Spacer member in an electrochemical battery

Abstract

The secondary battery includes an electrode assembly disposed within the constraint. The electrode assembly includes a population of unit cells including, in stacked series, an electrode current collector layer, an electrode layer, a separator layer, a counter electrode layer, and a counter electrode current collector layer. A subset of the unit cell population includes a spacer member stretched between the electrode current collector layer and the counter electrode current collector layer. One of the spacer members is laterally spaced from the other stretched spacer member, and at least a portion of the counter electrode active material of the counter electrode layer is located between the spacer members such that the portion of the counter electrode active material and the spacer member lie in a common plane defined by the x-axis and the z-axis, and each of the stretched spacer members extends a distance SD in the x-axis direction beyond the x-axis edge of the constraint.

Description

[Technical field]

[0001] The field of the disclosure relates generally to energy storage technology, such as battery technology, and more specifically to spacers for providing protection for battery enclosures, systems and methods therefor. [Background technology]

[0002] 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.

[0003] Known energy storage devices, such as batteries, fuel cells, and electrochemical capacitors, typically have two-dimensional layered architectures, such as planar or spiral-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).

[0004] Three-dimensional secondary batteries may offer increased capacity and life span compared to layered secondary batteries, however, fabrication of such three-dimensional secondary batteries presents manufacturing and cost challenges.

[0005] During the manufacturing process of some secondary batteries, an enclosure is placed over the internal components. In some cases, the enclosure comes into contact with the edges of the internal components, causing wear or rupture to the enclosure, which may reduce the performance of the battery or, in the worst case, may cause a failure or short circuit condition of the battery. Therefore, it would be desirable to fabricate secondary batteries while addressing the problems of the known art. Summary of the Invention

[0006] In one embodiment, a secondary battery for cycling between charged and discharged states is disclosed, the battery comprising a constraint and an electrode assembly disposed within the constraint, the electrode assembly having mutually perpendicular transverse, longitudinal and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system, the electrode assembly comprising a collection of unit cells comprising longitudinally successively stacked electrode current collector layers, electrode layers, separator layers, counter electrode layers and counter electrode current collector layers, the electrode layers comprising an electrode active material, the counter electrode layers comprising a counter electrode active material, one of the electrode active material and the counter electrode material being a cathode active material and the other of the electrode active material and the counter electrode material being a cathode active material. is an anode active material, and the subset of the unit cell population further comprises a pair of elongated spacer members located in stacked series between the electrode current collector layer and the counter electrode current collector layer, one of the spacer members being laterally spaced from the other elongated spacer member, at least a portion of the counter electrode active material of the counter electrode layer being located between the spacer members such that the portion of the counter electrode active material and the spacer members are in a common plane defined by the x-axis and z-axis, and each of the elongated spacer members extends a distance SD in the x-axis direction beyond the x-axis edge of the constraint.

[0007] In another embodiment, a method of manufacturing a battery assembly for use with a secondary battery is disclosed. The battery assembly has mutually perpendicular horizontal, longitudinal, and vertical axes corresponding to the x, y, and z axes, respectively, of a three-dimensional Cartesian coordinate system. The method includes preparing a unit cell by stacking an electrode current collector layer, an electrode layer, a separator layer, a counter electrode layer, and a counter electrode current collector layer in a longitudinally successive manner, where the electrode layer includes an electrode active material, the counter electrode layer includes a counter electrode active material, one of the electrode active material and the counter electrode material is a cathode active material, and the other of the electrode active material and the counter electrode material is an anode active material, and disposing a group of stacked successively stretched spacer members between the electrode current collector layer and the counter electrode current collector layer, where one of the stretched spacer members is spaced apart in a y-axis direction from the other spacer member, and where the x-axis extent of the stretched spacer member is a distance SD that is greater than the x-axis extent of the unit cell.

[0008] In yet another embodiment, an electrode assembly for a secondary battery has mutually perpendicular horizontal, longitudinal and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system. The electrode assembly includes a unit cell including an electrode current collector layer, an electrode layer, a separator layer, a counter electrode layer and a counter electrode current collector layer in longitudinal succession, the electrode layer including an electrode active material, the counter electrode layer including a counter electrode active material, one of the electrode active material and the counter electrode material being a cathode active material and the other of the electrode active material and the counter electrode material being an anode active material, and a collection of stretched spacer members between the electrode current collector layer and the counter electrode current collector layer, one of the stretched spacer members being spaced apart from the other spacer member in the y-axis direction, the x-axis extent of the stretched spacer members being a distance SD greater than the x-axis extent of the unit cell.

[0009] In yet another embodiment, a method of manufacturing an electrode assembly for a secondary battery is disclosed. The electrode assembly has mutually perpendicular horizontal, longitudinal and vertical axes corresponding to the x, y and z axes, respectively, of a three-dimensional Cartesian coordinate system. The method includes preparing a unit cell by stacking an electrode current collector layer, an electrode layer, a separator layer, a counter electrode layer and a counter electrode current collector layer in a longitudinally sequential manner, the electrode layer including an electrode active material, the counter electrode layer including a counter electrode active material, one of the electrode active material and the counter electrode material being a cathode active material and the other of the electrode active material and the counter electrode material being an anode active material, disposing a collection of stretched spacer members between the electrode current collector layer and the counter electrode current collector layer, one of the stretched spacer members being spaced apart from the other spacer member in the y-axis direction, and disposing the unit cell within the constraint such that the x-axis extent of the stretched spacer members is a distance SD that is greater than the x-axis extent of the constraint. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 is a front perspective view of one preferred embodiment of a battery assembly having a cutout portion prior to application of an enclosure according to the present disclosure. [Figure 2A] 2 is a cross-sectional view taken from section line DD of the electrode assembly of FIG. 1 without the extended spacer. [Figure 2B] 2 is a cross-sectional view taken from section line DD of the electrode assembly of FIG. 1 having an extended spacer in accordance with an embodiment of the present disclosure. [Figure 2C] 2 is a cross-sectional view taken from section line DD of the electrode assembly of FIG. 1 having an extended spacer in accordance with an embodiment of the present disclosure. [Diagram 3] FIG. 2 is an enlarged partial perspective view of a battery assembly within a constraint according to the present disclosure. [Figure 4A] FIG. 1 is a partial view of a battery assembly without an extended spacer. [Figure 4B]FIG. 2 is a partial view of a battery assembly including an extended spacer according to an embodiment of the present disclosure. [Diagram 5] FIG. 2 is a perspective view of a battery assembly partially disposed within a battery enclosure. [Figure 6] FIG. 6 is a perspective view of the battery assembly of FIG. 5 including a second cover for the battery enclosure. [Figure 7] FIG. 2 is a front view of the completed battery after being sealed in the battery enclosure. [Figure 8] FIG. 2 is a perspective view of a spacer member according to an embodiment of the present disclosure. [Figure 9] 1A-1C are schematic diagrams of a method of preparing a battery assembly including an extended spacer member according to an embodiment of the present disclosure.

[0011] definition As used herein, "a," "an," and "the" (i.e., singular) refer to plural references 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.

[0012] As used herein, "about" and "approximately" refer to plus or minus 10%, 5%, or 1% of the stated value. For example, in one example, about 250 μm would include 225 μm to 275 μm. As a further example, in one example, about 1,000 μm would include 900 μm to 1,100 μm. Unless otherwise indicated, all numbers expressing quantities (e.g., measurements, and the like) and the like used in the specification and claims are to be understood as being modified in all instances by the term "about". Thus, unless otherwise 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.

[0013] "Anode" as used herein in the context of a secondary battery refers to the negative electrode in the secondary battery.

[0014] As used herein, "anode material" or "anode active" means a material suitable for use as the negative electrode of a secondary battery.

[0015] "Cathode" as used herein in the context of a secondary battery refers to the positive electrode in the secondary battery.

[0016] As used herein, "cathode material" or "cathode active" means a material suitable for use as the positive electrode of a secondary battery.

[0017] "Conversion chemically active material" or "conversion chemistry" refers to a material that undergoes a chemical reaction during the charge and discharge cycle of a secondary battery.

[0018] As used herein, "counter electrode" may refer to the negative or positive electrode (anode or cathode) opposite an electrode of a secondary battery, unless the context clearly indicates otherwise.

[0019] In the context of cycling a secondary battery between a charging state and a discharging state, "cycling" as used herein refers to charging and / or discharging the battery to move the battery in a cycle 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., a charging state if the first state was discharged, or a discharging state if the first state was charged), 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 a discharging state to a charging state and then returning to the discharging state to complete the cycle, as in a charging cycle. A single cycle can also include discharging the battery from a charging state to a discharging state and then charging back to a charging state to complete the cycle, as in a discharging cycle.

[0020] As used herein, "electrochemically active material" means an anode active material or a cathode active material.

[0021] As used herein, "electrode" may refer to either the negative or positive electrode (anode or cathode) of a secondary battery, unless the context clearly indicates otherwise.

[0022] As used herein, an "electrode current collector layer" can refer to an anode (eg, negative) current collector layer or a cathode (eg, positive) current collector layer.

[0023] As used herein, "electrode material" may refer to either an anode material or a cathode material, unless the context clearly indicates otherwise.

[0024] As used herein, "electrode structure" may refer to an anode structure (e.g., anode structure) or a cathode structure (e.g., cathode structure) adapted for use in a battery, unless the context clearly indicates otherwise.

[0025] As used herein, "longitudinal axis", "transverse axis", and "vertical axis" refer to mutually perpendicular axes (i.e., each perpendicular to the other). For example, "longitudinal axis", "transverse axis", and "vertical axis" as used herein are akin 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, the axes may be interchangeable when referring to 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 scoring, cutting, perforating, or the like, 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

[0026] This application claims priority to U.S. Provisional Patent Application No. 63 / 210,773, filed June 15, 2021, the disclosure of which is incorporated by reference in its entirety.

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

[0028] One preferred embodiment of a battery assembly generally designated 100 is described with reference to FIG. 1. As shown in FIG. 1, the battery assembly 100 includes a collection of adjacent electrode subunits 102. Each electrode subunit 102 has an X-axis, a Y-axis, and a Z-axis dimension, 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 in the Z-axis may be referred to as the "height," the X-axis dimension may be referred to as the "length," and the Y-axis dimension may be referred to as the "width." Each electrode subunit 102 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 one another by a separator layer 108. It should be understood that in suitable and 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 cathode active layer 106 of each electrode subunit 102, respectively, via electrode tabs 114. Thus, the bus bar 110 seen in FIG. 1 may be referred to as the anode bus bar, and the bus bar 112 may be referred to as the cathode bus bar. In one embodiment, a constraint 116 may be applied to one or both of the XY surfaces of the battery assembly 100. In the embodiment shown in FIG. 1 , the constraint 116 includes a population of perforations 118 to facilitate distribution or flow of the 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 may 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) and an electrochemically active material layer (i.e., a layer of anode active material or a layer of cathode active material) on at least one major surface thereof, while in other embodiments, one or more of the anode active layer and the cathode active layer may be a single layer of a suitable material.

[0031] 2A-2C, the individual layers of the electrode subunits 102 are described. For each of the electrode subunits 102, in some embodiments, the separator layer is an ion-permeable polymer woven material suitable for use as a separator in a secondary battery. A cross-sectional view of one embodiment of a unit cell 200 that may comprise one or more subunits 102 is shown in FIG. 2A. In this embodiment, the electrode unit cell 200 comprises a central anode current collector layer 206, anode active material layer 104 in a stacked configuration, a separator 108, a cathode active material layer 106, and a cathode current collector layer 210. In an alternative embodiment, the arrangement of the cathode active material layer 106 and the anode active material layer 104 may be swapped such that the cathode active material layer(s) 106 are toward the center and the anode active material layer(s) are distal to the cathode active material layer 106. In one embodiment, unit cell 200A includes, in stacked sequence from right to left in the illustration of Figure 2A, 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. In an alternative embodiment, unit cell 200B includes, in stacked sequence (from left to right in the illustration of Figure 2A), a separator 108, a first layer of cathode active material layers 106, a cathode current collector 210, a second layer of cathode active material layers 106, a separator 108, a first layer of anode active material layers 104, an anode current collector 206, a second layer of anode active material layers 104, and a separator 108.

[0032] In one embodiment, the anode current collector layer 206 may include a conductive metal such as copper, a copper alloy, 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 and second opposing surfaces may be referred to as the major surfaces, or front and back surfaces, of the layer. As used herein, a major surface refers to a surface defined by a plane formed by the length of the material in the X-axis direction (not shown in FIG. 2A) and the height of the material in the Z-axis direction.

[0033] In one embodiment, the anode active material layer(s) 104 may each have a thickness of at least about 10 um. For example, in one embodiment, the anode active material layer(s) 104 (each) have a width in the Y-axis direction of at least about 40 um. By way of further example, in one such embodiment, the anode active material layer(s) (each) have a width of 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. In this specification, the terms thickness and width may be used interchangeably to refer to measurements in the Y-axis direction.

[0034] Generally, negative electrode active materials (e.g., positive electrode active materials) include any of the following: (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; (c) Si, Ge, Sn, Pb, Sb, Bi, Zn, The lithium-containing oxide may be selected from the group consisting of oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Al, Ti, Fe, 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) particles of graphite and carbon; (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 alloy 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 an 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 includes 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 incorporated into or depart from the anode active material during charge and discharge processes. In general, the void volume fraction of each of the anode active material layer(s) 104 is at least 0.1. Typically, however, the void volume fraction of each of the anode active material layer(s) is 0.8 or less. For example, in one embodiment, the void volume fraction of each of the anode active material layer(s) 104 is between about 0.15 and about 0.75. By way of further example, in one embodiment, the void volume fraction of (each of) the anode active material layer(s) 104 is between about 0.2 and about 0.7. By way of further example, in one embodiment, the void volume fraction of each of the anode active material layer(s) 104 is between about 0.25 and about 0.6.

[0037] Depending on the composition of the microstructured anode active material and its method of 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 1-50 micrometers, and pore morphologies characterized by a generally "spongy" and irregular appearance, non-smooth walls, and branched pores. Mesoporous materials are typically characterized by pore dimensions of 10-50 nm, wall dimensions of 10-50 nm, pore depths of 1-100 micrometers, and pore morphologies characterized by more or less 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 morphology that can be smooth-walled or rough-walled. In addition, 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 negative electrode active material includes porosity with openings at the lateral surfaces of the negative electrode active material through which lithium ions (or other carrier ions) can enter and exit the positive electrode active material, e.g., lithium ions can enter the positive electrode active material through the porosity openings after exiting the negative electrode active material. In another embodiment, the void volume includes closed porosity, i.e., the positive electrode active material includes porosity surrounded by the positive electrode active material. In general, open porosity can provide a larger interfacial surface area for carrier ions, while closed porosity tends to be less susceptible to solid electrolyte interfaces, each providing room for expansion of the positive electrode active material upon ingress of carrier ions. Thus, in certain embodiments, it is preferred that the anode active material contain 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 may be formed, for example, by anodization, by etching (e.g., by depositing a noble 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. In addition, 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 such embodiment, the anode active material comprises a porous silicon alloy (such as 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 fibers of aluminum, tin or silicon, or alloys thereof. The individual fibers may have a diameter (thickness dimension) of about 5 nm to about 10,000 nm, and a length that generally corresponds to the thickness of the anode active material. The fibers (nanowires) of silicon 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. In addition, 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 such embodiment, the anode active material comprises silicon alloy (e.g., 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 positive electrode 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 source 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 to 3 mg / cm 2 The lithium particulate material may be applied to the positive electrode active material layer 104 (e.g., the negative electrode) by spraying, filling, 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% on 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 resistance of at least about 10 3 For example, in one such embodiment, the anode current collector has a conductivity of at least about 10 Siemens / cm. 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 conductive materials suitable for use as the anode current collector 206 include metals such as copper, nickel, cobalt, titanium, and tungsten, and alloys thereof.

[0042] 2A-2C, in another preferred embodiment, the unit cell 200 includes one or more cathode current collector layers 210 and one or more anode active material layers 106. The cathode current collector layer 210 of 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 intermixed with the cathode active material layer 106.

[0043] In one embodiment, the cathode active material layer(s) 106 each have a thickness of at least about 20 um. For example, in one embodiment, the cathode active material layer(s) 106 each have a thickness of at least about 40 um. By way of further example, in one such embodiment, the cathode active material layer(s) each have a thickness of at least about 60 um. By way of further example, in one such embodiment, the cathode active material layers each have a thickness of at least about 100 um. Typically, however, the cathode active material layer(s) 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, negative electrode) 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, NiF2, etc., where 0≦d≦0.5 and the like.

[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 and may be selectively used cathode active materials selected from transition metal oxides, transition metal sulfides, transition metal nitrides, lithium transition metal oxides, lithium transition metal sulfides, and lithium transition metal nitrides. The transition metal elements of these transition metal oxides, transition metal sulfides, and transition metal nitrides may include metal elements having d-shells or f-shells. 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 Mn1.5 O4, Li(Ni x 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 has at least about 10 3 For example, in one such embodiment, the cathode current collector 210 has a 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 10 ...

[0048] 2A-2C, in one embodiment, electrically insulating separator layer(s) 108 are adapted to electrically insulate each member of the anode active material layer 104 from each member of the cathode active material layer 106. The electrically insulating separator layer 108 will typically comprise a microporous separator material capable of being permeated by 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. 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 the separator layer(s) 108 can be selected from a wide range 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 6.4 La3Zr 1.4 Ta 0.6 O 12 ), and lithium aluminum titanium phosphate (Li 1.4 Al 0.4Ti 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 that includes a particulate material and a binder and has a porosity of at least about 20% by volume. The pores of the microporous separator material have a diameter of at least 50 Å, typically falling within the range of about 250-2,500 Å. The microporous separator material typically has a porosity of less than about 75%. In one embodiment, the microporous separator material has a porosity 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 containing vinylidene fluoride, hexafluoropropylene, tetrafluoropropene, etc. In another embodiment, the binder is a polyolefin such as polyethylene, polypropylene, or polybutene having any of a range of molecular weights and densities. 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, hi another embodiment, the binder is a copolymer or blend of two or more of the foregoing polymers.

[0056] The particulate material comprising the microporous separator material may 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 is 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 -6The particle material has a conductivity for carrier ions of less than 10 ... 2、 SiO 2、 Particulate materials include 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 by techniques such as sintering, bonding, curing, etc., while maintaining a desired porosity for electrolyte infiltration to provide ionic conductivity for the functioning of the battery.

[0058] In an assembled energy storage device, such as the battery assembly 100, the microporous separator material is infiltrated 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(CH)4, LiN(SOCF)2, LiN(SOCF)3, LiNSOCF3, LiNSOCF5, LiNSO2C4F9, LiNSO2C5F 11 , LiNSO2C6F13 , 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, alkyl tetrahydrofuran, dialkyl tetrahydrofuran, alkoxy tetrahydrofuran, dialkoxy tetrahydrofuran, 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 ethers, diethylene glycol dialkyl ethers, triethylene glycol dialkyl ethers, and tetraethylene glycol dialkyl ethers.

[0059] In one embodiment, the microporous separator layer(s) 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 2A-2C, in one embodiment, bus bars 110 and 112 are placed through bus bar openings of respective electrode or counter electrode (e.g., anode or cathode as the case may be) current collector tabs 120 to connect the anode current collectors 206 (in a battery with multiple electrode unit cells) to one another, and the other of the bus bars connects the cathode current collectors 210 to one another in a battery with multiple electrode unit cells 200. In one embodiment, bus bars 110, 112 are welded or otherwise electrically coupled to the respective folded current collector tabs 120 before being welded. In one embodiment, bus bar 110 is a copper bus bar and is welded to the anode tab of the anode current collector layer 206, and 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 electrically conductive material to allow 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 is in electrical contact with all of the electrode tabs 120 for the anode and cathode, respectively.

[0061] As referred to herein, the anode population member comprises at least an anode current collector 206 and an anode active material layer 104. In some embodiments, the anode population member comprises an anode current collector 206 and an anode active material layer 104 disposed on each major surface of the anode current collector 206. The length of the anode population member will vary depending on the energy storage device and its intended use. In general, however, the anode population member typically has a length ranging from about 5 mm to about 500 mm. For example, in one such embodiment, the anode population member has a length from about 10 mm to about 250 mm. By way of further example, in one such embodiment, the anode population member has a length from about 25 mm to about 100 mm.

[0062] The width of the members of the anode population (range of the Y axis) will also vary depending on the energy storage device and its intended use. In general, however, each member of the anode population typically has a width in the range of about 0.01 mm to about 2.5 mm. For example, in one embodiment, the width of each member of the anode population ranges from about 0.025 mm to about 2 mm. By way of further example, in one embodiment, the width of each member of the anode population ranges from about 0.05 mm to about 1 mm.

[0063] The height (Z-axis range) of the members of the anode population also varies depending on the energy storage device and its intended use. In general, however, the members of the anode population typically have a height in the range of about 0.05 mm to about 10 mm. For example, in one embodiment, the height of each member of the anode population ranges from about 0.05 mm to about 5 mm. As a further example, in one embodiment, the height of each member of the anode population ranges from about 0.1 mm to about 1 mm. According to one embodiment, the members of the anode population include one or more first electrode members having a first height and one or more second electrode members having a second height other than the first height. In yet another embodiment, the different heights of the one or more first electrode members and the one or more second electrode members can be selected to fit a predetermined shape of the electrode assembly, such as an electrode assembly shape having different heights along one or more of the longitudinal and / or lateral axes, and / or to provide a predetermined performance characteristic of the secondary battery.

[0064] In general, the members of the anode population have a length (X-axis extent) that is substantially greater than each of their widths and their heights. For example, in one embodiment, the ratio of length to each of the widths and heights is at least 5:1 for each member of the anode population (i.e., the ratio of length to width is at least 5:1, and the ratio of length to height is at least 5:1). By way of further example, in one embodiment, the ratio of length to each of the widths and heights is at least 10:1. By way of further example, in one embodiment, the ratio of length to each of the widths and heights is at least 15:1. By way of further example, in one embodiment, the ratio of length to each of the widths and heights is at least 20:1 for each member of the anode population.

[0065] In one embodiment, the ratio of height to width of each of the members of the anode population is at least 0.4:1. For example, in one embodiment, the ratio of height to width is at least 2:1 for each member of the anode population. As a further example, in one embodiment, the ratio of height to width is at least 10:1 for each of the members of the anode population. As a further example, in one embodiment, the ratio of height to width is at least 20:1 for each of the members of the anode population. Typically, however, the ratio of height to width is generally less than 1,000:1 for each of the members of the anode population. For example, in one embodiment, the ratio of height to width is less than 500:1 for each of the members of the anode population. As a further example, in one embodiment, the ratio of height to width is less than 100:1 for each of the members of the anode population. As a further example, in one embodiment, the ratio of height to width is less than 10:1 for each of the members of the anode population. As a further example, in one embodiment, the ratio of height to width is in the range of about 2:1 to about 100:1 for each of the members of the anode population.

[0066] As referred to herein, a member of the cathode population includes at least a cathode current collector 210 and an anode active material layer 106. The length of the members of the cathode population will vary depending on the energy storage device and its intended use. In general, however, each member of the cathode population typically has a length ranging from about 5 mm to about 500 mm. For example, in one such embodiment, each member of the cathode population has a length ranging from about 10 mm to about 250 mm. By way of further example, in one such embodiment, each member of the cathode population has a length ranging from about 25 mm to about 100 mm.

[0067] The widths of the members of the cathode population (range of the Y-axis) will also vary depending on the energy storage device and its intended use. In general, however, the members of the cathode population typically have widths in the range of about 0.01 mm to about 2.5 mm. For example, in one embodiment, the width of each member of the cathode population ranges from about 0.025 mm to about 2 mm. As a further example, in one embodiment, the width of each member of the cathode population ranges from about 0.05 mm to about 1 mm.

[0068] The height (Z-axis range) of the members of the negative electrode population also varies depending on the energy storage device and its intended use. In general, however, the members of the negative electrode population typically have a height in the range of about 0.05 mm to about 10 mm. For example, in one embodiment, the height of each member of the negative electrode population ranges from about 0.05 mm to about 5 mm. As a further example, in one embodiment, the height of each member of the negative electrode population ranges from about 0.1 mm to about 1 mm. According to one embodiment, the members of the negative electrode population include one or more first negative electrode members having a first height and one or more second negative electrode members having a second height other than the first height. In yet another embodiment, the different heights of the one or more first negative electrode members and the one or more second negative electrode members can be selected to fit a predetermined shape of the electrode assembly, such as an electrode assembly shape having different heights along one or more of the longitudinal and / or lateral axes, and / or to provide a predetermined performance characteristic of the secondary battery.

[0069] In general, each member of the cathode population 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 length to each of the width and height is at least 5:1 for each member of the cathode population (i.e., the ratio of length to width is at least 5:1 and the ratio of length to height is at least 5:1). By way of further example, in one embodiment, the ratio of length to each of the width and height is at least 10:1 for each member of the anode population. By way of further example, in one embodiment, the ratio of length to each of the width and height is at least 15:1 for each member of the cathode population. By way of further example, in one embodiment, the ratio of length to each of the width and height is at least 20:1 for each member of the cathode population.

[0070] In one embodiment, the ratio of height to width of each of the members of the anode population is at least 0.4:1. For example, in one embodiment, the ratio of height to width is at least 2:1, respectively, for each member of the cathode population. As a further example, in one embodiment, the ratio of height to width is at least 10:1, respectively, for each member of the cathode population. As a further example, in one embodiment, the ratio of height to width is at least 20:1, respectively, for each member of the cathode population. Typically, however, the ratio of height to width is less than about 1,000:1, respectively, for each member of the anode population. For example, in one embodiment, the ratio of height to width is less than 500:1, respectively, for each member of the cathode population. As a further example, in one embodiment, the ratio of height to width is less than 100:1, respectively. As a further example, in one embodiment, the ratio of height to width is less than 10:1, respectively. By way of further example, in one embodiment, the height to width ratio ranges from about 2:1 to about 100:1, respectively, for each member of the cathode population.

[0071] In one embodiment, the anode current collector 206 also has an electrical conductance substantially greater than that of the negative electrode active material layer 104. It should be noted that the negative electrode active material layer 104 may be the same as or similar to the anode active material layer 106. For example, in one embodiment, the ratio of the electrical conductance of the anode current collector 206 to the electrical conductance 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. As a further example, in some embodiments, the ratio of the electrical conductance of the anode current collector 206 to the electrical conductance 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 conductance of the anode current collector 206 to the electrical conductance of the negative electrode active material layer 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 conductance of the anode current collector 206 to the electrical conductance of the anode active material layer 104 is at least 5000:1 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 conductance of the anode current collector 206 to the electrical conductance of the anode active material layer 104 is at least 10,000:1 when there is an applied current to store energy in the device or an applied load to discharge the device.

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

[0073] 2B and 2C, an embodiment of the present disclosure including a spacer member 225 is described. Additional description of the spacer member is disclosed in U.S. Patent Application No. 63 / 115,266, filed November 18, 2020, the entire contents of which are incorporated herein by reference. In one embodiment, the spacer member 225 is a continuous or discontinuous strip of an organic or inorganic material. The spacer member 225 can be continuous or discontinuous in one or more of the Z-axis and the X-axis. In some embodiments, the spacer member 225 includes an electrically insulating material and / or an ion-permeable polymeric woven material. In one embodiment, the spacer member 225 is made from the same material as the separator 108. In some embodiments, the spacer member 225 includes polyethylene terephthalate (PET) or polyimide (PI). In other embodiments, the spacer member 225 includes a conductive material. Note that although the spacer members 225 are shown as four spacer members, there can be any number of spacer members 225 from one or more.

[0074] In some embodiments, the spacer member 225 comprises a spacer material including a polymeric material, a composite material such as adhesive tape, an electrode current collector, an electrode active material, a counter electrode active material, a counter electrode current collector, a separator material, or a material that is chemically inert (in the battery environment). For example, in one embodiment, the spacer member 225 comprises an anode active material capable of accepting carrier ions, and in this embodiment, the anode active material generally preferably comprises graphite, graphene, or other anode active material having a capacity of carrier ions that is less than one mole per mole of spacer material. As a further example, in one embodiment, the spacer member comprises a cathode active material capable of accepting carrier ions. By way of further example, in one embodiment, the spacer member may comprise a polymeric material (e.g., a homopolymer, copolymer, or polymer blend), and in such an embodiment, the spacer member may be made of a material selected from the group consisting of vinylidene fluoride, hexafluoropropylene, tetrafluoropropene, polyolefins such as polyethylene, polypropylene, or polybutene, ethylene-diene-propene terpolymers, polystyrene, polymethyl methacrylate, polyethylene glycol, polyvinyl acetate, polyvinyl butyral, polyacetal, and polyethylene glycol diacrylate, methylcellulose, carboxymethylcellulose, styrene rubber, butadiene rubber, styrene-butadiene rubber, isoprene rubber, polyacrylamide, polyvinyl ether, polyacrylic acid, poly(vinyl chloride), ... polymethacrylic acid, polyacrylate, polyvinylidene fluoride polyacrylonitrile, polyethyleneoxy, acrylate, styrene, epoxy, silicone, polyvinylidene fluoride-hexafluoropropylene, polyvinylidene fluoride-trichloroethylene, polymethylacrylate, polyethylacrinol, polyethylvinylethyl, polyethylethyleneate, polyethylethyl, polyethylene oxide, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, cyanoethyl pullulan, cyanoethyl polyvinyl alcohol, cyanoethyl cellulose, cyanoethyl sucrose, pullulan, carboxymethyl cellulose, acrylonitrile-styrene-butadiene copolymer, polyimide, polyvinylidene fluoride-hexafluoropropylene,Fluoropolymers derived from monomers containing polyvinylidene fluoride-trichloroethylene, polymethyl methacrylate, polyacrylonitrile, polyvinylpyrrolidone, polyvinyl acetate, ethylene vinyl acetate copolymer, polyethylene oxide, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, cyanoethyl pullulan, cyanoethyl polyvinyl alcohol, cyanoethyl cellulose, cyanoethyl sucrose, pullulan, carboxymethyl cellulose, acrylonitrile styrene butadiene copolymer, polyimide, polyethylene terephthalate, polybutylene terephthalate, polyester, polyacetal, polyamide, polyether ether ketone, polyether sulfone, polyphenylene oxide, polyphenylene sulfide, polyethylene naphthalene, and / or combinations or copolymers thereof.

[0075] In one embodiment, the spacer member 225 is in the form of an adhesive tape having a base and an adhesive layer provided on one surface of the base. The composition of the adhesive tape base is not particularly limited, and various bases known to be usable for adhesive tapes can be used. Generally, plastic films are preferred, and specific examples include polyolefin films such as polyethylene, polypropylene, polyethylene terephthalate, polybutylene terephthalate, polyphenylene sulfide, polyimide, or polyamide films. In some embodiments, polyolefin, polyethylene terephthalate, and polyimide films may be preferred for their heat resistance and chemical resistance suitable for battery applications. The adhesive tape base may have a thickness of about 4 μm to 200 μm, such as in the range of 6 μm to 150 μm, or even in the range of about 25 μm to 100 μm. The adhesive constituting the adhesive layer of the adhesive tape may include, for example, a rubber-based adhesive, an acrylic-based adhesive, a silicone-based adhesive, or a combination thereof.

[0076] Spacer member 225 (and similarly elongated spacer member 425) has a width W s , length in the X-axis direction L s , and the height in the Z-axis direction Hs (Figure 8) s can be predetermined such that when the electrode unit cells are assembled, the spacer members 225 increase the distance in the Y-axis direction by a predetermined amount through the gaps 227 between adjacent layers of unit cells (such as unit cells 200A, 200B).

[0077] In one embodiment, the width W s is equal to or greater than 50 percent of the width (extent of the Y-axis) of the cathode active material layer 106 in the Y-axis direction. s is 50 percent or more of the cathode active material layer 106 plus the width of the cathode current collector layer 210 in the Y-axis direction (the extent of the Y-axis).

[0078] In one embodiment, the spacer member 225 is a tape material having an adhesive applied to a first surface 250 of the spacer member 225 that secures the spacer member 225 to one of the active material layers or separator layers. In some embodiments, the adhesive is a strong adhesive that permanently secures the spacer member 225 to the active material layer or separator layer. In other embodiments, the adhesive is a weak adhesive that removably secures the spacer member 225 to the active material layer or separator layer. As used herein, a strong adhesive is defined as an adhesive that has sufficient strength such that the spacer member 225 cannot be removed from the active material layer or separator layer without damaging the spacer member 225 and / or one or both of the materials to which it is adhered. As used herein, a weak adhesive is defined as one that adheres the spacer member 225 to the active material layer or separator layer, but has sufficient strength to at least permit the spacer member to be removed without causing material damage to the active material layer or separator layer. In another embodiment, the spacer member 225 has an adhesive applied to both the first surface 250 and the second opposing surface 252. In one embodiment, the spacer member 225 is applied using a printing process, such as a 3D printing process. In yet another embodiment, the spacer member 225 is applied by melting or welding the spacer member 225 to the respective layer.

[0079] In an embodiment, the spacer member 225 has a width W sufficient to define an expansion gap 227 between the separator layer 108 and the anode active material layer 104 or the cathode active material layer 106. s Each of the width W s The expansion gap 227 is specified as width W G In the embodiment, the width W G is set to be from 0 micrometers (e.g., no gap) to 1000 micrometers, for example, 1 μm, 2 μm, 5 μm, 10 μm, 20 μm, 50 μm, 100 μm, 200 μm, 300 μm, 400 μm, 500 μm, 600 μm, 700 μm, 800 μm, 900 μm, or 1000 μm, or more.

[0080] 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 an enclosure is disposed thereon. Battery assembly 300 includes an electrode assembly 301 comprising a population of electrode subunits (which may be the same as or similar to subunits 102) organized in a stacked arrangement along a Y axis to form a population of unit cells 302 (which may be the same as or similar to unit cells 200). Each of unit cells 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.

[0081] In a preferred embodiment, the electrode assembly 301 is held within a constraint 316 (which in some embodiments may be the same as or similar to constraint 116). In one embodiment, constraint 316 comprises stainless steel, such as SS316, 440C, or 440C hard. In other embodiments, the constraint is 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), PEEK with carbon (e.g., Victrex 90HMF40 or Xycomp 1000-04), polyphenylene sulfide (PPS) with carbon (e.g., Tepex Dynalite 207), polyetherketone (PEEK) with 30% glass (e.g., Victrex 90HMF40 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.

[0082] The constraint 316 comprises a first cover 320 generally aligned along the XY plane and a second cover on the opposite side of the battery assembly 300 generally aligned along the XY plane, having a thickness t1 (FIG. 3A) measured in the Z-axis direction. The thickness (t1) of the constraint 316 may depend on a range of factors including, for example, the material(s) 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. As a further example, in another embodiment, the constraint 316 comprises an aluminum sheet (e.g., 7075-T6) having a thickness of about 40 μm. As a 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 with a packing density of greater than 50%. Each of the first cover 320 and the second cover 322 may 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 pre-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 for facilitating pre-lithiation. In one embodiment, the third cover 324 and the fourth cover 326 of the constraint 316 are each generally aligned along the XZ axis. 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 radiused or angled corners.In one embodiment, the first and second corners 328 and 329 are at an angle between 90 degrees and 100 degrees. In another embodiment, the third and fourth covers can be a single cover.

[0083] In one embodiment, a casing edge gap 338 is defined between the third cover 324 and the fourth cover 326 with a 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 cover 324 and the fourth cover 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 similar constraints as the third and fourth covers 324 and 326. The third cover 324 includes a flap edge 330 defined along the X-axis and the Z-axis, and the fourth cover 326 includes a second flap edge 332 defined along the X-axis and the Z-axis.

[0084] 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 quantity 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 mitigating the machining, stamping process, or peeling of the first cover 320 or the second cover 322 from the material stock used in the manufacturing process of the first cover 320 or the second cover 322. In addition, the battery assembly 300 includes bus bar(s) 310 electrically coupled to one of the unit cells 302. Due to the material thickness t1 used for the constraint 316, the constraint includes a constraint edge 340 protruding from the electrode assembly 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 bus bar(s) 310 protrude from the battery side 344 in the X-axis direction at the bus bar edge 342. The protruding edges may create friction or high stress areas that may puncture the battery packaging (e.g., enclosure 700) in some cases. For example, a protruding edge of approximately 50 μm×50 μm (i.e., approximately 2500 μm) may be used. 2 A protruding edge having a size of approximately 1.5 mm (surface area) and an applied force of approximately 18 N (2 kgf) may generate a stress of approximately 50 MPa. In one embodiment, the battery package or enclosure 700 comprises an aluminum polymer laminate and has a burst strength of approximately 30 MPa to 70 MPa. In other embodiments, the battery package 700 may have a burst strength of 1 MPa to 300 MPa, depending on the material composition of the battery package 700 and its thickness. These protruding areas may be referred to as potential puncture points, as they are more likely to cause a puncture through the outer casing than non-protruding portions.

[0085] Referring to FIG. 4A, a partial detailed view of a corner area of ​​the battery assembly 300 is illustrated with an enclosure 700 surrounding the battery assembly 300 without the elongated spacer member (FIG. 4B). In one embodiment, the battery assembly 300 includes a current collector tab 414 with an opening 480 that allows the bus bar 410 (which may be the same as or similar to the bus bars 110, 112) to pass therethrough. In this embodiment, the enclosure 700 is tightly wrapped around the protruding areas such as the constraining edge 340 and the current collector tab 414 (which may be the same as or similar to the electrode tab 114). As the enclosure 700 contacts the constraining edge 340 and / or the current collector tab 414, the enclosure may be exposed to areas of high stress 450, 451, which may cause the enclosure 700 to be abraded, torn, or burst in certain circumstances. Although shown with two areas of high stress 450, 451, any area where the enclosure 700 contacts a sharp edge of a component of the battery assembly 300 can create other areas of high stress that can create potential puncture points.

[0086] 4B, a stretched spacer member 425 is utilized to facilitate reducing or eliminating the possibility of areas of high stress 450 causing wear, tear, or rupture of the enclosure 700. In this embodiment, the stretched spacer member 425 may be comparable in material composition, width and thickness, and Z-axis positioning to the spacer member 225 described herein. However, the stretched spacer member 425 is configured to extend in the X-axis direction a sufficient length to prevent the high stress areas 450 from exerting sufficient stress on the enclosure 700 to cause wear, tear, and rupture of the enclosure 700. In this embodiment, the stretched spacer member 425 is configured to have an X-axis length that extends a distance SD1 beyond the constraining edge 340 in the X-axis direction. By doing so, the enclosure R of the inner enclosure radius 435A of the enclosure 700 when the stretched spacer is not used is reduced. EaCompared to the radius of curvature of the ZX plane of the enclosure, the inner enclosure radius of 435 is the enclosure R E The radius of curvature of the ZX plane of the distance SD 1は 100 μm to 4000 μm, for example, 100 μm, 200 μm, 300 μm, 400 μm, 500 μm, 600 μm, 700 μm, 800 μm, 900 μm, 1000 μm, 1100 μm, 1200 μm, 1300 μm, 1400 μm, 1500 μm, 1600 μm, 1700 μm, 1800 μm, 1900 μm, 2000 μm, 2100 μm, 2200 μm, In some embodiments, the radius R may be greater than or less than 2300 μm, 2400 μm, 2500 μm, 2600 μm, 2700 μm, 2800 μm, 2900 μm, 3000 μm, 3100 μm, 3200 μm, 3300 μm, 3400 μm, 3500 μm, 3600 μm, 3700 μm, 3800 μm, 3900 μm, or 4000 μm, although other embodiments may be greater than or less than this range. E corresponds to the distance SD1, and hence the radius R E is in the range of 100 μm to 4000 μm, for example, 100 μm, 200 μm, 300 μm, 400 μm, 500 μm, 600 μm, 700 μm, 800 μm, 900 μm, 1000 μm, 1100 μm, 1200 μm, 1300 μm, 1400 μm, 1500 μm, 1600 μm, 1700 μm, 1800 μm, 1900 μm, 2000 μm, 2100 μm, 2200 μm, 2300 μm, 2400 μm, 2500 μm, 2600 μm, 2700 μm, 2800 μm, 2900 μm, 3000 μm, 3100 μm, 3200 μm, 3300 μm, 3400 μm, 3500 μm, 3600 μm, 3700 μm, 3800 μm, 3900 μm, or 4000 μm, although other embodiments may be greater or less than this range. In another embodiment, the stretched spacer member 425 is also configured to facilitate stress reduction in the high stress area 451. In this embodiment, when the stretched spacer is not used, the enclosure R of the inner enclosure radius 437A of the enclosure 700 is E2a Compared with the radius of curvature of E2(FIG. 4A). In one embodiment, the extended spacer members 425 extend a sufficient distance SD1 such that the inner enclosure radius 437 becomes infinite (e.g., the inner package surface 460 becomes parallel to the bus bars 410 and / or current collector tabs 414).

[0087] In one embodiment, the distal end of the extended spacer member 425 is substantially flat. In other embodiments, the distal end of the extended spacer member 425 may include edge detail 485, such as a chamfer or radius on one or more edges in the ZX and / or XY axes. The extended spacer member 425 may also include one or more notches 487 to allow another component, such as a bus bar or the like, to pass therethrough. In such an embodiment, the notches 487 are sized and shaped to accommodate the component such that the component does not protrude in any direction beyond the extended spacer member 425.

[0088] Reference is now made to Figures 5-7. After the battery assembly 300 is prepared, it is placed into an enclosure 700 to form a complete battery 760. In an embodiment, the battery enclosure 700 comprises a first enclosure layer 500 and a second enclosure layer 600. Each of the first and second enclosure layers may comprise a flexible or semi-flexible material, such as aluminum, polymer, or the like. In an embodiment, one or more of the first and second enclosure layers 500, 600 comprises a multi-layer aluminum polymer material, plastic, or the like. In an embodiment, one or more of the first and second enclosure layers 500, 600 comprises a polymer material laminated on a metal substrate, such as aluminum.

[0089] In the embodiment illustrated in FIG. 5, the battery assembly 300 is disposed on the first enclosure layer 500 such that the major surface F6 (the lower surface shown in FIG. 5) of the constraint 316 contacts the first enclosure layer 500. In one embodiment, the battery assembly 300 is disposed in a recess 502 formed in the first enclosure layer 500. The recess 502 is sized and shaped to match the outer size and shape of the battery assembly 300. In one embodiment, the second enclosure layer 600 is disposed on top of the battery assembly 300 such that the major surface F5 of the constraint 316 contacts the second enclosure layer 600. The second enclosure layer 600 can be positioned (such as by moving in the arrangement direction P1) to cover the entirety of the major surface F5 and the recess 502. The conductive terminals 605 and 607 remain uncovered by the first and second enclosure layers 500, 600. After the second enclosure layer 600 is properly positioned, the first and second enclosure 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 enclosure layers 500, 600 may be trimmed before or after sealing. The first and second enclosure layers may be sealed along the sealing edge S1 by welding, heat sealing, adhesives, combinations thereof, or the like. In another embodiment, the first and second enclosure layers 500, 600 may be sealed along three sides of the sealing edge S1 creating a pocket therein. In such an embodiment, the battery assembly 300 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 hot press that applies a controlled temperature and pressure to the sealing edge S1 to bond or fuse the first and second enclosure layers 500, 600 together along the sealing edge S1. In another embodiment, a vacuum is applied to the battery assembly 300 during the sealing process to evacuate any excess volume occupied by air or other gases. The amount of time the sealing edges are exposed to the hot press can be controlled and depends on the materials selected for the first and second enclosure layers 500, 600.When sealed over the battery assembly 300, the sealed first and second enclosure layers 500, 600 form a battery package 700. When sealed, the enclosure 700 is liquid-tight and / or air-tight, depending on the desired application. Terminals 705, 707 are left exposed and uncovered by the enclosure 700, allowing a user to connect the terminals to a powered device or battery charger.

[0090] In some embodiments, prior to sealing the enclosure 700, a vacuum is applied to the interior of the enclosure 700 such that the enclosure substantially conforms to the exterior surface of the battery assembly 300. In this embodiment, the stretched spacer member 425 should have a sufficient distance SD1 beyond the constraining edge 340 in the X-axis direction such that after application of the vacuum and subsequent sealing, the radii Re and RE2 are large enough to reduce or eliminate the high stress areas 450 and 451 from having sufficient stress to cause wear, tear, or rupture to the enclosure 700.

[0091] The method of the present disclosure is described with reference to FIGS. 1-9. In one embodiment, a battery assembly, such as battery assembly 300, is prepared as described above by stacking 900 one or more layers of unit cells 200. To facilitate reducing or eliminating the possibility of areas of high stress 450 causing wear, tear or rupture of enclosure 700, stretched spacer members 425 are disposed 910 within unit cells within the battery assembly. In this embodiment, stretched spacer members, such as stretched spacer member 425, may be comparable in material composition, width and thickness, and Z-axis positioning to spacer member 225 described herein. In this embodiment, stretched spacer member 425 is assembled and positioned 920 such that it extends in the X-axis direction for a sufficient length to prevent high stress areas 450 from applying sufficient stress to enclosure 700 to cause wear, tear and rupture of enclosure 700. In this embodiment of the method, the extended spacer member 425 is configured and positioned 920 within the unit cell to have an X-axis length that extends a distance SD1 in the X-axis direction beyond the constraining edge 340. By doing so, the enclosure R of the inner enclosure radius 435A of the enclosure 700 is reduced when the extended spacer is not in use. Ea Compared to the radius of curvature of the inner enclosure radius of 435, the enclosure R EIn one embodiment, the distance SD1 is between 100 μm and 4000 μm, for example, 100 μm, 200 μm, 300 μm, 400 μm, 500 μm, 600 μm, 700 μm, 800 μm, 900 μm, 1000 μm, 1100 μm, 1200 μm, 1300 μm, 1400 μm, 1500 μm, 1600 μm, 1700 μm, 1800 μm, 1900 μm, 2000 μm, 2100 μm, In some embodiments, the radius R may be greater than or equal to 2200 μm, 2300 μm, 2400 μm, 2500 μm, 2600 μm, 2700 μm, 2800 μm, 2900 μm, 3000 μm, 3100 μm, 3200 μm, 3300 μm, 3400 μm, 3500 μm, 3600 μm, 3700 μm, 3800 μm, 3900 μm, or 4000 μm, although other embodiments may be greater than or less than this range. E corresponds to the distance SD1, and hence the radius R E is in the range of 100 μm to 4000 μm, for example, 100 μm, 200 μm, 300 μm, 400 μm, 500 μm, 600 μm, 700 μm, 800 μm, 900 μm, 1000 μm, 1100 μm, 1200 μm, 1300 μm, 1400 μm, 1500 μm, 1600 μm, 1700 μm, 1800 μm, 1900 μm, 2000 μm, 2100 μm, 2200 μm, 2300 μm, 2400 μm, 2500 μm, 2600 μm, 2700 μm, 2800 μm, 2900 μm, 3000 μm, 3100 μm, 3200 μm, 3300 μm, 3400 μm, 3500 μm, 3600 μm, 3700 μm, 3800 μm, 3900 μm, or 4000 μm, but may be greater or less than this range in other embodiments. In another embodiment of this method, the stretched spacer members 425 are also configured and arranged 910 within the unit cells to facilitate stress reduction in the high stress areas 451. In this embodiment, the radius of curvature R E2 Also, when the stretched spacers are not used, the enclosure 700 has an inner enclosure radius of 437A, which is the enclosure R E2a4A , the radius of curvature of the inner enclosure radius 437 is increased by the placement of the extended spacer members. In one embodiment, the extended spacer members 425 are positioned to extend a sufficient distance SD1 such that the inner enclosure radius 437 becomes infinite (e.g., the inner package surface 460 becomes substantially parallel to the bus bars 410 and / or current collector tabs 414).

[0092] In one embodiment of the method, after the battery assembly 300 is prepared, the battery assembly 300 is placed 930 within the constraint, as described above. The battery assembly 300 within the constraint is then placed 940 within the enclosure 700 to form a complete battery 760. In an embodiment, the battery enclosure 700 comprises a first enclosure layer 500 and a second enclosure layer 600. In some embodiments of the method, prior to sealing 950 the enclosure 700, a vacuum is applied to the interior of the enclosure 700 such that the enclosure substantially conforms to the exterior surface of the battery assembly 300. In this embodiment, the stretched spacer member 425 should have a sufficient distance SD1 beyond the constraint edge 340 in the X-axis direction, such that after application of the vacuum and subsequent sealing 950, the radii Re and RE2 are large enough to reduce or eliminate the high stress areas 450 and 451 from having sufficient stress to cause wear, tear, or rupture to the enclosure 700.

[0093] In one embodiment, the battery assembly 300 is placed on the first enclosure layer 500 such that the major surface F6 (lower surface as shown in FIG. 5 ) of the constraint 316 contacts the first enclosure layer 500. In one embodiment of the method, the battery assembly 300 is placed in a recess 502 formed in the first enclosure layer 500. The recess 502 is sized and shaped to match the outer size and shape of the battery assembly 300. In one embodiment of the method, the second enclosure layer 600 is placed on top of the battery assembly 300 such that the major surface F5 of the constraint 316 contacts the second enclosure layer 600. The second enclosure layer 600 is positioned (such as by moving in the placement direction P1) to cover the entirety of the major surface F5 and the recess 502. The conductive terminals 605 and 607 are positioned to remain uncovered by the first and second enclosure layers 500, 600. After the second enclosure layer 600 is properly positioned, the first and second enclosure layers 500, 600 are sealed 950 along the sealing edge S1 (shown by the dotted line in FIG. 7 ), for example, by heat sealing, heat staking, or the like. In one embodiment of the method, excess material of the first and second enclosure layers 500, 600 is trimmed before or after sealing. In another embodiment, the first and second enclosure layers 500, 600 are sealed along three sides of the sealing edge S1 creating a pocket therein. In such an embodiment, the battery assembly 300 is then placed into the pocket and the final edge of the sealing edge S1 is subsequently sealed. In one embodiment of the method, the sealing edge S1 is sealed using a hot press that applies a controlled temperature and pressure to the sealing edge S1 to bond or fuse the first and second enclosure layers 500, 600 together along the sealing edge S1. In another embodiment, a vacuum is applied to the battery assembly 300 during the sealing process to evacuate any excess volume occupied by air or other gases. The amount of time the sealed edges are exposed to the hot press can be controlled and depends on the materials selected for the first and second enclosure layers 500, 600.When sealed over the battery assembly 300, the sealed first and second enclosure layers 500, 600 form a battery package 700. Upon sealing 950, the enclosure 700 is liquid-tight and / or air-tight, depending on the desired application. Terminals 705, 707 remain exposed and uncovered by the enclosure 700, allowing a user to connect the terminals to a powered device or a battery charger. The enclosure 700 may also be referred to as a battery package.

[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 for cycling between a charged state and a discharged state, the battery comprising: a constraint; and an electrode assembly disposed within the constraint, the electrode assembly having mutually perpendicular transverse, longitudinal, and vertical axes corresponding to the x, y, and z axes, respectively, of a three-dimensional Cartesian coordinate system, the electrode assembly comprising a collection of unit cells comprising, in longitudinally stacked succession, an electrode current collector layer, an electrode layer, a separator layer, a counter electrode layer, and a counter electrode current collector layer, the electrode layer comprising an electrode active material, the counter electrode layer comprising a counter electrode active material, one of the electrode active material and the counter electrode material being a cathode active material, the electrode a secondary battery in which the other of the active material and the counter electrode material is an anode active material, and the subset of the unit cell population further comprises a pair of elongated spacer members located in stacked series between the electrode current collector layer and the counter electrode current collector layer, one of the spacer members being laterally spaced from the other elongated spacer member, at least a portion of the counter electrode active material of the counter electrode layer being located between the spacer members such that the portion of the counter electrode active material and the spacer members are in a common plane defined by the x-axis and z-axis, and each of the elongated spacer members extends in the x-axis direction beyond the x-axis edge of the constraint a distance SD.

[0096] Embodiment 2. The secondary battery of embodiment 1, wherein the distance SD is up to 4 mm.

[0097] Embodiment 3. A secondary battery as described in any preceding embodiment, wherein the electrode assembly and the constraint are disposed within a sealed enclosure.

[0098] Embodiment 4. A secondary battery as described in any preceding embodiment, wherein the elongated spacer members facilitate a radius of curvature of the inner surface of the enclosure around the x-axis edge of a maximum constraint of 3 mm.

[0099] Embodiment 5. A secondary battery as described in any preceding embodiment, wherein the elongated spacer member has a length extending in the X-axis direction, and the length of the spacer member is 3000 μm or less.

[0100] Embodiment 6. The secondary battery of any preceding embodiment, wherein the electrode material is a cathode active material and the counter electrode active material is an anode active material.

[0101] Embodiment 7. The secondary battery of any preceding embodiment, wherein an elongated spacer member is disposed between the separator layer and the electrode layer.

[0102] Embodiment 8. The secondary battery of any preceding embodiment, wherein a spacer member is disposed between the separator layer and the electrode current collector layer.

[0103] Embodiment 9. The secondary battery of any preceding embodiment, wherein a spacer member is disposed between the separator and the counter electrode layer.

[0104] Embodiment 10. The secondary battery of any preceding embodiment, wherein a spacer member is disposed between the separator layer and the counter electrode current collector layer.

[0105] Embodiment 11. A secondary battery as described in any preceding embodiment, wherein the stretched spacer member is adhered to at least one of the electrode current collector layer, the electrode layer, the separator layer, the counter electrode layer, and the counter electrode current collector layer.

[0106] Embodiment 12. A secondary battery as described in any preceding embodiment, wherein the spacer member is adhered to the electrode current collector layer.

[0107] Embodiment 13. A secondary battery as described in any preceding embodiment, wherein the spacer member is adhered to the electrode layer.

[0108] Embodiment 14. A secondary battery according to any preceding embodiment, wherein the spacer member is adhered to the separator layer.

[0109] Embodiment 15. A secondary battery as described in any preceding embodiment, wherein the spacer member is adhered to the counter electrode current collector layer.

[0110] Embodiment 16. A secondary battery as described in any preceding embodiment, wherein (i) the members of the unit cell population are stacked consecutively in the longitudinal direction, (ii) the unit cell population includes two sets of adjacent pairs of unit cells, and (iii) one of the two sets of adjacent pairs shares a common electrode current collector layer and the other of the two sets of adjacent pairs shares a common counter electrode current collector layer.

[0111] Embodiment 17. A secondary battery as described in any preceding embodiment, wherein the unit cell population comprises at least five members.

[0112] Embodiment 18. A secondary battery according to any preceding embodiment, wherein the unit cell population comprises at least 10 members.

[0113] Embodiment 19. A secondary battery as described in any preceding embodiment, wherein the unit cell population comprises at least 25 members.

[0114] Embodiment 20. A secondary battery as described in any preceding embodiment, wherein the unit cell population comprises at least 50 members.

[0115] Embodiment 21. A secondary battery as described in any preceding embodiment, wherein the unit cell population comprises at least 100 members.

[0116] Embodiment 22. A secondary battery as described in any preceding embodiment, wherein the unit cell population comprises at least 250 members.

[0117] Embodiment 23. A secondary battery as described in any preceding embodiment, wherein the unit cell population comprises at least 500 members.

[0118] Embodiment 24. A secondary battery according to any preceding embodiment, wherein the elongated spacer member comprises an electrically insulating material.

[0119] Embodiment 25. A secondary battery as described in any preceding embodiment, wherein the elongated spacer member comprises a positive electrode active material.

[0120] Embodiment 26. A secondary battery as described in any preceding embodiment, wherein the expanded spacer member comprises a positive electrode active material having a capacity of carrier ions that is less than 1 mole per mole of spacer material.

[0121] Embodiment 27. The secondary battery of any preceding embodiment, wherein the expanded spacer members comprise graphite or graphene.

[0122] Embodiment 28. A secondary battery as described in any preceding embodiment, wherein the elongated spacer member comprises a negative electrode active material.

[0123] Embodiment 29. A secondary battery as described in any preceding embodiment, wherein the elongated spacer member comprises a polymer material.

[0124] Embodiment 30. A secondary battery of any preceding embodiment, wherein the expanded spacer member comprises a homopolymer, copolymer, or polymer blend.

[0125] Embodiment 31. The stretched spacer member is made of a material selected from the group consisting of vinylidene fluoride, hexafluoropropylene, tetrafluoropropene, polyolefins such as polyethylene, polypropylene, or polybutene, ethylene-diene-propene terpolymers, polystyrene, polymethyl methacrylate, polyethylene glycol, polyvinyl acetate, polyvinyl butyral, polyacetal, and polyethylene glycol diacrylate, methylcellulose, carboxymethylcellulose, styrene rubber, butadiene rubber, styrene-butadiene rubber, isoprene rubber, polyacrylamide, polyvinyl ether, polyacrylic acid, polymethacrylic acid, polyacrylate, polyvinylidene fluoride polyacrylonitrile, polyethyleneoxy, acrylate, styrene, epoxy, silicone, polyvinylidene fluoride-hexafluoropropylene, polyvinylidene fluoride-trichloroethylene, polymethylacrylate, polyethylacrylamide, polyethylvinylethyl, polyethylethylenate, polyethylethyl, polyethylene oxide, cellulose acetate, cellulose acetate butyrate. , cellulose acetate propionate, cyanoethyl pullulan, cyanoethyl polyvinyl alcohol, cyanoethyl cellulose, cyanoethyl sucrose, pullulan, carboxymethyl cellulose, acrylonitrile-styrene-butadiene copolymer, polyimide, polyvinylidene fluoride-hexafluoropropylene, polyvinylidene fluoride-trichloroethylene, polymethyl methacrylate, polyacrylonitrile, polyvinylpyrrolidone, polyvinyl acetate, ethylene vinyl acetate copolymer, polyethylene oxide, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, cyanoethyl pullulan, cyanoethyl polyvinyl alcohol, cyanoethyl cellulose, cyanoethyl sucrose, pullulan, carboxymethyl cellulose, acrylonitrile styrene butadiene copolymer, polyimide, polyethylene terephthalate, polybutylene terephthalate, polyester, polyacetal, polyamide, polyether ether ketone, polyether sulfone, polyphenylene oxide, polyphenylene sulfide, polyethylene naphthalene,and / or combinations or copolymers thereof.

[0126] Embodiment 32. A secondary battery as described in any preceding embodiment, wherein the expanded spacer member comprises a fluoropolymer.

[0127] Embodiment 33. A secondary battery as described in any preceding embodiment, wherein the expanded spacer member comprises a polyolefin.

[0128] Embodiment 34. A secondary battery according to any preceding embodiment, wherein the expanded spacer member comprises a polyolefin selected from the group consisting of homopolymers, copolymers, and polymer blends of polyethylene, polypropylene, and polybutene.

[0129] Embodiment 35. A secondary battery according to any preceding embodiment, wherein the expanded spacer member comprises polyethylene or polypropylene.

[0130] Embodiment 36. A secondary battery as described in any preceding embodiment, wherein the stretched spacer member comprises an adhesive tape having a base and an adhesive layer provided on one surface of the base.

[0131] Embodiment 37. A secondary battery as described in any preceding embodiment, wherein the stretched spacer member comprises an adhesive tape having a base and an adhesive layer provided on one surface of the base, and the base of the adhesive tape comprises a polymer film selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, polybutylene terephthalate, polyphenylene sulfide, polyimide, and polyamide films, and combinations thereof.

[0132] Embodiment 38. A secondary battery as described in any preceding embodiment, wherein the stretched spacer member comprises an adhesive tape having a base and an adhesive layer provided on one surface of the base, and the base of the adhesive tape comprises a polymer film selected from the group consisting of polyolefin, polyethylene terephthalate and polyamide films.

[0133] Embodiment 39. A secondary battery as described in any preceding embodiment, wherein the stretched spacer member comprises an adhesive tape having a base and an adhesive layer provided on one surface of the base, the base of the adhesive tape having a thickness in the range of about 4 to 200 μm.

[0134] Embodiment 40. A secondary battery as described in any preceding embodiment, wherein the stretched spacer member comprises an adhesive tape having a base and an adhesive layer provided on one surface of the base, the base of the adhesive tape having a thickness in the range of about 6 to 150 μm.

[0135] Embodiment 41. A secondary battery as described in any preceding embodiment, wherein the stretched spacer member comprises an adhesive tape having a base and an adhesive layer provided on one surface of the base, the base of the adhesive tape having a thickness in the range of about 25 to 100 μm.

[0136] Embodiment 42. A secondary battery as described in any preceding embodiment, wherein the stretched spacer member comprises an adhesive tape having a base and an adhesive layer provided on one surface of the base, and the adhesive constituting the adhesive layer of the adhesive tape comprises a rubber-based adhesive, an acrylic-based adhesive, a silicone-based adhesive, or a combination thereof.

[0137] Embodiment 43. A secondary battery as described in any preceding embodiment, wherein the stretched spacer member comprises the same material as the separator layer.

[0138] Embodiment 44. A secondary battery as described in any preceding embodiment, wherein the elongated spacer member comprises a conductive material.

[0139] Embodiment 45. A secondary battery as described in any preceding embodiment, wherein the elongated spacer members comprise the same material as the electrode layers.

[0140] Embodiment 46. A secondary battery as described in any preceding embodiment, wherein the elongated spacer members define, in part, length ends of the unit cells.

[0141] Embodiment 47. A secondary battery as described in any preceding embodiment, wherein the elongated spacer members have an overall length greater than the overall length of the electrode layers measured in the x-axis direction.

[0142] Embodiment 48. The secondary battery of any preceding embodiment, wherein the elongated spacer member has an overall length greater than an overall length of the counter electrode layer measured in the x-axis direction.

[0143] Embodiment 49. A secondary battery as described in any preceding embodiment, wherein the unit cells have a height measured in the vertical direction and the extended spacer members have a height measured in the z-axis direction, and the height of the unit cells is equal to the height of the extended spacer members.

[0144] Embodiment 50. A secondary battery as described in any preceding embodiment, wherein the unit cells have a height measured in the z-axis direction, the elongated spacer members have a height measured in the z-axis direction, and the height of the unit cells is greater than the height of the spacer members.

[0145] Embodiment 51. A secondary battery as described in any preceding embodiment, wherein the unit cells have a height measured in the z-axis direction, the spacer members have a height measured in the z-axis direction, and the height of the unit cells is less than the height of the spacer members.

[0146] Embodiment 52. One of the electrode active material and the counter electrode material is 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; (c) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, or Cd with other elements; (d) oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of O, V, or Cd, and mixtures, composites, or lithium-containing composites thereof; (e) salts and hydroxides of Sn; (f) lithium titanate, lithium manganate, lithium aluminate, lithium-containing titanium oxides, lithium transition metal oxides, ZnCo2O4; (g) particles of graphite and carbon; and (h) combinations thereof.

[0147] Embodiment 53. The secondary battery of any preceding embodiment, wherein one of the electrode active material and the counter electrode material is 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).

[0148] Embodiment 54. The secondary battery of any preceding embodiment, wherein one of the electrode active material and the counter electrode material is 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.

[0149] Embodiment 55. The secondary battery of any preceding embodiment, wherein one of the electrode active material and the counter electrode material is 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.

[0150] Embodiment 56. The secondary battery of any preceding embodiment, wherein one of the electrode active material and the counter electrode material is an anode active material selected from the group consisting of oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Si.

[0151] Embodiment 57. The secondary battery of any preceding embodiment, wherein one of the electrode active material and the counter electrode material is an anode active material selected from the group consisting of silicon and oxides and carbides of silicon.

[0152] Embodiment 58. The secondary battery of any preceding embodiment, wherein one of the electrode active material and the counter electrode material is a positive electrode active material comprising lithium metal.

[0153] Embodiment 59. The secondary battery of any preceding embodiment, wherein one of the electrode active material and the counter electrode material is an anode active material selected from the group consisting of graphite and carbon.

[0154] Embodiment 60. A secondary battery of any preceding embodiment, wherein within the enclosure, the secondary battery further comprises a non-aqueous organic electrolyte.

[0155] Embodiment 61. A secondary battery of any preceding embodiment, wherein within the enclosure, the secondary battery further comprises a non-aqueous electrolyte comprising a mixture of a lithium salt and an organic solvent.

[0156] Embodiment 62. A secondary battery as described in any preceding embodiment, wherein within the enclosure, the secondary battery further comprises a polymer electrolyte.

[0157] Embodiment 63. A secondary battery as described in any preceding embodiment, wherein within the enclosure, the secondary battery further comprises a solid electrolyte.

[0158] Embodiment 64. A secondary battery as described in any preceding embodiment, wherein within the enclosure, the secondary battery further comprises a solid electrolyte selected from the group consisting of sulfide-based electrolytes.

[0159] Embodiment 65. In an enclosure, a secondary battery is a lithium tin sulfide (Li 10 SnP2S 12 ), lithium phosphorus sulfide (β-Li3PS4), and lithium sulfide chloride (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:

[0160] Embodiment 66. A secondary battery as described in any preceding embodiment, wherein within the enclosure, the secondary battery further comprises a polymer-based electrolyte.

[0161] Embodiment 67. A secondary battery as described in any preceding embodiment, wherein within the enclosure, 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.

[0162] Embodiment 68. A secondary battery as described in any preceding embodiment, wherein within the enclosure, the secondary battery further comprises a solid electrolyte selected from the group consisting of oxide-based electrolytes.

[0163] Embodiment 69. Within the enclosure, a 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 La3Zr1.4 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).

[0164] Embodiment 70. A secondary battery according to any preceding embodiment, wherein one of the electrode active material and the counter electrode material is a cathode active material selected from the group consisting of intercalation chemistry cathodes and conversion chemistry cathodes.

[0165] Embodiment 71. A secondary battery as described in any preceding embodiment, wherein one of the electrode active material and the counter electrode material is a cathode active material comprising an intercalation chemistry cathode material.

[0166] Embodiment 72. The secondary battery of any preceding embodiment, wherein one of the electrode active material and the counter electrode material is a cathode active material comprising a conversion chemistry cathode active material.

[0167] Embodiment 73. One of the electrode active material and the counter electrode material is S (or Li2S in the lithiated state). )、 LiF, Fe, Cu, Ni, FeF2, FeO d F 3.2d , FeF3, CoF3, CoF2, CuF2, NiF2, and 0≦d≦0.5.

[0168] Embodiment 74. A method of manufacturing a battery assembly for use with a secondary battery, the battery assembly having mutually perpendicular horizontal, longitudinal, and vertical axes corresponding, respectively, to the x, y, and z axes of a three-dimensional Cartesian coordinate system, the method comprising: preparing unit cells by stacking electrode current collector layers, electrode layers, separator layers, counter electrode layers, and counter electrode current collector layers in a longitudinal sequence, wherein the electrode layers include an electrode active material, the counter electrode layers include a counter electrode active material, one of the electrode active material and the counter electrode material is a cathode active material, and the other of the electrode active material and the counter electrode material is an anode active material; and disposing a collection of stacked sequentially stretched spacer members between the electrode current collector layers and the counter electrode current collector layers, wherein one of the stretched spacer members is spaced apart in a y-axis direction from the other spacer member, and wherein the x-axis extent of the stretched spacer member is a distance SD that is greater than the x-axis extent of the unit cells.

[0169] Embodiment 75. The method of embodiment 74, wherein the distance SD is up to 4 mm.

[0170] Embodiment 76. The method of any preceding embodiment, further comprising positioning the unit cell within the constraint such that the extended spacer member extends a distance SD from an edge of the constraint.

[0171] Embodiment 77. The method of any preceding embodiment, further comprising sealing the unit cell in a sealed enclosure.

[0172] Embodiment 78. The method of any preceding embodiment, further comprising increasing the radius of curvature of the inner surface of the enclosure around the x-axis edge of the constraint by up to 3 mm.

[0173] Embodiment 79. The method of any preceding embodiment, wherein the stretched spacer member has a length extending in the x-axis direction, and the length of the spacer member is 3000 μm or less.

[0174] Embodiment 80. The method of any preceding embodiment, further comprising disposing an expanded spacer member between the separator layer and the electrode layer.

[0175] Embodiment 81. The method of any preceding embodiment, further comprising disposing an elongated spacer member between the separator layer and the electrode current collector layer.

[0176] Embodiment 82. The method of any preceding embodiment, further comprising disposing an elongated spacer member between the separator layer and the counter electrode layer.

[0177] Embodiment 83. The method of any preceding embodiment, further comprising disposing an elongated spacer member between the separator layer and the counter electrode current collector layer.

[0178] Embodiment 84. The method of any preceding embodiment, further comprising adhering the stretched spacer member to at least one of an electrode current collector layer, an electrode layer, a separator layer, a counter electrode layer, and a counter electrode current collector layer.

[0179] Embodiment 85. The method of any preceding embodiment, wherein the stretched spacer member is adhered to the electrode current collector layer.

[0180] Embodiment 86. The method of any preceding embodiment, wherein the stretched spacer member is adhered to the electrode layer.

[0181] Embodiment 87. The method of any preceding embodiment, wherein the stretched spacer member is adhered to the separator layer.

[0182] Embodiment 88. The method of any preceding embodiment, wherein the stretched spacer member is adhered to the counter electrode current collector layer.

[0183] Embodiment 89. An electrode assembly for a secondary battery, the electrode assembly having mutually perpendicular horizontal, longitudinal and vertical axes corresponding respectively to the x, y and z axes of a three-dimensional Cartesian coordinate system, the electrode assembly comprising: a unit cell having an electrode current collector layer, an electrode layer, a separator layer, a counter electrode layer and a counter electrode current collector layer in longitudinal succession, the electrode layer comprising an electrode active material, the counter electrode layer comprising a counter electrode active material, one of the electrode active material and the counter electrode material being a cathode active material, and the other of the electrode active material and the counter electrode material being an anode active material; and a collection of stretched spacer members between the electrode current collector layer and the counter electrode current collector layer, one of the stretched spacer members being spaced apart from the other spacer member in the y-axis direction, the x-axis extent of the stretched spacer member being a distance SD greater than the x-axis extent of the unit cell.

[0184] Embodiment 90. An electrode assembly as described in embodiment 89, wherein the distance SD is up to 4 mm.

[0185] Embodiment 91. An electrode assembly as described in any preceding embodiment, wherein the unit cell is disposed within the constraint such that the extended spacer members extend a distance SD from the edge of the constraint.

[0186] Embodiment 92. A method of manufacturing an electrode assembly for a secondary battery, the electrode assembly having mutually perpendicular horizontal, longitudinal, and vertical axes corresponding to the x, y, and z axes, respectively, of a three-dimensional Cartesian coordinate system, the method comprising: preparing a unit cell by stacking in longitudinal succession an electrode current collector layer, an electrode layer, a separator layer, a counter electrode layer, and a counter electrode current collector layer, the electrode layer comprising an electrode active material, the counter electrode layer comprising a counter electrode active material, one of the electrode active material and the counter electrode material being a cathode active material, and the other of the electrode active material and the counter electrode material being an anode active material; disposing a collection of stretched spacer members between the electrode current collector layer and the counter electrode current collector layer, one of the stretched spacer members being spaced apart in the y-axis direction from the other spacer member; and disposing the unit cell within the constraint such that the x-axis extent of the stretched spacer members is a distance SD greater than the x-axis extent of the constraint.

[0187] Embodiment 93. The method of embodiment 92, wherein the distance SD is up to 4 mm.

[0188] This written description uses examples to disclose the invention, including the best mode, and to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems 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. An apparatus for electrical storage and electrical current conduction, comprising: A constraint section; A unit cell connected to the constraint section, the constraint section being configured to accommodate at least a part of the unit cell, the unit cell having components including an electrode and a counter electrode separated from each other by a separator, the components being a unit cell stacked along a stacking axis; and, A spacer member disposed (a) between the separator and the electrode and / or (b) between the separator and the counter electrode, the spacer member (I) each extending beyond the constraint section in a lateral axial direction perpendicular to the stacking axis, and / or (II) the electrode including an electrode active material coupled to an electrode current collector, wherein, during use of the apparatus, the spacer member and the electrode active material are disposed in a common lateral plane perpendicular to the stacking axis.

2. The apparatus according to claim 1, wherein each of the spacer members extends beyond the constraint section along a lateral axis perpendicular to the stacking axis.

3. The apparatus according to claim 1, wherein, during use of the apparatus, the spacer member and the electrode active material are disposed in a common lateral plane perpendicular to the stacking axis.

4. The apparatus according to claim 1, wherein the spacer members are spaced apart from each other along a lateral axis perpendicular to the stacking axis, and at least a part of the electrode active material is disposed laterally between the spacer members.

5. The unit cell uses charge carriers including lithium ions, and use of the apparatus includes pre-lithiation of the unit cell, cycling between a charged state and a discharged state, or any combination thereof, according to claim 1.

6. Use of the apparatus includes cycling, and the unit cell is configured to undergo volume expansion and volume contraction during cycling, according to claim 5.

7. The unit cell uses charge carriers including lithium ions, and the use of the device includes pre-lithiation of the unit cell; and optionally, the pre-lithiation promotes the diffusion of lithium through (A) using a lithium foil electrode and / or (B) features that promote pre-lithiation. The device according to claim 1, wherein the features include pores.

8. The restraining part is configured to (a) restrain the dimensional expansion of the unit cell during the operation of the device and / or (b) allow carrier ions to pass therethrough for electric current conduction. The device according to claim 1.

9. The spacer member is a pair of spacer members, and the electrode active material is disposed between the spacer members. The device according to claim 1.

10. The spacer member is adhered to the surface of the separator facing the electrode and / or facing the counter electrode. The device according to claim 1.

11. The counter electrode includes a counter electrode current collector, and the spacer member is disposed between the separator and the electrode current collector and / or between the separator and the counter electrode current collector. The device according to claim 1.

12. The counter electrode includes a counter electrode current collector, and the spacer member is adhered to at least one of (a) the electrode current collector, the electrode, the separator, the counter electrode, and the counter electrode current collector. The device according to claim 1.

13. The spacer member includes a polymer material, and optionally, the spacer member includes a homopolymer, a copolymer, or a polymer blend. The device according to claim 1.

14. The unit cell includes an anode active material including silicon, and optionally, the anode active material includes SiO x, a silicon-carbon composite material, soft carbon, hard carbon, graphite, graphene, carbon nanotubes, or any combination thereof. The device according to claim 1.

15. The spacer member is the device according to claim 1, including an adhesive tape.

16. The restraint part is the device according to claim 1, including a first cover aligned with the opposing second cover.

17. The electrode current collector is connected to the electrode bus bar, and optionally, at least part of the connection is formed by the bus bar engaging with the electrode through the opening of the electrode, and optionally, at least part of the connection is formed by the bus bar being welded to the electrode. The device according to claim 1.

18. The device is the device according to claim 1, including a lithium ion battery and / or a lithium polymer battery.

19. The device includes a wound cell or a unit cell stacked along a stacking axis, and the unit cell is similar to and includes the unit cell. The device according to claim 1.

20. A method for manufacturing the device according to any one of claims 1 to 19, including performing one or more operations for manufacturing the device; and optionally, the manufacturing process includes pre-lithiation of the device.

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