a second busbar, wherein a portion of the first busbar or the second busbar defines a protrusion.

[0102] Embodiment 8. A secondary battery assembly as described in any preceding embodiment, wherein a housing protection layer is disposed on at least one of the first bus bar and the second bus bar.

[0103] Embodiment 9. A secondary battery assembly as described in any preceding embodiment, wherein the housing protective layer comprises a polymer.

[0104] Embodiment 10. A secondary battery assembly as described in any preceding embodiment, wherein the polymer comprises at least one of polyvinylidene fluoride (PVDF), polyethylene (PE), ethylene acrylic acid (EAA), ethylene methacrylic acid (EMAA), or functional derivatives or copolymers thereof.

[0105] Embodiment 11. A secondary battery assembly as described in any preceding embodiment, wherein the electrode assembly comprises a rectangular prism shape having six rectangular sides, the constraint comprising a first cover in contact with at least three of the rectangular sides and a second cover spaced from the first cover in contact with at least three of the rectangular sides, and the constraint defines a protrusion.

[0106] Embodiment 12. A secondary battery assembly as described in embodiment 11, wherein the first cover is provided with a group of through holes extending through the entire height dimension of the first cover, at least a portion of the through holes defining a protrusion.

[0107] Embodiment 13. A secondary battery assembly as described in any preceding embodiment, wherein the second cover includes a group of through holes extending through the entire height dimension of the second cover, and at least a portion of the through holes in the second cover define a protrusion.

[0108] Embodiment 14. A secondary battery assembly as described in any preceding embodiment, wherein the housing protective layer substantially covers at least two of the rectangular faces.

[0109] Embodiment 15. A secondary battery comprising: an electrode assembly having mutually perpendicular lateral, longitudinal, and vertical axes corresponding, respectively, to the X-, Y-, and Z-axes of a three-dimensional Cartesian coordinate system; a constraint defining a volume within which the electrode assembly is contained, wherein at least one of the electrode assembly or the constraint defines at least one protrusion extending in an XY plane defined by the X- and Y-axes, the protrusion having a first radius of curvature in the XY plane; and a housing protection layer disposed over at least a portion of the protrusion and between the protrusion and a battery housing, the housing protection layer defining a second radius of curvature that overlaps the first radius of curvature in the XY plane, the second radius of curvature being greater than the first radius of curvature, thereby reducing the likelihood that the protrusion will cause damage to the battery housing; wherein the battery housing encapsulates the electrode assembly, the constraint, and the housing protection layer, and at least a portion of the battery housing is in direct contact with the housing protection layer.

[0110] Embodiment 16. A secondary battery as described in embodiment 15, wherein the housing protection layer is heat staked to at least one of the electrode assembly or the constraint.

[0111] 17. The secondary battery of any preceding embodiment, wherein the housing protective layer comprises at least one of polyvinylidene fluoride (PVDF), polyethylene (PE), ethylene acrylic acid (EAA), ethylene methacrylic acid (EMAA), or functional derivatives or copolymers thereof.

[0112] Embodiment 18. The secondary battery of any preceding embodiment, wherein the battery housing comprises aluminum.

[0113] Embodiment 19. A secondary battery according to any preceding embodiment, wherein the electrode assembly is a rectangular prism shape having at least six rectangular faces, and a housing protection is subsequently disposed on at least four of the rectangular faces.

[0114] Embodiment 20. The secondary battery of any preceding embodiment, wherein the housing protective layer has a thickness of 25 μm to 500 μm.

[0115] Embodiment 21. A secondary battery as described in any preceding embodiment, wherein the height of the housing protective layer measured in the Z-axis direction is substantially equal to the height of the electrode assembly measured in the Z-axis direction.

[0116] Embodiment 22. The secondary battery of any preceding embodiment, wherein the housing protection layer is heat staked along at least 80% of the length of the housing protection layer measured in the x-axis direction.

[0117] Embodiment 23. The secondary battery of any preceding embodiment, wherein the housing protective layer is heat staked along at least 95% of the length measured in the X-axis direction of the housing protective layer.

[0118] Embodiment 24. An electrode assembly comprising: (a) silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (Co), and cadmium (Cd); (b) an alloy or intermetallic compound of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, or Cd with other elements; and (c) an alloy or intermetallic compound of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Fe, Ni, Co, V, or Cd. 4. The secondary battery of any preceding embodiment, comprising an anode active material selected from the group consisting of oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides, and mixtures, composites, or lithium-containing composites thereof; (d) salts and hydroxides of Sn; (e) lithium titanate, lithium manganate, lithium aluminate, lithium-containing titanium oxides, lithium transition metal oxides, ZnCo2O4; (f) particles of graphite and carbon; (g) lithium metal; and (h) combinations thereof.

[0119] Embodiment 25. The secondary battery of any preceding embodiment, wherein the electrode assembly comprises an anode active material selected from the group consisting of silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (Co), and cadmium (Cd).

[0120] Embodiment 26. The secondary battery of any preceding embodiment, wherein the electrode assembly comprises an anode active material selected from the group consisting of alloys and intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, or Cd with other elements.

[0121] Embodiment 27. The secondary battery of any preceding embodiment, wherein the electrode assembly comprises an anode active material selected from the group consisting of oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Fe, Ni, Co, V, and Cd.

[0122] Embodiment 28. The secondary battery of any preceding embodiment, wherein the electrode assembly comprises an anode active material selected from the group consisting of oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Si.

[0123] Embodiment 29. The secondary battery of any preceding embodiment, wherein the electrode assembly comprises an anode active material selected from the group consisting of silicon and oxides and carbides of silicon.

[0124] Embodiment 30. A secondary battery according to any preceding embodiment, wherein the electrode assembly comprises an anode active material comprising metallic lithium.

[0125] Embodiment 31. The secondary battery of any preceding embodiment, wherein the electrode assembly comprises an anode active material selected from the group consisting of graphite and carbon.

[0126] Embodiment 32. A secondary battery according to any preceding embodiment, wherein the secondary battery further comprises a non-aqueous organic electrolyte within the housing.

[0127] Embodiment 33. The secondary battery of any preceding embodiment, wherein within the housing, the secondary battery further comprises a non-aqueous electrolyte comprising a mixture of a lithium salt and an organic solvent.

[0128] Embodiment 34. A secondary battery according to any preceding embodiment, wherein the secondary battery further comprises a polymer electrolyte within the housing.

[0129] Embodiment 35. The secondary battery of any preceding embodiment, wherein the secondary battery further comprises a solid electrolyte within the housing.

[0130] Embodiment 36. The secondary battery of any preceding embodiment, wherein within the housing, the secondary battery further comprises a solid electrolyte selected from the group consisting of sulfide-based electrolytes.

[0131] Embodiment 37. A secondary battery is disposed in a housing, the secondary battery being a lithium tin sulfide (Li 10 SnP2S12 ), lithium phosphorus sulfide (β-Li3PS4), and lithium phosphorus sulfide iodide (Li6PS5Cl 0.9 I 0.1 4. The secondary battery of any preceding embodiment, further comprising a solid electrolyte selected from the group consisting of:

[0132] Embodiment 38. A secondary battery according to any preceding embodiment, wherein the secondary battery further comprises a polymer-based electrolyte within the housing.

[0133] Embodiment 39. The secondary battery of any preceding embodiment, wherein within the housing, the secondary battery further comprises a polymer electrolyte selected from the group consisting of PEO-based polymer electrolyte, polymer ceramic composite electrolyte (solid), polymer ceramic composite electrolyte, and polymer ceramic composite electrolyte.

[0134] Embodiment 40. The secondary battery of any preceding embodiment, wherein within the housing, the secondary battery further comprises a solid electrolyte selected from the group consisting of oxide-based electrolytes.

[0135] Embodiment 41. A secondary battery is installed in the housing. The secondary battery is a lithium lanthanum titanate (Li 0.34 La 0.56 TiO3), Al-doped lanthanum zirconate lithium (Li 6.24 La3Zr2Al 0.24 O 11.98 ), Ta-doped lithium lanthanum zirconate (Li 6.4 La3Zr 1.4 Ta 0.6 O 12 ), and lithium aluminum titanium phosphate (Li 1.4 Al 0.4 Ti 1.6 3. The secondary battery of any preceding embodiment, further comprising a solid electrolyte selected from the group consisting of: (PO4)3).

[0136] Embodiment 42. The secondary battery of any preceding embodiment, wherein one of the electrode active material and counter electrode material of the electrode assembly is a cathode active material selected from the group consisting of intercalation chemistry positive electrodes and conversion chemistry positive electrodes.

[0137] Embodiment 43. The secondary battery of any preceding embodiment, wherein one of the electrode active material and counter electrode material of the electrode assembly is a cathode active material comprising an intercalation chemistry positive electrode material.

[0138] Embodiment 44. The secondary battery of any preceding embodiment, wherein one of the electrode active material and counter electrode material of the electrode assembly is a cathode active material comprising a conversion chemistry positive electrode active material.

[0139] Embodiment 45. One of the electrode active material and counter electrode material of the electrode assembly is S (or Li2S in the lithiated state), LiF, Fe, Cu, Ni, FeF2, FeO d F 3.2d , FeF3, CoF3, CoF2, CuF2, NiF2, where 0≦d≦0.5.

[0140] Embodiment 46. A method of making a battery assembly for use with a secondary battery, the method comprising: making an electrode assembly having mutually perpendicular lateral, longitudinal, and vertical axes corresponding to the X-, Y-, and Z-axes, respectively, of a three-dimensional Cartesian coordinate system; and disposing the electrode assembly within a volume defined by the constraint such that the constraint is disposed on an outer surface of the electrode assembly, wherein at least one of the electrode assembly or the constraint has at least one protruding portion extending in an XY plane defined by the X- and Y-axes. and disposing an electrode assembly, the electrode assembly, the constraint, and the housing protection layer over at least a portion of the protrusion, the housing protection layer defining a second radius of curvature that overlaps the first radius of curvature in the XY plane, the second radius of curvature being greater than the first radius of curvature, thereby reducing a likelihood that the protrusion will cause damage to the battery housing. encapsulating the electrode assembly, the constraint, and the housing protection layer within a battery housing such that the housing protection layer is disposed between the constraint and the battery housing.

[0141] Embodiment 47. The method of embodiment 46, wherein adhering comprises applying heat to the housing protective layer.

[0142] Embodiment 48. The method of embodiment 47, wherein adhering a housing protective layer over at least one protrusion includes increasing a radius over at least one potential puncture point of the protrusion.

[0143] Embodiment 49. The method of any preceding embodiment, wherein adhering a housing protection layer over the at least one protrusion includes extending the housing protection layer over at least four sides of the electrode assembly.

[0144] Embodiment 50. A method of manufacturing a secondary battery, comprising: preparing an electrode assembly having mutually perpendicular lateral, longitudinal, and vertical axes corresponding to the X-, Y-, and Z-axes, respectively, of a three-dimensional Cartesian coordinate system; and disposing the electrode assembly within a volume defined by the constraint such that the constraint is disposed on an outer surface of the electrode assembly, wherein at least one of the electrode assembly or the constraint defines at least one protrusion extending in an XY plane defined by the X- and Y-axes, and the protrusion defines a first half of curvature in the XY plane. a first radius of curvature in an XY plane, the second radius of curvature being greater than the first radius of curvature, thereby reducing a likelihood that the protrusion will cause damage to the battery housing; encapsulating the electrode assembly, the constraint, and the housing protection layer within a battery housing such that the housing protection layer is disposed between the constraint and the battery housing; and vacuum sealing the battery housing.

[0145] Embodiment 51. The method of embodiment 50, wherein the housing protection layer comprises at least one of polyvinylidene fluoride (PVDF), polyethylene (PE), ethylene acrylic acid (EAA), ethylene methacrylic acid (EMAA), or functional derivatives or copolymers thereof, and the adhering comprises applying heat to the housing protection layer.

[0146] Embodiment 52. The method of any preceding embodiment, wherein the bonding comprises heat staking the housing protective layer along at least 80% of the length of the housing protective layer measured in the X-axis direction.

[0147] Embodiment 53. The method of any preceding embodiment, wherein adhering includes applying heat and pressure to the housing protective layer.

[0148] Embodiment 54. A secondary battery, comprising an electrode assembly having mutually perpendicular lateral, longitudinal, and vertical axes corresponding to the X-axis, Y-axis, and Z-axis, respectively, of a three-dimensional Cartesian coordinate system, the electrode assembly comprising a group of unit cells, an electrode bus bar, and a counter electrode bus bar, a constituent unit of the group of unit cells comprising an electrode structure, a separator structure, and a counter electrode structure, (a) the electrode structure comprising an electrode active material layer and an electrode current collector, (b) the counter electrode current collector comprising a counter electrode active material layer and a counter electrode current collector, the electrode structure being electrically connected in parallel to the electrode bus bar via the electrode current collector, and the counter electrode structure being electrically connected in parallel to the counter electrode bus bar via the counter electrode current collector, and the electrode assembly is contained therein. 1. A secondary battery comprising: a constraint defining a volume, wherein at least one of the electrode assembly or the constraint defines at least one protrusion extending in an XY plane defined by an X-axis and a Y-axis, the protrusion having a first radius of curvature in the XY plane; and a housing protection layer disposed over at least a portion of the protrusion and between the protrusion and a battery housing, the housing protection layer defining a second radius of curvature that overlaps the first radius of curvature in the XY plane, the second radius of curvature being greater than the first radius of curvature, thereby reducing a likelihood that the protrusion will cause damage to the battery housing, wherein the battery housing encloses the electrode assembly, the constraint, and the housing protection layer, and at least a portion of the battery housing is in direct contact with the housing protection layer.

[0149] Embodiment 55. An electrode assembly as described in embodiment 54, wherein the electrode assembly has a first longitudinal end face and a second longitudinal end face separated from each other in the longitudinal direction, and a side face surrounding the electrode assembly longitudinal axis and connecting the first and second longitudinal end faces, and wherein groups of unit cells are stacked in series in the longitudinal direction.

[0150] Embodiment 56. An electrode assembly according to any preceding embodiment, wherein the electrode assembly has a prismatic shape.

[0151] Embodiment 57. An electrode assembly as described in any preceding embodiment, wherein the constraints comprise (i) first and second primary growth constraints separated in the longitudinal direction, and (ii) first and second secondary growth constraints separated in the vertical direction and connecting the first and second primary growth constraints, (iii) the first secondary growth constraint is further connected to an upper end surface of an electrode or counter electrode structure of a subset of the unit cells, and (iv) the second secondary growth constraint is further connected to a lower end surface of an electrode or counter electrode structure of a subset of the unit cells.

[0152] This written description uses examples to disclose the invention, including the best mode, and also enables any person skilled in the art to practice the invention, including making and using any device or system, and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal words of the claims, or if they include equivalent structural elements with differences that do not substantially differ from the literal words of the claims.

Claims

1. A device for storing energy, comprising: an electrode assembly having mutually perpendicular lateral, longitudinal and vertical axes corresponding respectively to the X-, Y- and Z-axes of a three-dimensional Cartesian coordinate system; the electrode assembly includes at least one protrusion extending in an XY plane defined by the X-axis and the Y-axis, the protrusion having a first radius of curvature in the XY plane; a housing enclosing the electrode assembly; a protective layer disposed over at least a portion of the at least one protrusion and between the at least one protrusion and the housing, the protective layer having a second radius of curvature that overlaps the first radius of curvature in the XY plane, the second radius of curvature being greater than the first radius of curvature, thereby reducing a likelihood that the at least one protrusion will cause damage to the housing.

2. The at least one protrusion includes at least one busbar corner coupled to the electrode assembly, a collector tab of the electrode assembly, and / or a constraining edge configured to constrain the electrode assembly. The device of claim 1 .

3. The tab of the current collector tab is folded over against the current collector to which it is coupled. The device of claim 2.

4. The electrode assembly includes a current collector having the current collector tab, the current collector tab configured to operably couple to at least one bus bar. The device of claim 2.

5. The current collector tab is welded to the current collector tab. The device of claim 4.

6. The current collector tabs are a group of electrode current collector tabs and a group of counter electrode current collector tabs, the at least one busbar includes an electrode busbar and a counter electrode busbar, the group of electrode current collector tabs are configured to operably couple with the electrode busbar, and the group of counter electrode current collector tabs are configured to operably couple with the counter electrode busbar. The device of claim 4.

7. The current collector tab is an electrode current collector tab, and the at least one bus bar is an electrode bus bar. The device of claim 6.

8. The electrode assembly according to claim 1, wherein the electrode assembly is operatively coupled to an outer surface of the electrode assembly, the electrode assembly being disposed in the housing. The device of claim 2.

9. The method of claim 1, wherein the constraint comprises a composite, an elemental metal, a metal alloy, a polymer, or a ceramic. The device of claim 2.

10. The constraint has a first cover opposite a second cover, and the electrode assembly is disposed between the first cover and the second cover. The device of claim 2.

11. The constraint has a curved perforation. The device of claim 2.

12. The electrode assembly has a rectangular prism shape having six sides, and the constraint includes a first cover in contact with at least three of the six sides, and a second cover spaced apart from the first cover in contact with at least three other of the six sides. The device of claim 2.

13. The electrode assembly has a face type with a maximum surface area, and the protective layer is disposed on at least one side of the electrode assembly that is different from the face type with the maximum surface area. The device of claim 1 .

14. The protective layer comprises and / or is in the form of a web or tape. The device of claim 1 .

15. The protective layer comprises a polymer and / or an elastomeric material. The device of claim 1 .

16. The electrode assembly having an anode active material comprising silicon. The device of claim 1 .

17. The electrode assembly, comprising an anode active material comprising a silicon and carbon composite. The device of claim 1 .

18. The electrode assembly is configured for use with lithium ions. The device of claim 1 .

19. The electrode assembly, wherein the electrode assembly is configured for use as a secondary battery. The device of claim 1 .

20. The protective layer is configured to reduce or eliminate the possibility of puncturing the housing, and the housing is a pouch. The device of claim 1 .

21. The electrode assembly having a rectangular prism shape. The device of claim 1 .

22. The protective layer is heat staked to at least one of the electrode assembly and a constraint operatively coupled to the electrode assembly. The device of claim 1 .

23. The protective layer has a uniform thickness. The device of claim 1 .

24. The electrode assembly has a group of anodes and a group of cathodes, each cathode of the group of cathodes and each anode of the group of anodes has a height of 0.05 mm to 25 mm, a length of 5 to 500 mm, and a width of 0.01 mm to 2.5 mm, a subunit of the electrode assembly has the cathode and the anode, and the electrode assembly has 1 to 200 or more of the subunits. The device of claim 1 .

25. The electrode assembly has a group of anodes and a group of cathodes, each cathode in the group of cathodes having a height to width aspect ratio of at least 0.4:1 or having a large height relative to its width, each anode in the group of anodes having a height to width aspect ratio of less than 1000:1, each of the anodes having a length to width and height aspect ratio of at least 5:1, and / or each of the cathodes having a length to width and height aspect ratio of at least 5:1, a subunit of the electrode assembly comprises the anode and the cathode, and the electrode assembly has 1 to 200 or more of the subunits. The device of claim 1 .

26. A method for storing energy, comprising manufacturing a device as described in any one of claims 1 to 25, prelithiating the device, and / or using the device.

27. The method of claim 20, wherein manufacturing the device includes machining, stamping, cutting, gluing, separating, sealing, evacuating gases, rolling, drilling, folding, laser, heating, pressing, or a combination thereof.

27. The method of claim 26.

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