Electrochemical stack and method for assembling same - Patents.com

Abstract

The electrochemical stack assembly includes a laminate pouch surrounding a frame that encloses the solid electrochemical cells and the electrochemical stack. In some embodiments, the electrochemical stack assembly includes one or more electrochemical cells, each electrochemical cell including a solid electrolyte, forming at least one electrochemical stack having two major surfaces and four minor surfaces; a frame surrounding the at least one electrochemical stack, the frame having a space between the frame and each of the four minor surfaces; and a laminate pouch surrounding the frame and the at least one electrochemical stack, the laminate pouch contacting one or both of the major surfaces. In some embodiments, the frame includes a tray. In some embodiments, the electrochemical stack assembly includes two trays, each having an electrochemical stack including electrochemical cells, the cells including a solid electrolyte.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Patent Application No. 63 / 261,727, filed September 27, 2021; U.S. Patent Application No. 63 / 299,700, filed January 14, 2022; U.S. Patent Application No. 63 / 313,051, filed February 23, 2022; U.S. Patent Application No. 63 / 334,635, filed April 25, 2022; and U.S. Patent Application No. 63 / 392,093, filed July 25, 2022. This application incorporates by reference in its entirety all of these applications.

[0002] Field

[0002] This application relates to housings for storage batteries, in particular for solid-state lithium batteries. [Background technology]

[0003] background

[0003] Solid-state lithium batteries have many advantages over conventional lithium batteries that rely solely on liquid-based electrolytes. However, by their very nature, solids are less prone to deformation than liquids, making packaging of solid-state lithium batteries more difficult. Summary of the Invention [Problem to be solved by the invention]

[0004]

[0004] One of the challenges associated with packaging solid-state lithium batteries is the expansion and contraction of the battery during charge and discharge cycles. It is desirable to provide packaging that accommodates this expansion and contraction without adversely affecting battery performance. [Means for solving the problem]

[0005] overview

[0005] In some examples, an electrochemical stack assembly is described herein. In general, the electrochemical stack assembly includes at least one electrochemical stack, a frame, and a laminate pouch. In some examples, the electrochemical stack includes at least one electrochemical cell, each of which includes a solid electrolyte. The resulting electrochemical stack has two major surfaces and four minor surfaces. The frame surrounds the at least one electrochemical stack and does not contact the four minor surfaces of the at least one electrochemical stack. In some examples, such as during use, the laminate pouch includes the frame and the at least one electrochemical stack and contacts one or both major surfaces.

[0006] Throughout this specification, the terms "electrochemical stack assembly," "stack on frame assembly," and "prismatic frame in pouch" may be used to describe various embodiments and / or examples described herein. These terms may be used interchangeably to refer to the same structure. [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is a diagram of an element of a rectangular electrochemical stack including electrochemical cells, each of which includes a solid electrolyte. [Figure 2A]

[0008] FIG. 1 illustrates a laminate pouch including a frame and an electrochemical stack according to one embodiment. [Figure 2B] FIG. 1 is a diagram of a laminate pouch including a frame and an electrochemical stack according to one embodiment. [Figure 2C] FIG. 1 is a diagram of a laminate pouch including a frame and an electrochemical stack according to one embodiment. [Figure 2D] FIG. 1 is a diagram of a laminate pouch including a frame and an electrochemical stack according to one embodiment. [Figure 3A]

[0009] FIG. 2 is a cross-sectional view of a laminate pouch including a frame and two electrochemical stacks according to one embodiment. [Figure 3B] 1 is a cross-sectional view of a laminate pouch including a frame and two electrochemical stacks according to one embodiment. [Figure 3C]

[0009] A further view of the electrochemical stack within the pouch is shown. [Figure 3D]

[0009] A further view of the electrochemical stack within the pouch is shown. [Figure 3E] FIG. 1 is a top view of a laminate pouch according to one embodiment. [Figure 3F]

[0009] FIG. 1 is a top view of a laminate pouch with positive and negative terminals extending through the laminate pouch in one embodiment. [Figure 3G]

[0009] FIG. 1 is a side view of a laminate pouch with positive and negative terminals extending through the laminate pouch in one embodiment. [Figure 4A]

[0010] FIG. 2 is a diagram of a frame for housing an electrochemical stack according to one embodiment. [Figure 4B] FIG. 1 is a diagram of a frame for housing an electrochemical stack according to one embodiment. [Figure 4C] 1 is a schematic diagram of a frame according to one embodiment. [Figure 4D] 1 is a schematic diagram of a frame according to one embodiment. [Figure 4E] 1 is a schematic diagram of a frame according to one embodiment. [Figure 4F] 1 is a schematic diagram of a frame according to one embodiment. [Figure 4G] 1 is a schematic diagram of a portion of a frame according to one embodiment. [Figure 4H] 1 is a schematic diagram of a frame according to one embodiment. [Figure 4I] 1 is a schematic diagram of a portion of a frame according to one embodiment. [Figure 4J]1 is a schematic diagram of a molded portion of a laminate pouch according to one embodiment. [Figure 4K] 1 is a schematic diagram of a molded portion of a laminate pouch according to one embodiment. [Figure 5A]

[0011] FIG. 2 illustrates a frame portion for housing an electrochemical stack according to one embodiment. [Figure 5B] FIG. 1 is a diagram of a frame portion for housing an electrochemical stack according to one embodiment. [Figure 5C] 1 is a schematic diagram of a frame according to one embodiment. [Figure 5D] 1 is a schematic diagram of a frame according to one embodiment. [Figure 5E] 1 is a schematic diagram of a frame according to one embodiment. [Figure 5F] 1 is a schematic diagram of a frame according to one embodiment. [Figure 5G] 1 is a schematic diagram of a portion of a frame according to one embodiment. [Figure 5H] FIG. 1 is a diagram of a frame portion for housing an electrochemical stack according to one embodiment. [Figure 5I] FIG. 1 is an exploded view of a frame assembly for terminating an electrochemical stack according to one embodiment. [Figure 5J] FIG. 1 is a diagram of a frame portion for housing an electrochemical stack according to one embodiment. [Figure 5K] FIG. 1 is an exploded view of a frame assembly for housing an electrochemical stack according to one embodiment. [Figure 6A]

[0012] 1A-1D are diagrams of terminals for an electrochemical stack according to different embodiments. [Figure 6B] 1 is a diagram of a terminal for an electrochemical stack according to different embodiments. [Figure 6C] 1 is a diagram of a terminal for an electrochemical stack according to different embodiments. [Figure 6D]1 is a diagram of a terminal for an electrochemical stack according to different embodiments. [Figure 6E] 1 is a diagram of a terminal for an electrochemical stack according to different embodiments. [Figure 6F] 1 is a diagram of a terminal for an electrochemical stack according to different embodiments. [Figure 6G] 1 is a diagram of a terminal for an electrochemical stack according to different embodiments. [Figure 7A]

[0013] FIG. 2 is a side perspective view of an electrochemical stack according to one embodiment. [Figure 7B] 1 is a side perspective view of an electrochemical stack according to one embodiment. [Figure 7C] 1 is a front perspective view of an electrochemical stack according to one embodiment. [Figure 8]

[0014] FIG. 1 illustrates the welding of terminals on an electrochemical stack according to one embodiment. [Figure 9A]

[0015] 1 is an image of the top or bottom of a laminate pouch. [Figure 9B] 1 is an image of a laminate pouch having a frame and an electrochemical stack inside the pouch according to one embodiment. [Figure 9C] 1 is an image of a laminate pouch having a frame and an electrochemical stack inside the pouch according to one embodiment. [Figure 9D] 1 is an image of a laminate pouch having a frame and an electrochemical stack inside the pouch according to one embodiment. [Figure 9E] 1 illustrates a laminate forming part of a laminate pouch according to one embodiment. [Figure 9F] 1 shows details of a laminate according to one embodiment. [Figure 9G] 1 shows details of a laminate according to one embodiment. [Figure 9H] 1 shows details of a laminate according to one embodiment. [Figure 9I] 1 shows details of a laminate according to one embodiment. [Figure 9J] 1 shows details of a laminate according to one embodiment. [Figure 9K] 1 shows details of a laminate according to one embodiment. [Figure 9L] 1 shows details of a laminate according to one embodiment. [Figure 9M] 1 shows details of a laminate according to one embodiment. [Figure 9N] 1 illustrates a laminate pouch according to one embodiment. [Figure 9O]

[0015] Figure 9N shows typical dimensions of the laminate pouch. [Figure 9P] 1 illustrates a laminate pouch according to one embodiment. [Figure 9Q]

[0015] Figure 9P shows typical dimensions of a laminate pouch. [Figure 9R] 1 illustrates a laminate pouch according to one embodiment. [Figure 9S]

[0015] Figure 9R shows typical dimensions of the laminate pouch. [Figure 10A]

[0016] 1 is a high level diagram of the structure of an electrochemical stack according to different embodiments. [Figure 10B] 1 is a high-level diagram of the structure of an electrochemical stack according to different embodiments. [Figure 10C]

[0016] Figure 10A shows a high level diagram of the structure of an electrochemical stack according to different embodiments, and Figure 10C also shows the bonding of the electrochemical stack to a frame. [Figure 10D] FIG. 1 is a high level diagram of the structure of a laminate pouch including a frame and an electrochemical stack according to one embodiment. [Figure 11A]

[0017] 1A-1D are diagrams of frames according to different embodiments; [Figure 11B]1 is a diagram of a frame according to different embodiments; [Figure 11C] 1 is a diagram of a frame according to different embodiments; [Figure 11D] 1 is a diagram of a frame according to different embodiments; [Figure 12]

[0018] FIG. 13 is an exploded view of a prismatic frame in a pouch according to one embodiment. [Figure 13A]

[0019] 1 illustrates a frame and cell assembly according to one embodiment. [Figure 13B] 1 illustrates a frame and cell assembly according to one embodiment. [Figure 13C] 1 illustrates a frame and cell assembly according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Detailed Description

[0020] Various embodiments of frame structures are described below that hold the laminate pouch away from the ends of the electrochemical stack (the ends are also referred to herein as end surfaces or minor surfaces) to protect the ends while allowing pressure to be applied to desired locations on the top and bottom major surfaces of the electrochemical stack when desired. When sealed under vacuum, the laminate pouch creates pressure on the cell stack. The frame provides a structure to protect the cell stack. The frame also provides space and protection for expansion of the cells in the electrochemical stack during charge and discharge cycles. In one embodiment, the laminate pouch is an encapsulating laminate pouch. In one embodiment, the laminate pouch is a preformed laminate pouch. Thus, as used herein, the term "laminate pouch" can include an encapsulating laminate pouch and / or a preformed laminate pouch.

[0009]

[0021] An electrochemical stack (sometimes referred to herein as a stack, or cell stack, or electrochemical cell stack) includes a series of solid-state electrochemical cells stacked on top of one another. It is important to protect the cell stack from exposure to water and oxygen. Therefore, the stack is sealed under vacuum into a can, pouch, or another type of sealed housing. When sealed under vacuum, the pouch creates pressure on the cell stack. In one embodiment, this pressure is atmospheric pressure that does not resist the pressure inside the pouch. If the pressure on the cell stack is not evenly distributed, the solid electrolyte inside each of the one or more cells in the stack may be damaged by deformation, cracking, or breaking.

[0010]

[0022] To address these damage issues, as well as other issues associated with packaging solid-state electrochemical cells, the frame structure described herein allows a laminate pouch to seal the electrochemical stack while applying pressure only to the major surfaces of the electrochemical stack, and not to the ends or minor surfaces of the electrochemical stack. This type of structure allows pressure to be applied perpendicular to the major surfaces of the electrochemical stack (in the z-direction). When pressure is applied in this manner, a space is left around the ends or minor surfaces of the electrochemical stack, preventing or reducing pressure (in the x- or y-directions) being applied to the ends or minor surfaces of the electrochemical stack.

[0011]

[0023] The following description enables a person skilled in the art to make and use the disclosed subject matter, and to employ the subject matter in a number of applications. Various modifications and uses in different applications will be readily apparent to those skilled in the art. The general principles described herein are applicable to a wide range of embodiments. Thus, the present disclosure is not intended to be limited to the embodiments provided, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0012]

[0024] In the following detailed description, numerous specific details are set forth in order to provide a more thorough understanding of the disclosed structures and techniques. However, it will be apparent to those skilled in the art that the disclosed structures and techniques can be practiced without necessarily being limited to these specific details. In other instances, well-known structures and devices are shown in block diagram form, rather than in detail, in order to avoid obscuring the present disclosure.

[0013] definition

[0025] As used herein, the term "about" when used to modify a number, such as about 15 percent by weight (% w / w), refers to the modified number and, optionally, to a number within the range of the modified number, including ±10% of the number. For example, about 15% w / w includes 15% w / w, as well as 13.5% w / w, 14% w / w, 14.5% w / w, 15.5% w / w, 16% w / w, or 16.5% w / w. For example, "about 75°C" includes 75°C, as well as 67°C, 68°C, 69°C, 70°C, 71°C, 72°C, 73°C, 74°C, 75°C, 76°C, 77°C, 78°C, 79°C, 80°C, 81°C, 82°C, or 83°C.

[0014]

[0026] As used herein, "selected from the group consisting of" means one member from the group, two or more members from the group, or a combination of members from the group. For example, members selected from the group consisting of A, B, and C can include A only, B only, or C only, as well as A and B, A and C, B and C, and A, B, and C.

[0015]

[0027] As used herein, the phrase "electrochemical cell" or "battery cell" refers to a cell including a positive electrode and a negative electrode in ionic communication with each other via an electrolyte or ions, unless otherwise specified to the contrary. In some embodiments, a battery or module may include multiple positive electrodes and / or multiple negative electrodes sealed in a container or otherwise arranged on top of each other, such as a stack of electrochemical cells. A stack of electrochemical cells may be referred to as a multi-layer cell. A symmetric cell may be a cell with two Li metal anodes separated by a solid electrolyte.

[0016]

[0028] As used herein, the phrase "electrochemical stack" refers to a stack of at least one negative electrode (e.g., Li, LiC6) and a positive electrode (e.g., FeF3, NiF x (wherein x is 2 or 3), nickel cobalt aluminum oxide (NCA), lithium iron phosphate (LFP), LiNi x Mn y Co z O2, [NMC], or LiNi x Al y Co z O2[NCA], where x+y+z=1; 0≦x≦1; 0≦y≦1; and 0≦z≦1, optionally in combination with a solid electrolyte or gel electrolyte, and a solid electrolyte (e.g., lithium-filled garnet (e.g., Li7La3Zr2O 12) (such as an oxide electrolyte as described herein). In some examples, there is an additional layer between the solid electrolyte and the positive electrode that includes a compliant electrolyte (e.g., gel electrolyte, gel polymer electrolyte). The electrochemical stack can include one of these aforementioned units. The electrochemical stack can include several of these aforementioned units arranged in electrical communication (e.g., electrical connection in series or parallel). In some examples, when the electrochemical stack includes several units, the units are layered on top of each other in a row or otherwise bonded to each other. In some examples, when the electrochemical stack includes several units, the units are layered on top of each other in a row or otherwise bonded to each other. In some examples, when the electrochemical stack includes several units, the stack can be arranged such that one negative electrode current collector is shared by two or more positive electrodes. Alternatively, in some examples, when the electrochemical stack includes several units, the stack can be arranged such that one positive electrode current collector is shared by two or more negative electrodes. Where appropriate or necessary, an adhesive or another bonding material can be provided between the various layers in the stack. Optionally, or in addition, when cells are provided together to form a stack, the cells can simply be placed on top of one another, or one or more cells can be directly glued to one or both of the adjacent cells.

[0017]

[0029] As used herein, the term "positive electrode" refers to the electrode toward which positive ions, e.g., Li, are introduced during discharge of the battery. + As used herein, the term "negative electrode" refers to the electrode in a secondary battery from which positive ions, such as Li, are transferred during discharge of the battery. +Lithium-ion secondary battery refers to an electrode in a secondary battery through which Li ions flow or move. In a battery constructed with a Li metal electrode and an electrode containing a conversion chemistry, an intercalation chemistry, or a combination of conversion / intercalation chemistry, the electrode with the material of the conversion chemistry, intercalation chemistry, or combination of conversion / intercalation chemistry is called the positive electrode. In some usages, a cathode is used instead of the positive electrode, and an anode is used instead of the negative electrode. When a Li secondary battery is charged, Li ions flow into the positive electrode (e.g., NiF x , NMC, NCA) to the negative electrode (e.g., Li metal). When a Li secondary battery is discharged, Li ions move from the negative electrode to the positive electrode.

[0018]

[0030] As used herein, the phrase "positive terminal" refers to an electrical connection to a positive electrode. The positive terminal may also be referred to as a positive current collector.

[0019]

[0031] As used herein, the phrase "negative electrode terminal" refers to an electrical connection to a negative electrode. The negative electrode terminal may also be referred to as a negative electrode current collector.

[0020]

[0032] As used herein, the phrase "cathode active material" refers to a material capable of intercalating or reacting with lithium ions in a reversible manner. Examples include LiMPO4 (M=Fe, Ni, Co, Mn); Li x Ti y O z (wherein x is 0 to 8, y is 1 to 12, and z is 1 to 24); LiMn 2a Ni a O4 (wherein a is 0 to 2); nickel cobalt aluminum oxide; LiNi x Mn y Co z O2 (x+y+z=1, 0≦x≦1, 0≦y≦1, and 0≦z≦1); and LiNi x Co y Al zO2, where x+y+z=1, and 0≦x≦1, 0≦y≦1, and 0≦z≦1. In these formulas, x, y, and z are selected such that the formula is charge neutral.

[0021]

[0033] As used herein, the phrase "solid cathode" refers to a cathode that does not contain a liquid phase electrolyte. As used herein, the terms "cathode" and "anode" refer to the electrodes of a battery. Cathode and anode are often referred to in the art as positive and negative electrodes, respectively.

[0022]

[0034] As used herein, the phrase "solid catholyte" or the term "catholyte" means an ion conductor that is intimately mixed with or surrounded by the cathode (i.e., positive electrode) active material.

[0023]

[0035] As used herein, the term "electrolyte" refers to an ion, e.g., Li + An electrolyte is a material through which ions can move but electrons cannot be conducted through it. The electrolyte serves to electrically insulate the cathode and anode of a secondary battery and at the same time to transport ions, e.g. Li + can be transmitted through the electrolyte.

[0024]

[0036] As used herein, the phrase "solid electrolyte separator" is used synonymously with the phrase "solid separator" and is a separator that does not contain carbon and does not contain atomic ions (e.g., Li +) refers to a material that conducts but not electrons. A solid electrolyte separator is a solid material suitable for electrical insulation of the positive and negative electrodes of a lithium secondary battery while providing a conductive path for lithium ions. Examples of solid electrolytes include oxide electrolytes and sulfide electrolytes, which are further defined below. Non-limiting examples of sulfide electrolytes can be found, for example, in U.S. Patent No. 9,172,114, issued October 27, 2015, and U.S. Patent Application Publication No. 2017-0162901 A1, published June 8, 2017. Non-limiting examples of oxide electrolytes can be found, for example, in U.S. Patent Application Publication No. 2015-0200420 A1, published July 16, 2015, and published October 31, 2017 as U.S. Patent No. 9,806,372. In some examples, the inorganic solid electrolyte also includes a polymer, referred to as a composite electrolyte. Composite electrolytes can be found, for example, in U.S. Patent No. 9,666,870. The entire contents of the just-cited U.S. patents and published U.S. patent applications are hereby incorporated by reference in their entireties for all purposes.

[0025]

[0037] As used herein, the term "separator" refers to Li + It is an abbreviation for ionically conductive separator.

[0026]

[0038] Unless expressly stated to the contrary, the separators used herein are stable when in contact with lithium metal.

[0027]

[0039] As used herein, the terms "end surface" or "minor surface" can be used interchangeably to mean a side of a prismatic frame in an electrochemical cell stack, frame, or pouch.

[0028]

[0040] As used herein, the term "major surface" may be used interchangeably to mean a major surface of an electrochemical cell stack, frame, or prismatic frame in a pouch, and is contrasted with an "end surface" or a "minor surface," both of which have a substantially smaller surface area than the major surface. In some cases, depending on the orientation of the electrochemical stack, the major surface may be the top major surface or the bottom major surface. The "top surface" or "top major surface" is generally opposite the "bottom surface" or "bottom major surface."

[0029]

[0041] As used herein, the phrase "thickness" or "film thickness" refers to the distance or median measured distance between major surfaces of a layer or film. As used herein, a major surface refers to the side of a layer or film having the largest geometric surface area.

[0030]

[0042] As used herein, "thin" refers to a thickness dimension of less than 200 μm, in some cases less than 100 μm, in some cases between 0.1 and 60 μm, in other cases from about 10 nm to about 100 μm, and in other cases about 1 μm, 10 μm, or 50 μm thick, when modifying a solid electrolyte.

[0031]

[0043] As used herein, the phrase "% of z volume expansion and contraction" refers to the expansion and contraction of a solid-state electrochemical cell having a lithium metal anode as a result of charging and discharging, respectively. During charging, lithium metal plate-out occurs in the anode layer in each electrochemical cell, thereby causing each electrochemical cell to expand. This expansion occurs primarily in a direction transverse to the cathode, electrolyte, and anode layer sequence of the cell. Here, the z direction is a perpendicular line transverse to the cathode, electrolyte, and anode. Here, the x and y directions are contained within the plane of the cathode, electrolyte, or anode. During discharge, lithium metal peels off (detaches) from the anode layer in each electrochemical cell, thereby causing each electrochemical cell to shrink. The z volume expansion and contraction is the direction of this expansion and contraction of each electrochemical cell. This direction is parallel or substantially parallel to a line perpendicular to the top or bottom major surface of the electrochemical stack (referred to as the z axis elsewhere in this specification). For example, if an electrochemical stack is 100 μm thick and at 0% charge and then experiences a z-volume expansion and contraction of 20%, this means that the electrochemical stack expands by approximately 20 μm when charged to 100% charge and then contracts by approximately 20 μm when discharged to 0% charge. The laminate is shaped to be able to accommodate cell expansion between 0-20% of the electrochemical cell thickness and then return to its original shape during discharge.

[0032]

[0044] As used herein, the phrase "laminate conforms around the frame" refers to the flexibility of the laminate pouch to surround and enclose the frame without the laminate touching the frame or having a significant amount of space between the laminate and the frame. In some instances, the laminate makes intimate contact with the frame, especially when the pouch is under vacuum.

[0033]

[0045] As used herein, the phrase "preformed shape of the laminate pouch" refers to the shape that is formed in the laminate. In some examples, the laminate is produced from a flat sheet form that is placed in a pneumatic press. A die and a cavity are used to transform the flat sheet into the preformed shape. This includes debossing the shape to raise a portion of the laminate away from the laminate surface and embossing the shape to press a portion of the laminate away from the laminate surface. In some examples, a combination of debossing and embossing is used to form the shape of the laminate. By forming a shape in the laminate, the laminate does not need to be deformed too much, if at all, against the top or bottom major surface of the electrochemical stack. If a vacuum is used, the atmosphere presses the sealed laminate onto the frame and cell stack to take the shape of the frame and cell stack. In some examples, the stack is formed into the shape of the electrochemical stack at 0% charge state. Thus, the laminate is pre-stressed during its manufacture, so that when the laminate is stretched on the frame, there is no stress concentration on the electrochemical stack. When the laminate is pulled on the frame, there is a draft when the laminate is stretched on the frame. This draft is where a space occurs between the laminate and the electrochemical stack, so that the laminate only contacts the top or bottom major surface of the electrochemical stack. When a vacuum is pulled on the sealed laminate, the draft collapses against the frame, but not against the minor surface of the electrochemical stack. After a vacuum is pulled inside the sealed laminate, the pre-formed portion of the laminate takes the shape of the frame.

[0034]

[0046] As used herein, the phrases "top major surface" and "bottom major surface" refer to particular orientations of a laminate pouch, frame, electrochemical cell, and / or electrochemical stack. Such orientations may be shown in one or more of the figures herein. Those skilled in the art will recognize that the orientations of the elements described immediately above, or indeed the resulting electrochemical stack assembly, module, or pack, are relative.

[0035]

[0047] As used herein, the phrase "geometric surface area" is the length times the width of the region of the surface being considered, assuming a flat surface.

[0036]

[0048] As used herein, the phrase "lithium-filled garnet" refers to an oxide characterized by a crystal structure related to the garnet crystal structure. U.S. Patent Application Publication No. 2015 / 0099190, published April 9, 2015 and filed October 7, 2014 as U.S. Patent Application No. 14 / 509,029, is incorporated herein by reference in its entirety for all purposes. This application describes Li-filled garnet solid electrolytes for use in solid-state lithium batteries.

[0037]

[0049] Unless otherwise stated to the contrary, lithium filled garnets are those of the formula Li A La B M' C M” D Zr E O F , Li A La B M' C M” D Ta E O F , or Li A La B M' C M” D Nb E O F(where 4 < A < 8.5, 1.5 < B < 4, 0 ≤ C ≤ 2, 0 ≤ D ≤ 2; 0 ≤ E ≤ 2, 10 < F < 13, and each of M” and M” is independently selected from Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, or Ta), or Li a La b Zr C Al d Me” e O f (where 5 < a < 7.7; 2 < b < 4; 0 ≤ c ≤ 2.5; 0 ≤ d ≤ 2; 0 ≤ e ≤ 2, 10 < f < 13, and Me” is a metal selected from Nb, Ta, V, W, Mo, Ga, or Sb), and those described herein are included.

[0038]

[0050] Li garnet is Li A La B M’ C M” D Zr E O F , Li A La B M’ C M” D Ta E O F , or Li A La B M’ C M” D Nb E O F (where 4 < A < 8.5, 1.5 < B < 4, 0 ≤ C ≤ 2, 0 ≤ D ≤ 2; 0 ≤ E < 3, 10 < F < 13, and each of M’ and M” is independently selected from Ga, Al, Mo, W, Nb, Sb, Ca, Ba, Sr, Ce, Hf, Rb, or Ta), or Li a La b Zr c Al d Me” e O f(where 5 < a < 8.5; 2 < b < 4; 0 < c ≤ 2.5; 0 ≤ d < 2; 0 ≤ e < 2, and 10 < f < 13, and Me” is a metal selected from Ga, Nb, Ta, V, W, Mo, or Sb), and it may be another one described in US Patent Application Publication No. 2015 / 0099190. As used herein, lithium-filled garnet, and garnet generally, but not limited to, Li 7.0 La3(Zr t1 +Nb t2 +Ta t3 )O 12 +0.35Al 12 O3 may be mentioned; where (t1 + t2 + t3 = 2), so the La:(Zr / Nb / Ta) ratio is 3:2. Also, as the garnet used herein, Li x La3Zr2O F+yAl2O3, where x is in the range of 5.5-9; y is in the range of 0.05-1. In these examples, the subscripts x, y, and F are selected such that the garnet is charge neutral. In some examples, x is 7 and y is 1.0. In some examples, x is 5 and y is 1.0. In some examples, x is 6 and y is 1.0. In some examples, x is 8 and y is 1.0. In some examples, x is 9 and y is 1.0. In some examples, x is 7 and y is 0.35. In some examples, x is 5 and y is 0.35. In some examples, x is 6 and y is 0.35. In some examples, x is 8 and y is 0.35. In some examples, x is 9 and y is 0.35. In some examples, x is 7 and y is 0.7. In some examples, x is 5 and y is 0.7. In some examples, x is 6 and y is 0.7. In some examples, x is 8 and y is 0.7. In some examples, x is 9 and y is 0.7. In some examples, x is 7 and y is 0.75. In some examples, x is 5 and y is 0.75. In some examples, x is 6 and y is 0.75. In some examples, x is 8 and y is 0.75. In some examples, x is 9 and y is 0.75. In some examples, x is 7 and y is 0.8. In some examples, x is 5 and y is 0.8. In some examples, x is 6 and y is 0.8. In some examples, x is 8 and y is 0.8. In some examples, x is 9 and y is 0.8. In some examples, x is 7 and y is 0.5. In some examples, x is 5 and y is 0.5. In some examples, x is 6 and y is 0.5. In some examples, x is 8 and y is 0.5. In some examples, x is 9 and y is 0.5. In some examples, x is 7 and y is 0.4. In some examples, x is 5 and y is 0.4. In some examples, x is 6 and y is 0.4. In some examples, x is 8 and y is 0.4. In some examples, x is 9 and y is 0.4. In some examples, x is 7 and y is 0.3. In some examples, x is 5 and y is 0.3.In some examples, x is 6 and y is 0.3. In some examples, x is 8 and y is 0.3. In some examples, x is 9 and y is 0.3. In some examples, x is 7 and y is 0.22. In some examples, x is 5 and y is 0.22. In some examples, x is 6 and y is 0.22. In some examples, x is 8 and y is 0.22. In some examples, x is 9 and y is 0.22. Garnet as used herein also includes Li. x La3Zr2O 12 In one embodiment, the Li-filled garnets herein include, but are not limited to, Li7Li3Zr2O3. 12 In another embodiment, the Li-filled garnet herein has a composition of Li7Li3Zr2O 12 In yet another embodiment, the Li-filled garnet herein has a composition of Li7Li3Zr2O 12 In yet another embodiment, the Li-filled garnet herein has a composition of Li7Li3Zr2O 12 In another embodiment, the Li-filled garnet herein has a composition of Li7Li3Zr2O 12 In another embodiment, the Li-filled garnet herein has a composition of Li7Li3Zr2O 12 It has a composition of .0.75Al2O3.

[0039]

[0051] As used herein, garnet includes YAG-garnet (i.e., yttrium aluminum garnet, e.g., Y3Al5O 12As used herein, garnet does not include garnets of the silicate family, such as pyrope, almandine, spessartine, grossular, hessonite, or cinnamon, tsavorite, uvarovite, and andradite, and the solid solutions pyrope-almandine-spessarite and uvarovite-grossular-andradite. Garnets herein do not include nesosilicates having the general formula X3Y2(SiO4)3, where X is Ca, Mg, Fe, and / or Mn; Y is Al, Fe, and / or Cr.

[0040] Electrochemical stack in a pouch

[0052] In some examples, as used herein, an electrochemical stack includes at least one or more electrochemical cells, each of which includes a solid electrolyte. In these examples, the electrochemical stack has two major surfaces and four minor surfaces. A laminate pouch contacts one or both major surfaces. A frame is contained within the laminate pouch and surrounds the at least one electrochemical stack. The frame does not contact the four minor surfaces.

[0041]

[0053] In some examples, as used herein, a laminate on a frame assembly includes at least one electrochemical cell, the electrochemical cell including at least one positive terminal and at least one negative terminal, forming at least one electrochemical stack having two major surfaces and four minor surfaces; a laminate pouch; and a frame contained within the laminate pouch and surrounding the at least one electrochemical stack; wherein the frame does not contact the four minor surfaces; and wherein the laminate pouch contacts both major surfaces.

[0042]

[0054] In some examples, the laminate on frame assembly described herein includes at least one electrochemical stack including at least one or more electrochemical cells, each electrochemical cell including: at least one positive terminal and at least one negative terminal; at least one electrochemical stack including a solid electrolyte and having two major surfaces and four minor surfaces; a laminate pouch; and a frame contained within the laminate pouch and surrounding the at least one electrochemical stack; wherein the frame does not contact the four minor surfaces; and the laminate pouch contacts both major surfaces.

[0043]

[0055] In some examples, a laminate on a frame assembly as referred to herein includes at least one electrochemical stack, the electrochemical stack including a solid electrolyte and at least one positive terminal and at least one negative terminal, the electrochemical stack having two major surfaces and four minor surfaces; a laminating pouch; and a frame contained within the laminating pouch and surrounding the at least one electrochemical stack; wherein the frame does not contact the four minor surfaces; and wherein the laminating pouch contacts both major surfaces.

[0044]

[0056] In some examples, as used herein, a laminate on a frame assembly includes at least one electrochemical cell, the electrochemical cell including at least one solid electrolyte, at least one positive terminal, and at least one negative terminal, having two major surfaces and four minor surfaces, forming at least one electrochemical stack; a laminate pouch; and a frame contained within the laminate pouch and surrounding the at least one electrochemical stack; wherein the frame does not contact the four minor surfaces; and wherein the laminate pouch contacts both major surfaces.

[0045]

[0057] In some examples, including any of the above, the frame is adhered to either major surface of the electrochemical stack.

[0046]

[0058] In some examples, including any of the above, the frame is adhered to either major surface of the electrochemical stack with a pressure sensitive adhesive.

[0047]

[0059] In some examples, including any of the above, there is a first electrochemical stack and a second electrochemical stack, and the first electrochemical stack is separated from the second electrochemical stack by a thermally conductive central wall.

[0048]

[0060] In some examples, including any of the above, the second electrochemical stack is the same as the first electrochemical stack, hi some examples, the second electrochemical stack can have a different number of electrochemical cells, a different type of electrochemical cells, or a different size of electrochemical cells compared to the first electrochemical stack.

[0049]

[0061] In some examples, including any of the above, the electrochemical stack further includes at least one positive terminal and at least one negative terminal.

[0050]

[0062] In some examples, including any of the above, the frame is at a negative potential relative to the lithium metal, which has zero voltage in a lithium metal battery.

[0051]

[0063] In some examples, including any of the above, the frame is at a positive potential relative to the lithium metal, which has zero voltage in a lithium metal battery.

[0052]

[0064] In some examples, including any of the above, the frame is insulated.

[0053]

[0065] In some examples, including any of the above, the frame includes anodized aluminum. In some examples, the frame includes glass, such as tempered glass. In some examples, the frame includes plastic, such as a plastic with a thermal additive.

[0054]

[0066] In some examples, including any of the above, the frame prevents forces from being applied on the four minor surfaces of the electrochemical stack.

[0055]

[0067] In some instances, including any of the above, the laminate pouch is under vacuum and the frame prevents atmospheric pressure from being applied onto the four minor surfaces of the electrochemical stack.

[0056]

[0068] Turning now to the embodiments of the invention with reference to the drawings, FIG. 1 shows top and bottom views of a rectangular electrochemical stack 100 including electrochemical cells (not shown separately), each of which includes a solid electrolyte. The views are not necessarily to scale or high resolution. The top view shows top and bottom major surfaces 101 and 102, as well as end or side or minor surfaces 103, 104, 105, and 106. The bottom view shows inverted top and bottom major surfaces 101 and 102, as well as inverted ends or sides 103 and 105. The electrochemical stack has a thickness 107. In one embodiment, the electrochemical stack fits within a frame, as described further herein, which has a size or dimension that prevents the stack from contacting the ends or minor surfaces of the electrochemical stack when a vacuum is used. The frame provides a space around the electrochemical stack so that there is no physical interference with the electrochemical stack during charging and discharging.

[0057]

[0069] In certain examples, including any of the above, the top major surface 101 and / or bottom major surface 102 of the electrochemical stack are attached to a surface on the frame via a pressure sensitive adhesive (PSA) material. In different embodiments, the PSA material is found in 3M adhesives or Avery Dennison adhesives. The PSA material can include an elastomer with a tackifier. The PSA keeps either the top major surface 101 or the bottom major surface 102 of the stack on the surface of the frame and prevents the stack from moving inside the frame during charging and discharging. In some embodiments, the PSA prevents minor surfaces of the electrochemical stack from contacting the frame. In some examples, the top major surface 101 is bonded to the frame at a center wall as described herein. In some examples, the bottom major surface 102 is bonded to the frame at a center wall. The center wall may be referred to as a center plane, center plate, or joining plate (in some embodiments, the joining plate refers to the attachment of the stack to the plate). The movement of the stack within the frame can be evaluated by vibration testing using a simulated mass. With little or no motion, there is little or no change in the position of the mass relative to the midplane.

[0058]

[0070] In some examples, including any of the foregoing, the amount of gap between the frame and the sub-surface of the electrochemical stack is at least 0.5 mm. In some applications, the gap may be greater or less. In some other examples, the amount of gap between the frame and the sub-surface of the electrochemical stack is at least 0.4 mm. In yet other examples, the amount of gap between the frame and the sub-surface of the electrochemical stack is at least 0.3 mm. In further examples, the amount of gap between the frame and the sub-surface of the electrochemical stack is at least 0.2 mm. In further examples, the amount of gap between the frame and the sub-surface of the electrochemical stack is at least 0.1 mm.

[0059]

[0071] In some examples, including any of the above, the electrochemical stack has a rectangular shape with two major surfaces having the largest geometric surface area. There are four minor surfaces at an angle of about 90° to the major surfaces, each of which has a geometric surface area less than the geometric surface area of ​​either major surface. In some examples, including any of the above, the angle between the major surface and the minor surface may be close to but not exactly 90° depending on how the solid electrolyte is formed. For example, one or more edges of the solid electrolyte may be slightly rounded. In these examples, two of the four minor surfaces have a smaller area than another two of the four minor surfaces.

[0060]

[0072] In some examples, including any of the above, the electrochemical stack has a square shape with two major surfaces having the largest geometric surface area. There are four minor surfaces at angles of about 90° to the major surfaces, each of which has a geometric surface area less than the geometric surface area of ​​either major surface. In some examples, including any of the above, the angle between the major surface and the minor surface may be close to but not exactly 90° depending on how the solid electrolyte is formed. For example, one or more edges of the solid electrolyte may be slightly rounded. In these examples, the four minor surfaces have approximately the same surface area.

[0061]

[0073] In some examples, including any of the above, the solid electrolyte has a rectangular shape with two major surfaces having the largest geometric surface area. In some examples, including any of the above, there are four minor surfaces at an angle of about 90° to the major surfaces, each of which has a geometric surface area less than the geometric surface area of ​​either major surface. In some examples, including any of the above, depending on how the solid electrolyte is formed, the angle between the major surface and the minor surface may be close to but not exactly 90°. For example, one or more edges of the solid electrolyte may be slightly rounded. In these examples, two of the four minor surfaces have a smaller surface area than another two of the four minor surfaces.

[0062]

[0074] In some examples, including any of the above, the solid electrolyte has a square shape with two major surfaces having the largest geometric surface area. There are four minor surfaces at angles of about 90° to the major surfaces, each of which has a geometric surface area less than the geometric surface area of ​​either major surface. In some examples, including any of the above, depending on how the solid electrolyte is formed, the angle between the major surface and the minor surface may be close to but not exactly 90°. For example, one or more edges of the solid electrolyte may be slightly rounded. In these examples, the four minor surfaces have approximately the same surface area.

[0063]

[0075] In some examples, including any of the above, the solid electrolyte is a thin film having a thickness of 1 μm to 100 μm. In some examples, the solid electrolyte is a thin film having a thickness of 20 μm to 100 μm. In some examples, the solid electrolyte is a thin film having a thickness of 40 μm to 100 μm. In some examples, the solid electrolyte is a thin film having a thickness of 20 μm to 80 μm. In some examples, the solid electrolyte is a thin film having a thickness of 40 μm to 80 μm. In some examples, the solid electrolyte is a thin film having a thickness of 20 μm to 60 μm. In some examples, the solid electrolyte is a thin film having a thickness of 10 μm to 30 μm. In some examples, the solid electrolyte is a thin film having a thickness of 10 μm. In some examples, the solid electrolyte is a thin film having a thickness of 11 μm. In some examples, the solid electrolyte is a thin film having a thickness of 12 μm. In some examples, the solid electrolyte is a thin film having a thickness of 13 μm. In some examples, the solid electrolyte is a thin film having a thickness of 14 μm. In some examples, the solid electrolyte is a thin film having a thickness of 15 μm. In some examples, the solid electrolyte is a thin film having a thickness of 16 μm. In some examples, the solid electrolyte is a thin film having a thickness of 17 μm. In some examples, the solid electrolyte is a thin film having a thickness of 18 μm. In some examples, the solid electrolyte is a thin film having a thickness of 19 μm. In some examples, the solid electrolyte is a thin film having a thickness of 20 μm. In some examples, the solid electrolyte is a thin film having a thickness of 21 μm. In some examples, the solid electrolyte is a thin film having a thickness of 22 μm. In some examples, the solid electrolyte is a thin film having a thickness of 23 μm. In some examples, the solid electrolyte is a thin film having a thickness of 24 μm. In some examples, the solid electrolyte is a thin film having a thickness of 25 μm. In some examples, the solid electrolyte is a thin film having a thickness of 26 μm. In some examples, the solid electrolyte is a thin film having a thickness of 27 μm. In some examples, the solid electrolyte is a thin film having a thickness of 28 μm. In some examples, the solid electrolyte is a thin film having a thickness of 29 μm. In some examples, the solid electrolyte is a thin film having a thickness of 30 μm. In some examples, the solid electrolyte is a thin film having a thickness of 31 μm.In some examples, the solid electrolyte is a thin film having a thickness of 32 μm. In some examples, the solid electrolyte is a thin film having a thickness of 33 μm. In some examples, the solid electrolyte is a thin film having a thickness of 34 μm. In some examples, the solid electrolyte is a thin film having a thickness of 35 μm. In some examples, the solid electrolyte is a thin film having a thickness of 36 μm. In some examples, the solid electrolyte is a thin film having a thickness of 37 μm. In some examples, the solid electrolyte is a thin film having a thickness of 38 μm. In some examples, the solid electrolyte is a thin film having a thickness of 39 μm. In some examples, the solid electrolyte is a thin film having a thickness of 40 μm.

[0064]

[0076] In certain examples, including any of the foregoing, the solid electrolyte is a thin film having a thickness of 10 μm. In certain other examples, the solid electrolyte is a thin film having a thickness of 20 μm. In yet other examples, the solid electrolyte is a thin film having a thickness of 30 μm. In certain examples, the solid electrolyte is a thin film having a thickness of 40 μm. In still other examples, the solid electrolyte is a thin film having a thickness of 50 μm. In still other examples, the solid electrolyte is a thin film having a thickness of 60 μm. In still other examples, the solid electrolyte is a thin film having a thickness of 70 μm. In still other examples, the solid electrolyte is a thin film having a thickness of 80 μm. In still other examples, the solid electrolyte is a thin film having a thickness of 90 μm. In still other examples, the solid electrolyte is a thin film having a thickness of 100 μm.

[0065]

[0077] In some examples, including any of the above, the frame is at a negative potential. For example, the frame may be at the same potential as the anode portion of the electrochemical stack. In some examples, the frame is electrically connected to the anode (i.e., negative electrode) of at least one electrochemical cell.

[0066]

[0078] In some examples, including any of the above, the frame is at a positive potential. For example, the frame may be at the same potential as the cathode portion of the electrochemical stack. In some examples, the frame is electrically connected to the cathode (i.e., positive electrode) of at least one electrochemical cell.

[0067]

[0079] 2A-2C are diagrams of an assembly having a frame and a laminate pouch housing an electrochemical stack according to an embodiment, which may be variously referred to as an electrochemical stack assembly, a stack on frame assembly, or a prismatic frame in a pouch.

[0068]

[0080] 2A, in order from top to bottom, in assembly 2000, top laminate portion 2010 is positioned on top of upper frame portion 2020. Electrochemical stack 2030 fits between upper frame portion 2020 and lower frame portion 2040. Upper frame portion 2020 and lower frame portion 2040 are attached to each other to form a frame around electrochemical stack 2030. The frame surrounds but does not contact minor surfaces of electrochemical stack 2030. Below lower frame portion 2040 is bottom laminate portion 2050. Top laminate portion 2010 and bottom laminate portion 2050 form a laminate pouch (sometimes referred to as a preformed laminate pouch) that surrounds the assembled frame and electrochemical stack 2030 contained therein. The top laminate portion 2010 and the bottom laminate portion 2050 are sealed together to form a seal around the periphery of the assembled frame and electrochemical stack 2030 contained therein.

[0069]

[0081] The electrochemical stack 2030 also has terminals (positive and negative or tabs) 2060 attached to the cathode and anode, respectively, of the electrochemical stack 2030. The cathode and anode extend through the frame and can contact the frame. In some examples, the terminals 2060 extend through the laminate pouch. In some examples, the terminals 2060 extend through the laminate pouch and form part of a seal.

[0070]

[0082] 2B, from top to bottom, in assembly 2100, upper laminate portion 2110 is positioned on top of upper frame portion 2120. Electrochemical stack 2130a fits between upper frame portion 2120 and lower frame portion 2140. Lower frame portion 2140 has a solid portion or surface 2140a to which electrochemical stack 2130a can be joined or otherwise attached. Lower frame portion 2140 has protruding ends 2141-2144 both above and below solid portion or surface 2140a, which form a tray-type structure 2145, which may be referred to as a tray elsewhere herein.

[0071]

[0083] The upper frame portion 2120 and the lower frame portion 2140 are attached to each other to form a frame around the electrochemical stack 2130a. The frame surrounds but does not contact the minor surfaces of the electrochemical stack 2130a. A further electrochemical stack 2130b is disposed below the surface 2140a, which may be bonded or otherwise attached to the surface 2140a. The frame encompasses but does not contact the minor surfaces of the electrochemical stack 2130b. In one embodiment, the electrochemical stack 2130b is thin enough to fit within the downwardly protruding end of the lower frame portion 2040, such that the downwardly protruding end of the lower frame portion 2140 surrounds but does not contact the ends of the electrochemical stack 2130b. Disposed below the lower frame portion 2140 is a bottom laminate portion 2150. The top laminate portion 2110 and the bottom laminate portion 2150 form a laminate pouch that encloses the assembled frame and electrochemical stacks 2130a and 2130b contained therein. The top laminate portion 2110 and the bottom laminate portion 2150 are sealed together to form a seal around the assembled frame and electrochemical stacks 2130a and 2130b contained therein.

[0072]

[0084] The electrochemical stack 2130a also has terminals (positive and negative or tabs) 2160 attached to the individual cell cathode terminals 2131a and individual cell anode terminals 2132a of the electrochemical stack 2130 and the individual cell cathode terminals 2131b and individual cell anode terminals 2132b of the electrochemical stack 2130b, respectively. These individual cell cathode terminals 2131a, 2131b and anode terminals 2132a, 2132b extend through the frame and can contact the frame. In some examples, the terminals 2160 extend through the laminate pouch. In some examples, the terminals 2160 extend through the laminate pouch and form part of a seal.

[0073]

[0085] 2C, in order from top to bottom, in the assembly 2200, the top laminate portion 2210 is placed on top of the electrochemical stack 2230. The electrochemical stack 2230 fits into the frame 2240. The frame 2240 surrounds the minor surfaces of the electrochemical stack 2230 but does not contact them. Under the outer frame 2040, the bottom laminate portion 2250 is placed. The top laminate portion 2210 and the bottom laminate portion 2250 form a laminate pouch that surrounds the frame 2240 and the electrochemical stack 2230 contained therein. The top laminate portion 2210 and the bottom laminate portion 2250 are sealed together to form a seal around the frame 2240 and the electrochemical stack 2240 contained therein. The positive terminal (cathode) 2231 and the negative terminal (anode) 2232 can be reached into the electrochemical stack 2230.

[0074]

[0086] Not shown in Figure 2C are terminals attached to the cathode protruding from opening 2231 and the anode protruding from opening 2232. If the embodiment of Figure 2C includes terminals, the terminals may extend through a laminate pouch that surrounds the assembly 2200 and form part of a seal.

[0075]

[0087] 2C also shows foam pads 2290, 2295 above and below laminate members 2210 and 2250, respectively. These pads can help cushion the assembled laminate pouch when it is loaded for use. In FIG. 2C, the pads 2290, 2295 are sized to cover approximately the same area as the central portions of the top and bottom laminate portions 2290, 2295.

[0076]

[0088] In FIG. 2D, from top to bottom, the top laminate portion 2310 is placed in the assembly 2300 on top of the unit stack 2330a having the electrodes 2331a and 2332a. To facilitate distribution of pressure across the surface area of ​​the electrochemical stack 2330a, a spacer block 2310a can be provided between the electrochemical stack 2330a and the frame portion 2340 having the center plate 2340a. In some embodiments, the spacer block 2310a provides additional volume in the assembly 2300 to facilitate contact of the top major surface of the electrochemical stack 2330a to the top laminate portion 2310. The frame portion 2340 has ends 2341-2344 extending upward from the center plate 2340a to accommodate the spacer block 2310a and the electrochemical stack 2330a. The entire structure of frame portion 2340, center plate 2340a, and upwardly extending ends 2341-2344 form a tray 2345. In one embodiment, spacer block 2310a may be compressible to provide a resilient surface upon which the electrochemical stack 2330a can be placed.

[0077]

[0089] To facilitate distribution of pressure over the surface area of ​​the electrochemical stack 2330b, an additional spacer block 2310b may be provided between the frame portion 2340 and the additional electrochemical stack 2330b having the electrodes 2331b and 2332b. In one embodiment, the spacer block 2310b may be compressible to provide a resilient surface on which the electrochemical stack 2330b can be placed. In some embodiments, the spacer block 2310b provides additional volume in the assembly 2300 to facilitate contact of the bottom major surface of the electrochemical stack 2330b to the bottom laminate portion 2350. The frame portion 2320 fits around the spacer block 2310b and the electrochemical stack 2330b. The bottom laminate portion 2350 is disposed below the frame portion 2320 and the electrochemical stack 2330b. In some embodiments, the spacer block 2310b provides additional volume in the assembly 2300 to facilitate contact of the bottom major surface of the electrochemical stack 2330b to the bottom laminate portion 2350. The tray 2345 and frame portion 2320 together form an assembled frame that surrounds, but does not contact, the minor surfaces of the electrochemical stack 2330b. The top laminate portion 2310 and the bottom laminate portion 2350 form a laminate pouch that surrounds the assembled frame and electrochemical stacks 2330a and 2330b contained therein. The top laminate portion 2310 and the bottom laminate portion 2350 are sealed together to form a seal around the assembled frame and electrochemical stacks 2330a and 2330b contained therein.

[0078]

[0090] The electrochemical stack 2330a also has terminals (positive and negative or tabs) 2360 attached to the cell cathode terminal 2331a and cell anode terminal 2332a of the electrochemical stack 2330a and the cell cathode terminal 2331b and cell anode terminal 2332b of the electrochemical stack 2330b, respectively. The cell cathode terminals 2331a, 2331b and anode terminals 2332a, 2332b extend to the ends of the frame and can contact the frame. The terminals 2060 are connected to the cathode terminals 2331a, 2331b and anode terminals 2332a, 2332b. In some examples, the terminals 2360 extend through the laminate pouch. In some examples, the terminals 2360 extend through the laminate pouch and form part of the seal.

[0079]

[0091] FIG. 3A shows two different cross-sectional views of a laminate pouch 300 according to an embodiment. In the above cross-sectional view, in some examples, including any of those mentioned above, a PSA is provided between electrochemical cell stack 1 (303a) and electrochemical cell stack 2 (303b), respectively. A central wall or surface 310 extends between the electrochemical cell stacks 303a, 303b and can extend to the exterior of the pouch. In one embodiment, the central wall 310 functions as a structural member. In one embodiment, the central wall or surface 310 functions as a thermal conductor. In one embodiment, the central wall or surface 310 functions as both a structural member and a thermal conductor.

[0080]

[0092] The central wall or face 310 as a thermal conductor improves the heat transfer from the electrochemical cell stack 303a, 303b into the frame by acting as a heat transfer wall to facilitate heat removal from the electrochemical cell stack 303a, 303b. In one embodiment, the central wall or face 310 also provides a mechanical constraint for the electrochemical cell stack 303a, 303b so that the stack does not move within the confines of the frame. Depending on the embodiment, the central wall or face 310 may be made of the same material as the frame or may be made of a different material. Depending on the embodiment, the central wall or face 310 may be aluminum (Al), anodized aluminum, magnesium (Mg), Mg-copper (Cu) alloy, or an Al-Mg alloy.

[0081]

[0093] In some examples, including any of the above, either or both of the electrochemical cell stacks 303a, 303b can have between 8 and 100 electrochemical cells.

[0082]

[0094] 3A, upper and lower frame portions 302, 304 form a frame within which electrochemical cell stacks 303a, 303b are placed with a central wall 310 sandwiched therebetween. Top and bottom laminate portions 301, 305 surround the frame. In one embodiment, central wall 310 may be part of upper frame portion 302. In one embodiment, central wall 310 may be part of lower frame portion 304. In one embodiment, central wall may not be part of either upper or lower frame portions 302, 304, but may instead be a separate element. As previously mentioned, in one embodiment, central wall 310 provides a heat sink in the center of the electrochemical stack to draw heat away from the interior of the electrochemical stack towards the ends of the frame and laminate pouch.

[0083]

[0095] The bottom cross-sectional view shows the gap 315 between the electrochemical cell stack 303a, 303b and the frame. The gap 315 allows for expansion and contraction of the electrochemical cell stack 303a, 303b during charge and discharge cycles. The bottom cross-sectional view in FIG. 3A also shows the provision of a vacuum within the lamination pouch 300. This view also shows that the outside of the lamination pouch 300 is at atmospheric pressure (14.7 pounds per square inch (PSI) or 101.4 kilopascals (kPa) at sea level). The pressure difference between the inside and outside of the stack causes the upper laminate portion 301 and the lower laminate portion 305 to be pressed against the opposing surfaces of the electrochemical cell stacks 303a, 303b, respectively. Those skilled in the art will recognize that an incomplete vacuum may be obtained within the lamination pouch 300. Depending on the embodiment, a sufficient pressure differential between the inside and outside of the laminate pouch 300 will be sufficient to obtain the necessary contact between the upper and lower laminate portions 301, 305 and the opposing surfaces of the electrochemical cell stacks 303a, 303b, respectively.

[0084]

[0096] A gap 315 extends around the electrochemical cell stack 303a, 303b between the stack and the frame. The frame is interposed between the pouch and the minor surface of the electrochemical cell stack 303a, 303b so that the pouch does not contact the minor surface of the stack. In some examples, there is a space of about 0.5 mm between the minor surface of the electrochemical stack and the frame. Figure 3A also shows a laminate seal 315 that joins the upper laminate portion 301 and the lower laminate portion 305 together to form a pouch that surrounds the frame and the electrochemical cell stack 303a, 303b. The bottom cross section of Figure 3A also shows a central wall 310 that extends through the pouch.

[0085]

[0097] FIG. 3B shows an enlarged view of a portion of the structure in FIG. 3A, showing further details of the upper laminate portion 301, the lower laminate portion 305, the electrochemical cell stacks 303a, 303b, and the central wall 310. Depending on the composition of the electrochemical stacks 303a, 303b, the amount of thickness expansion of the stack during operation can vary. The vacuum inside the laminate pouch, as opposed to the atmospheric pressure outside the laminate pouch, helps to maintain the force of the upper and lower laminate portions 301, 305 on the electrochemical stacks 303a, 303b. The central wall 310 adds to the overall cell structure and also transfers heat from the electrochemical stacks 303a, 303b to the cooler area outside the laminate pouch. In one embodiment, the central wall 310, which extends outside the laminate pouch, directly contacts the cooler structure to facilitate heat transfer.

[0086]

[0098] Figures 3C and 3D show high level cross-sectional views of the pouch 300 through the long dimension (Figure 3C) and short dimension (Figure 3D), respectively, where the electrochemical cell stacks 303a, 303b are rectangular. Both Figures 3C and 3D show the central wall 310 extending between the electrochemical cell stacks 303a, 303b, and the gap 315 between the electrochemical cell stacks 303a, 303b and the frame.

[0087]

[0099] FIG. 3E shows a top view of the electrochemical stack. In one embodiment, the electrochemical stack has dimensions of 64 mm by 79 mm. A frame is placed around the stack. In some examples, the frame has inside dimensions of 64.5 mm by 79.5 mm. In some examples, the inside dimensions are (64+x) mm by (79.5+x) mm, where x is the space between the frame and the electrochemical stack. In one embodiment, x can be the space above the foil tabs (e.g., positive terminal, negative terminal). In some examples, x is 1 mm. In some examples, x is 2 mm. In some examples, x is 3 mm. In some examples, x is 4 mm. In some examples, x is 5 mm. In some examples, x is 6 mm.

[0088]

[0100] Figures 3F and 3G show top and side views of a laminate pouch. In one embodiment, the laminate pouch has a thickness of 13.5 mm. In one embodiment, the laminate pouch has outer dimensions of 102 mm x 83 mm. In Figure 3F, in one embodiment, the positive and negative terminals 313, 323 extend 111 mm from the laminate pouch. The terminals 313, 323 can extend downward from the pouch, or can extend straight from the pouch, or can extend at an angle from the pouch.

[0089]

[0101] Figures 4A and 4B show different views of one embodiment of a frame portion 404, which may be an upper frame portion or a lower frame portion. In one embodiment, the frame portion 404 in Figures 4A and 4B can be used with a frame portion 5040 in Figures 5A and 5B discussed below, which has a solid portion or surface 5040a to which an electrochemical cell stack can be attached as discussed above with respect to Figure 2B. In one embodiment, the solid portion of surface 5040a functions as the central wall as discussed above.

[0090]

[0102] Figure 4C shows a top view of the frame portion. Figure 4D shows a cross section of Figure 4C through line DD. Figure 4E shows a cross section of Figure 4C through line EE. Figure 4F shows a side view of the frame portion. Figure 4G shows an enlarged portion of Figure 4E shown at circular section G. Figure 4G illustrates one way in which the upper and lower frame portions can be attached to form a frame by showing the mechanical interlocking of one frame portion with the other.

[0091]

[0103] Figures 4H and 4I show one way in which the upper and lower frame portions can be attached to form a frame. Figure 4H shows, as an example, a 2.00 mm gap between the frame and the electrochemical stack within the frame. Figure 4I, showing an enlarged portion of Figure 4H marked "I", shows the mechanical interlocking of one frame portion with the other.

[0092]

[0104] 4J and 4K show examples of the forming portion of a laminate pouch according to one embodiment. The dimensions shown are examples and are not intended to be limiting. In FIG. 4J, from the outer edge of the laminate pouch towards its center over the upper outer surface, there is a rise of about 100° in the laminate pouch where the forming portion begins. After this rise, the laminate pouch has a formed depression, the major plane of the depression dropping after a lateral distance of about 7.97 mm. In FIG. 4K, the thickness of the forming portion is about 6.57 mm. Also in FIG. 4K, there is a thickness increase of about 1.26 mm in the forming portion of the laminate pouch. In this example, the forming portion of the laminate pouch has a wall that extends to form a depression in which an electrochemical stack can be placed. This wall extends over a lateral distance of about 3.35 mm.

[0093]

[0105] Figures 5A and 5B show different views of one embodiment of a tray 5045 that includes a frame portion 5040, which may be an upper frame portion or a lower frame portion; a central plate or surface 5040a to which an electrochemical cell stack may be attached, as discussed above with respect to Figure 2B; and ends 5041-5044 extending upwardly from the central surface 5040a.

[0094]

[0106] Figure 5C shows a top view of the frame portion. Figure 5D shows a cross section of Figure 5C through line DD. Figure 5E shows a cross section of Figure 5C through line EE. Figure 5F shows a side view of the frame portion. Figure 5G shows an enlarged portion of Figure 5E indicated by circular portion G. Figure 5G illustrates one way in which the upper and lower frame portions can be attached to form a frame by showing the mechanical interlocking of one frame portion with the other.

[0095]

[0107] 5H shows one embodiment of a frame portion 5140 having a central surface 5140a and two spaced apart openings 5160, 5160 at one end for receiving the anode and cathode terminals of the cells in the pack. Ends 5141-5144 extend away from the central surface 5140a. The frame 5140, its central surface 5140a, and its ends 5141-5144 form a tray 5145.

[0096]

[0108] FIG. 5I shows two frame portions 5140 having respective central faces 5140a facing each other and ends 5141-5144 extending away from the respective central faces 5140a. The frame 5140, its central faces 5140a, and its ends 5141-5144 form a tray 5145. Thus, FIG. 5I shows two trays 5145 having central faces 5140a arranged back to back. Parts 508, 508 are attached to an end of the frame portion 5140 that includes an opening 5160. Part 508 includes protrusions 508a and 508b that extend downward from a major surface 508c to form an opening 508d complementary to the opening 5160 in the frame portion 5140. In one embodiment, the frame portion 5140 can be stamped or manufactured using CNC. In one embodiment, the part 508 can be injection molded.

[0097]

[0109] 5J shows an embodiment of a frame portion 5240 having a central surface 5240a and one opening 510 at one end for receiving the anode and cathode terminals of the cells in the pack. Ends 5241-5244 extend away from the central surface 5240a. The frame 5240, its central surface 5240a, and its ends 5241-5244 form a tray 5245.

[0098]

[0110] FIG. 5K shows two frame portions 5240 with respective central faces 5240a facing each other and ends 5241-5244 extending away from the respective central faces 5240a. The frame 5240, its central faces 5240a, and its ends 5241-5244 form a tray 5245. Thus, FIG. 5I shows two trays 5245 with central faces 5240a arranged back to back. The parts 508, 508 are attached to the ends of the frame portion 5240 that include respective openings 510 to provide appropriate spacing for the cell anodes and cathodes in the pack. As in FIG. 5I, the part 508 includes protrusions 508a and 508b that extend downward from a major surface 508c to form openings 508d complementary to the openings 510 in the frame portion 5240. In one embodiment, the frame portion 5240 can be stamped or manufactured using CNC. In one embodiment, the part 508 may be injection molded.

[0099]

[0111] 5H-5K, particularly Figures 5I and 5K, according to another embodiment, one of frame portions 5140 and 5240 may lack a central surface, as previously described (see, e.g., Figures 4A and 4B), while part 508 still forms the cathode and anode openings.

[0100]

[0112] Depending on the embodiment, there can be a slot on at least one side of one frame portion into which a complementary protrusion on another frame portion can be mounted to facilitate joining of the parts.

[0101]

[0113] In some examples, including any of the above, the frame prevents forces from being applied on the four minor surfaces of the electrochemical stack. When the lamination pouch is under vacuum, the lamination pouch contacts the major surfaces of the electrochemical stack. At the same time, the lamination pouch does not contact the minor surfaces of the electrochemical stack. A space exists between the minor surfaces and the frame. The lamination pouch contains the frame and the electrochemical stack. When the lamination pouch is under vacuum, a space remains between the minor surfaces and the frame.

[0102]

[0114] In some examples, including any of the above, the laminate pouch is under vacuum. The frame prevents atmospheric pressure from being applied to the four minor surfaces. Atmospheric pressure can be applied to the pouch from the outside. However, since the pouch does not contact the four minor surfaces, atmospheric pressure does not act on the minor surfaces.

[0103]

[0115] In some examples, including any of the above, the electrochemical stack includes electrochemical cells that each include a lithium metal negative electrode.

[0104]

[0116] In some examples, including any of the above, the frame provides a space around the electrochemical stack for expansion and contraction during charge and discharge cycles. In some examples, the electrochemical stack expands and contracts up to 20% of its thickness, inclusive. This expansion and contraction occurs substantially in one direction that is perpendicular to the stack when the stack is considered from the cathode to the anode. This is also referred to as the z-direction. If an xyz three-dimensional coordinate system is placed on the top major surface of the solid electrolyte, the x-axis and y-axis are in the plane of the top major surface, and the z-axis is perpendicular to the top major surface. In this example, the z-axis is parallel or substantially parallel to the z-direction of expansion and contraction described above. The laminate pouch provides sufficient space around the minor surface of the electrochemical stack to accommodate this expansion and contraction.

[0105]

[0117] In some examples, including any of the above, the frame provides space around minor surfaces of the electrochemical stack for expansion and contraction to occur during charging cycles without causing deformation, cracking, or destruction of the solid electrolyte.

[0106]

[0118] In some examples, including any of the above, the laminate pouch causes about 10-20% z volume expansion and contraction without causing deformation, cracking, or destruction of the solid electrolyte. In some examples, including any of the above, the laminate pouch causes about 20% z volume expansion and contraction without causing deformation, cracking, or destruction of the solid electrolyte. In some examples, including any of the above, the laminate pouch causes about 19% z volume expansion and contraction without causing deformation, cracking, or destruction of the solid electrolyte. In some examples, including any of the above, the laminate pouch causes about 18% z volume expansion and contraction without causing deformation, cracking, or destruction of the solid electrolyte. In some examples, including any of the above, the laminate pouch causes about 17% z volume expansion and contraction without causing deformation, cracking, or destruction of the solid electrolyte. In some examples, including any of the above, the laminate pouch causes about 16% z volume expansion and contraction without causing deformation, cracking, or destruction of the solid electrolyte. In some examples, including any of the above, the laminate pouch provides about a 15% z volume expansion and contraction without causing deformation, cracking, or destruction of the solid electrolyte. In some examples, including any of the above, the laminate pouch provides about a 14% z volume expansion and contraction without causing deformation, cracking, or destruction of the solid electrolyte. In some examples, including any of the above, the laminate pouch provides about a 13% z volume expansion and contraction without causing deformation, cracking, or destruction of the solid electrolyte. In some examples, including any of the above, the laminate pouch provides about a 12% z volume expansion and contraction without causing deformation, cracking, or destruction of the solid electrolyte. In some examples, including any of the above, the laminate pouch provides about a 11% z volume expansion and contraction without causing deformation, cracking, or destruction of the solid electrolyte. In some examples, including any of the above, the laminate pouch provides about a 10% z volume expansion and contraction without causing deformation, cracking, or destruction of the solid electrolyte.

[0107]

[0119] In some examples, including any of the above, the pressure distribution across both major surfaces is uniform or substantially uniform. In some examples, the uniform distribution of pressure is within 10 mm 2 In some cases, the uniform distribution of pressure is over a surface area of ​​10 cm 2 In some cases, the uniform distribution of pressure is over a surface area of ​​10 m 2 over a surface area of.

[0108]

[0120] In some cases, the uniform distribution of pressure is 20 mm 2 In some cases, the uniform distribution of pressure is over a surface area of ​​20 cm 2 In some cases, the uniform distribution of pressure is over a surface area of ​​20 m 2 over a surface area of.

[0109]

[0121] In some cases, the uniform distribution of pressure is 30 mm 2 In some cases, the uniform distribution of pressure is over a surface area of ​​30 cm 2 In some cases, the uniform distribution of pressure is over a surface area of ​​30 m 2 over a surface area of.

[0110]

[0122] In some examples, including any of the above, the laminate pouch fits around the frame.

[0111]

[0123] In some examples, including any of the above, when a vacuum is applied inside the laminate pouch, the shape of the laminate pouch does not change. In some other examples, when a vacuum is applied, the thickness of the electrochemical stack is compressed. In these examples, the laminate pouch can change shape to accommodate this compression. However, the laminate pouch still maintains a space around the four minor surfaces of the cell.

[0112]

[0124] In some examples, including any of the above, the laminate pouch is sealed and under vacuum.

[0113]

[0125] In some examples, including any of the above, the laminate pouch exerts a total force of 115.2 pounds (794.3 kilopascals (kPa)) on both major surfaces of an electrochemical stack having dimensions of 64 mm by 79 mm at atmospheric pressure. Different electrochemical stack surface dimensions exert different amounts of force. Examples of different dimensions are provided herein. In these examples, when under vacuum sealed conditions, each end or minor surface of the electrochemical stack experiences a total force of 115.2 pounds (794.3 kPa) on an electrochemical stack having dimensions of 64 mm by 79 mm.

[0114]

[0126] In some examples, including any of the above, the vacuum creates an atmospheric pressure of up to 14.7 pounds per square inch (PSI) (101.4 kPa) on both major surfaces of the electrochemical stack.

[0115]

[0127] In some examples, including any of the above, the vacuum creates a pressure of up to 13 PSI (89.63 kPa) on both major surfaces of the electrochemical stack.

[0116]

[0128] In some examples, including any of the above, the vacuum creates a pressure of up to 12 PSI (82.74 kPa) on both major surfaces of the electrochemical stack.

[0117]

[0129] In some instances, including any of the above, the vacuum creates a pressure of up to 11 PSI (75.84 kPa) on both major surfaces of the electrochemical stack.

[0118]

[0130] In some instances, including any of the above, the vacuum creates a pressure of up to 10 PSI (68.95 kPa) on both major surfaces of the electrochemical stack.

[0119]

[0131] In some instances, including any of the above, the vacuum creates a pressure of up to 9 PSI (62.05 kPa) on both major surfaces of the electrochemical stack.

[0120]

[0132] In some instances, including any of the above, the vacuum creates a pressure of up to 8 PSI (55.16 kPa) on both major surfaces of the electrochemical stack.

[0121]

[0133] In some instances, including any of the above, the vacuum creates a pressure of up to 7 PSI (48.26 kPa) on both major surfaces of the electrochemical stack.

[0122]

[0134] In some instances, including any of the above, the vacuum creates a pressure of up to 6 PSI (41.37 kPa) on both major surfaces of the electrochemical stack.

[0123]

[0135] In some instances, including any of the above, the vacuum creates a pressure of up to 5 PSI (34.47 kPa) on both major surfaces of the electrochemical stack.

[0124]

[0136] In some instances, including any of the above, the vacuum creates a pressure of up to 4 PSI (27.58 kPa) on both major surfaces of the electrochemical stack.

[0125]

[0137] In some instances, including any of the above, the vacuum creates a pressure of up to 3 PSI (20.68 kPa) on both major surfaces of the electrochemical stack.

[0126]

[0138] In some instances, including any of the above, the vacuum creates a pressure of up to 2 PSI (13.79 kPa) on both major surfaces of the electrochemical stack.

[0127]

[0139] In some instances, including any of the above, the vacuum creates a pressure of up to 1 PSI (6.895 kPa) on both major surfaces of the electrochemical stack.

[0128]

[0140] In some examples, including any of the above, the vacuum creates a pressure of at least 1 PSI (6.895 kPa) on both major surfaces of the electrochemical stack.

[0129]

[0141] In some examples, including any of the above, the laminate pouch has a bonded seal at the seam between the opposing laminate materials. The bonded seal can be formed by a heat sealing method. In one heat sealing method, two hot metal bars are pressed simultaneously against the two laminate pouch parts until the polymer layers on each laminate melt and the two sheets are bonded (e.g., welded) together. In some examples, including any of the above, the bonded seal can be formed by an ultrasonic welding method, or by laser welding, or by adhesive, or by external fastening, or by stitch welding. The purpose is to achieve a seal suitable for supporting evacuation or substantial evacuation within the laminate pouch.

[0130]

[0142] In some embodiments, including any of the above, the vacuum in the laminate pouch is less than 120 Torr.

[0131]

[0143] In some embodiments, including any of the above, the vacuum in the laminate pouch is less than 115 Torr.

[0132]

[0144] In some embodiments, including any of the above, the vacuum in the laminate pouch is less than 110 Torr.

[0133]

[0145] In some embodiments, including any of the above, the vacuum in the laminate pouch is less than 105 Torr.

[0134]

[0146] In some embodiments, including any of the above, the vacuum in the laminate pouch is less than 20 Torr.

[0135]

[0147] In some embodiments, including any of the above, the vacuum in the laminate pouch is less than 15 Torr.

[0136]

[0148] In some embodiments, including any of the above, the vacuum in the laminate pouch is less than 10 Torr.

[0137]

[0149] In some embodiments, including any of the above, the vacuum in the laminate pouch is less than 5 Torr.

[0138]

[0150] In some examples, including any of the above, the tray, frame, and / or frame portions may be composed of metal, plastic, rubber, silicone, ceramics, clay, glass, tempered glass, glass with thermal additives or tempered glass, or combinations thereof. In some examples, the tray, frame, and / or frame portions may be metal. In other examples, the tray, frame, and / or frame portions may be plastic. In yet other examples, the tray, frame, and / or frame portions may be composites of metal and non-metallic materials. In other examples, the tray, frame, and / or frame portions may be composites of two or more different types of metals. In other examples, the tray, frame, and / or frame portions may be made of polyetheretherketone (PEEK) or glass-filled (GF) PEEK. In yet other examples, the tray, frame, and / or frame portions may be made of PEEK or GF PEEK and another material, such as polyetherimide, silicone, urethane, or polypropylene. In some examples, the metal is aluminum, anodized aluminum, magnesium, an alloy of aluminum, or an alloy of magnesium.

[0139]

[0151] In different embodiments, the tray, frame, and / or frame portions can be machined, for example, using computer numerical control (CNC) machining, or by various types of tooling (e.g., incremental and stepped tooling), or by die casting. When using CNC or tooling, the frame can include two parts as shown in Figures 2A-2D, 5I, 5K, and 10D. In an embodiment, the metal used with one of these processes can be aluminum, although other metals can be suitably used as described above. In another embodiment, a frame made of plastic, thermoplastic, silicone, or rubber as described above can be manufactured by molding, such as injection molding. In another embodiment, a frame made of ceramics, clay, glass, or reinforced glass as described above can be manufactured by molding or firing, for example. In some embodiments, carbon fiber or metal-plastic composites can be used.

[0140]

[0152] In some examples, including any of the above, the laminate pouch has a molded shape. In some examples, the molded portion of the laminate pouch is formed using a die and a cavity to deboss and / or emboss the molded shape onto the laminate. The laminate is then sealed together around the frame and electrochemical stack.

[0141]

[0153] In some examples, including any of the above, the ratio of the surface area of ​​the major surface of the molded shape of the laminate pouch to the surface area of ​​the major surface of the electrochemical stack is greater than 1. This ratio of greater than 1 causes the laminate pouch to surround a frame, which in turn surrounds the electrochemical stack, forming a space between each minor surface of the electrochemical stack and the frame.

[0142]

[0154] In some examples, including any of the above, the ratio of the surface area of ​​the major surface of the molded shape of the laminate pouch to the surface area of ​​the major surface of the electrochemical stack is greater than 1.1. Similar to what was discussed immediately above, this ratio causes the laminate pouch to surround the frame, creating more space between each minor surface of the electrochemical stack and the frame.

[0143]

[0155] In some examples, including any of the above, the ratio of the surface area of ​​the major surface of the molded shape of the laminate pouch to the surface area of ​​the major surface of the electrochemical stack is greater than 1.2, again causing the laminate pouch to surround the frame, creating more space between each minor surface of the electrochemical stack and the frame.

[0144]

[0156] FIG. 6A shows a flat terminal or tab 6060 similar to terminal or tab 2060, 2160 in FIGS. 2A and 2B. To reduce the head space, in one embodiment the terminal or tab can be shortened by various types of bends to reduce the head space. FIG. 6B shows a bent terminal or tab 6160. To obtain more terminal area while still reducing the head space, a variation in FIG. 6C shows a terminal or tab 6260 with a Z-shaped bend. In yet another variation, FIG. 6D shows a folded terminal or tab 6360, where a crease 6260a can be seen under the folded portion of the terminal or tab 6360.

[0145]

[0157] Figures 6E-6G show various types of fixtures for configurations such as Figure 2C having a cathode cell terminal 2231 and an anode cell terminal 2232. In one embodiment, a flat portion 616 in each of Figures 6E-6G can be attached to the cathode 2231 and anode 2232, respectively. In Figure 6E, a protrusion 626 can extend from the flat portion 616. Although the protrusion 626 in Figure 6E is shown as having a cylindrical cross-section, one of ordinary skill in the art will recognize that the protrusion can have another cross-section, such as square or rectangular, and / or can extend from the flat portion 616 a different amount as needed or desired.

[0146]

[0158] In Figure 6F, tab 636 extends from flat portion 616 and has a through hole 638. In Figure 6G, folded or bent portion 646 extends from flat portion 616. In any of the embodiments of Figures 6F-6G, protrusion 626, tab 636, or folded or bent portion 646 can function as a terminal for electrically connecting cathode 2231 or anode 2232 as part of an overall battery system.

[0147]

[0159] Figure 7A shows a frame 7020 surrounding an electrochemical stack 7030 with terminals 7060 (similar to those shown in Figure 6A) extending from the cathode and anode (not shown), respectively. Figure 7B shows a variation of the structure in Figure 7A with bent terminals or tabs 7160 (similar to those shown in Figure 6B), which reduces headspace in the resulting solid electrolyte battery in its laminate pouch. Figure 7C shows a similar variation with the electrochemical stack 7030 and bent terminals or tabs 7260 extending therefrom.

[0148]

[0160] In some examples, including any of the above, the major surface of the electrochemical stack has a rectangular shape and dimensions of 64 mm by 79 mm. Figure 7C shows an example of an electrochemical stack 7030. In one embodiment, the stack 7030 has dimensions of 64 mm by 79 mm. On the left side of Figure 7C are two terminals or tabs 7260 that contact and extend away from the electrochemical stack 7030.

[0149]

[0161] In different embodiments, the dimensions of the electrochemical stack may be larger or smaller depending on how the finished pouch is to be placed or installed. The ratio between the length and width may also vary. For example, the electrochemical stack may range from about 60 mm to about 100 mm in width and about 70 mm to about 250 mm in length. In some examples, the electrochemical stack may range from about 80 mm to about 100 mm in width and about 100 mm to about 130 mm in length. In some examples, the ratio between the length and width may be between about 1.2:1 and about 2.50:1. In some examples, the ratio may be between about 1.2:1 and about 1.5:1.

[0150]

[0162] In some instances, the terminals or tabs can be bent. In some instances, the terminals or tabs can be folded. In some instances, the terminals or tabs can be bent or folded to reduce head space.

[0151]

[0163] In some examples, including any of the above, the electrochemical cells on one side of the central wall include a cathode and the electrochemical cells on the other side of the central wall include a second cathode, the cathode being thicker than the second cathode.

[0152]

[0164] In some examples, including any of the above, the electrochemical cells on one side of the central wall include a cathode and the electrochemical cells on the other side of the central wall include a second cathode, the cathode having a higher energy density than the second cathode.

[0153]

[0165] In some examples, including any of the above, the electrochemical cells on one side of the central wall include a cathode and the electrochemical cells on the other side of the central wall include a second cathode, the cathode providing a higher power output than the second cathode.

[0154]

[0166] In some examples, including any of the above, the electrochemical cell on one side of the central wall includes a cathode and the electrochemical cell on the other side of the central wall includes a second cathode, the cathode providing a higher capacity than the second cathode.

[0155]

[0167] In some examples, including any of the foregoing, a module includes two or more of any of the electrochemical stacks and / or electrochemical stack assemblies described herein.

[0156]

[0168] In some examples, including any of the above, the module includes a positive electrode in each electrochemical cell, and the thickness of the positive electrode in at least one of the two or more electrochemical stack assemblies is greater than the positive electrode in another electrochemical stack assembly. In these examples, the thicker positive electrode has more active material and a higher energy density. In these examples, the thinner positive electrode has less active material and a higher power output.

[0157]

[0169] In some examples, energy cells are described herein. Energy cells are electrochemical cells in an electrochemical stack assembly. In some examples, power cells are described herein. Power cells are electrochemical cells in an electrochemical stack assembly. Energy cells are considered energy cells because they have a thicker positive electrode (i.e., more cathode active material, e.g., NMC, LFP, lithium titanium oxide (LTO), etc.) compared to power cells (i.e., less cathode active material). In some examples, a battery module includes one or more electrochemical stack assemblies, some of which include energy cells and other electrochemical stack assemblies include power cells. In some examples, a battery module includes one or more electrochemical stack assemblies, each of which includes a combination of energy cells and power cells. In some examples, a battery module includes one or more electrochemical stack assemblies, each of which includes a combination of energy cells and power cells, and there are more energy cells than power cells. In some other examples, a battery module includes one or more electrochemical stack assemblies, where each electrochemical stack assembly includes a combination of energy cells and power cells, and where there are more power cells than energy cells. In some examples, the energy and capacity of these cells and modules are tailored to customer specifications and requirements.

[0158]

[0170] In some examples, including any of the above, the module includes a positive electrode in each electrochemical cell, and the thickness of the positive electrode in at least one of the two or more electrochemical stack assemblies is less than the thickness of the positive electrode in another of the electrochemical stack assemblies.

[0159]

[0171] In some examples, including any of the above, the module includes a positive electrode in each electrochemical cell, and the positive electrode in at least one of the two or more electrochemical stack assemblies has a higher energy density than a positive electrode in another of the electrochemical stack assemblies.

[0160]

[0172] In some examples, including any of the above, the module includes a positive electrode in each electrochemical cell, and the positive electrode in at least one of the two or more electrochemical stack assemblies has a higher power output than a positive electrode in another of the electrochemical stack assemblies.

[0161]

[0173] In some examples, including any of the above, the module includes a positive electrode in each electrochemical cell, and the positive electrode in at least one of the two or more electrochemical stack assemblies has a higher capacity than the positive electrode in another electrochemical stack assembly.

[0162]

[0174] In some examples, including any of the above, the module includes a positive electrode in each electrochemical cell, wherein the positive electrode in at least one or more of the two or more electrochemical stack assemblies has a higher power output than a positive electrode in another of the electrochemical stack assemblies; and further, the positive electrode in at least one or more others of the two or more electrochemical stack assemblies has a higher energy density than the positive electrode electrochemical stack assembly.

[0163]

[0175] In some examples, including any of the foregoing, described herein are packs that include a module described herein, or a combination of modules described herein.

[0164]

[0176] For example, various electrochemical stack assemblies that can be used with the disclosure herein are shown below: This list is not meant to be limiting as other configurations are contemplated.

[0165]

[0177] Packs including modules, so-called energy modules, that have a higher energy density than other modules in the same pack are contemplated herein. Packs including modules, so-called power modules, that provide a higher power output than other modules in the same pack are contemplated herein. Packs including modules that have a higher capacity than other modules in the same pack are contemplated herein. Provided herein is a pack including one type of module and another pack including another type of module, the pack including a higher energy density than the other pack. Provided herein is a pack including one type of module and another pack including another type of module, the pack including a higher power output than the other pack. Provided herein is a pack including one type of module and another pack including another type of module, the pack including a higher capacity than the other pack.

[0166]

[0178] In some examples, for a particular electrochemical stack assembly having 16 layers or 8 unit cells as described herein, the capacity (measured at C / 3, 25° C.) is 1.35 Ah to 1.65 Ah, the energy density (measured at C / 3, 25° C.) is 5.2 Wh to 6.2 Wh, the Specify Energy is 45 Wh / kg to 55 Wh / kg, the energy density is 61 Wh / L to 73 Wh / L, the specific energy of the active stack is 155 Wh / kg to 189 Wh / kg, and the energy density of the active stack is 520 Wh / L to 634 Wh / L.

[0167]

[0179] In some examples, for a particular electrochemical stack assembly having 32 layers or 16 unit cells as described herein, the capacity (measured at C / 3, 25° C.) is between 1.7 Ah and 3.2 Ah, the energy density (measured at C / 3, 25° C.) is between 10.4 Wh and 12.4 Wh, the Specify Energy is between 90 Wh / kg and 110 Wh / kg, the energy density is between 122 Wh / L and 146 Wh / L, the specific energy of the active stack is between 310 Wh / kg and 380 Wh / kg, and the energy density of the active stack is between 1040 Wh / L and 1268 Wh / L.

[0168]

[0180] In some examples, for a particular electrochemical stack assembly having 48 layers or 24 unit cells as described herein, the capacity (measured at C / 3, 25° C.) is 7.7 Ah to 9.3 Ah, the energy density (measured at C / 3, 25° C.) is 29.7 Wh to 34.1 Wh, the Specify Energy is 167 Wh / kg to 203 Wh / kg, the energy density is 348 Wh / L to 424 Wh / L, the specific energy of the active stack is 288 Wh / kg+352 Wh / kg, and the energy density of the active stack is 983 Wh / L to 1201 Wh / L.

[0169]

[0181] In some examples, for a particular electrochemical stack assembly having 60 layers or 30 unit cells as described herein, the capacity (measured at C / 3, 25° C.) is 8 Ah to 11 Ah, the energy density (measured at C / 3, 25° C.) is 40 Wh to 60 Wh, the Specify Energy is 200 Wh / kg to 300 Wh / kg, the energy density is 400 Wh / L to 450 Wh / L, the specific energy of the active stack is 300 Wh / kg to 400 Wh / kg, and the energy density of the active stack is 1000 Wh / L to 1300 Wh / L.

[0170]

[0182] In some examples, for a particular electrochemical stack assembly having 72 layers or 36 unit cells as described herein, the capacity (measured at C / 3, 25° C.) is 46 Ah to 38 Ah, the energy density (measured at C / 3, 25° C.) is 148 Wh to 182 Wh, the Specify Energy is 315 Wh / kg to 386 Wh / kg, the energy density is 880 Wh / L to 1078 Wh / L, the specific energy of the active stack is 372 Wh / kg to 454 Wh / kg, and the energy density of the active stack is 1270 Wh / L to 1553 Wh / L.

[0171]

[0183] In some examples, for a particular electrochemical stack assembly having 72 layers or 36 unit cells as described herein, the capacity (measured at C / 3, 25° C.) is 37 Ah to 45 Ah, the energy density (measured at C / 3, 25° C.) is 140 Wh to 171 Wh, the Specify Energy is 308 Wh / kg to 377 Wh / kg, the energy density is 837 to 1023 Wh / L, the active stack specific energy is 369 Wh / kg to 451 Wh / kg, and the active stack energy density is 1270 Wh / L to 1553 (Wh / L).

[0172]

[0184] In some examples, for a particular electrochemical stack assembly having 84 layers or 42 unit cells as described herein, the capacity (measured at C / 3, 25° C.) is 50 Ah to 60 Ah, the energy density (measured at C / 3, 25° C.) is 250 to 50 Wh to 6.2 Wh, the Specify Energy is 45 Wh / kg to 56 Wh / kg, the energy density is 60 Wh / L to 74 Wh / L, the active stack specific energy is 154 Wh / kg to 189 Wh / kg, and the active stack energy density is 519 Wh / L to 634 Wh / L.

[0173]

[0185] In some examples, for a particular electrochemical stack assembly having 98 layers or 49 unit cells as described herein, the capacity (measured at C / 3, 25° C.) is between 33.6 Ah and 41.1 Ah, the energy density (measured at C / 3, 25° C.) is between 129.5 Wh and 158.3 Wh, the Specify Energy is between 266 Wh / kg and 325 Wh / kg, the energy density is between 769 Wh / L and 940 Wh / L, the active stack specific energy is between 312 Wh / kg and 382 Wh / kg, and the active stack energy density is between 1376 Wh / L and 1125 Wh / L.

[0174]

[0186] In some examples, for a particular electrochemical stack assembly having 98 layers or 49 unit cells as described herein, the capacity (measured at C / 3, 25° C.) is 32 Ah to 39 Ah, the energy density (measured at C / 3, 25° C.) is 123 Wh to 150 Wh, the Specify Energy is 260 to 318 Wh / kg, the energy density is 733 Wh / L to 895 Wh / L, the active stack specific energy is 309 Wh / kg to 377 Wh / kg, and the active stack energy density is 1376 Wh / L to 1125 Wh / L.

[0175]

[0187] Figure 8 illustrates an exemplary structure for welding a terminal to the cathode or anode of an electrochemical stack according to one embodiment. In Figure 8, the cathode 813 or anode 823 from electrochemical stacks 803a and 803b, respectively, along with a formed terminal 806, are pressed between a welding head 860 and anvil 870. Heat is applied to the welding head to weld the terminal 806 to the cathode 813 or anode 823. In Figure 8, the frame 802 or 804 surrounds the electrochemical stack 803b, so stack 803b is not visible in the figure.

[0176]

[0188] Figure 9A shows an image of the top or bottom portion of a laminate pouch, while Figures 9B, 9C, and 9D show images of the laminate pouch containing an electrochemical stack with positive and negative terminals extending through the laminate pouch.

[0177]

[0189] Figure 9E shows another image of the top or bottom portion of the laminate pouch. Figure 9F depicts a side view of the top or bottom portion of the laminate pouch, showing a width that in one embodiment can be about 70.5 mm. Figure 9G is a top view of the pouch portion, and Figures 9H and 9I are cross-sections of Figure 9G at lines HH and II, respectively, showing further dimensions of one embodiment of the pouch portion. Figure 9J shows further detail of Figure 9I at the circled element J. This circled element is the fold or bend portion that is also shown in detail in a different view in Figure 9L.

[0178]

[0190] Figure 9K shows further dimensions of some of the pouch portions according to one embodiment. Figures 9L and 9M show detailed views of circled elements L and M, respectively, in Figure 9H, and also show further dimensions of some of the pouch portions according to one embodiment.

[0179]

[0191] In one embodiment, as shown in FIG. 9N, the sides of the laminate pouch portion may remain flat when the pouch is assembled around the frame. FIG. 9O shows representative dimensions. In one embodiment, as shown in FIG. 9P, one or more ends of the pouch portion (in some cases up to three ends) may be rolled up in a manner similar to the "jelly roll" configuration of a battery cell. Rolling up the ends can save space when placing the pouch inside a motorized device such as an automobile. FIG. 9Q shows representative dimensions. With the ends rolled up, the length and width are smaller in FIG. 9P and 9Q than in FIG. 9N and 9O.

[0180]

[0192] In one embodiment, the side of the assembled laminate pouch opposite the electrodes may be left unrolled and may be inserted into a grooved metal piece 250 to facilitate heat dissipation, as shown in Figure 9R. In one embodiment, the side of the assembled pouch may be inserted between a flat metal piece 260 on a pedestal 270 to facilitate heat dissipation, as shown in Figure 9S.

[0181]

[0193] In some examples, including any of the above, the inner portion of the frame has dimensions of 65 mm by 80 mm, which provides a 1 mm margin around the perimeter of the 64 mm by 79 mm electrochemical stack. In one embodiment, the 1 mm margin is evenly distributed around the four edges or minor surfaces of the electrochemical stack, providing a 0.5 mm margin on each edge or minor surface of the electrochemical stack.

[0182]

[0194] In some examples, including any of the above, the inner portion of the frame has dimensions of 64.75 mm by 79.75 mm, resulting in a 0.75 mm margin around a 64 mm by 79 mm electrochemical stack. In one embodiment, the 0.75 mm margin is evenly distributed around the four ends or minor surfaces of the electrochemical stack, resulting in a 0.375 mm margin on each end or minor surface of the electrochemical stack. In some examples, the inner portion of the frame has dimensions of 64.5 mm by 79.5 mm, resulting in a 0.5 mm margin around a 64 mm by 79 mm electrochemical stack. In one embodiment, the 0.5 mm margin is evenly distributed around the four ends or minor surfaces of the electrochemical stack, resulting in a 0.25 mm margin on each end or minor surface of the electrochemical stack. More generally, whatever the size of the electrochemical stack that the frame surrounds, there may be a 0.75 mm margin around the stack, or a 0.5 mm margin around the stack. Those skilled in the art will recognize that depending on the size of the electrochemical stack, there should be an appropriate margin around the stack to accommodate expansion.

[0183]

[0195] As discussed above, the electrochemical stack may have a length to width ratio of about 1.2:1 to about 2.5:1. The spacing between the electrochemical stack and the frame may be provided as an absolute number, e.g., 0.5 mm to 2 mm, or as a percentage of the length and / or width, e.g., about 0.005% to 1%. Thus, in some examples, the electrochemical stack may have dimensions larger than those discussed above, and the length to width ratio may be as discussed above. In embodiments, the spacing is evenly distributed around the four ends of the electrochemical stack.

[0184]

[0196] In some examples, including any of the above, the thickness of the laminate pouch configuration may be about 13.5 mm.

[0185]

[0197] In some examples, including any of the above, the at least one positive terminal and the at least one negative terminal extend through the frame and the pre-formed pouch.

[0186]

[0198] In some examples, including any of the foregoing, the laminate pouch is a multi-layer pouch. In some examples, the laminate pouch has a layer of aluminum with one or more layers of polymeric material on either side of the aluminum. In some examples, the layer of aluminum is 10 μm thick. In some examples, the layer of aluminum is 20 μm thick. In some examples, the layer of aluminum is 30 μm thick. In some examples, the layer of aluminum is 40 μm thick. In some examples, the layer of aluminum is 50 μm thick. In some examples, the layer of aluminum is 60 μm thick. In some examples, the layer of aluminum is 70 μm thick. In some examples, the layer of aluminum is 80 μm thick. In some examples, the layer of aluminum is 90 μm thick. In some examples, the layer of aluminum is 100 μm thick.

[0187]

[0199] 10A is a high level diagram of the structure of an electrochemical stack according to one embodiment. In FIG. 10A, in one embodiment, an electrochemical stack 1000 includes an anode current collector 1050; a top seal 1060 below the anode current collector 1050 and a bottom seal 1060 at the bottom of the stack; a first film layer 1070 below the top seal 1060 and a second film layer 1080 above the bottom seal 1060; and a pair of cathode seals 1080 on either side of a dual cathode 1090.

[0188]

[0200] 10B is a high level view of the structure of an electrochemical stack bonded to a frame center plate according to one embodiment. Proceeding from right to left in FIG. 10B, the electrochemical stack is bonded to a center wall 1010 using an adhesive 1012, which may include a pressure sensitive adhesive according to one embodiment. In one embodiment, the center wall 1010 may be part of a frame. On top of the adhesive 1012 is an anode current collector 1050. On top of the anode 1050 is a seal 1060. On top of the seal is a first film 1070. The seal 1080 surrounds a cathode 1090. On top of the combination of the seal 1080 and cathode 1090 is an additional film 1070. Depending on the embodiment, a frame 1095 may surround the cathode 1080.

[0189]

[0201] 10C is a high level view of a two-layer unit cell 2430 according to one embodiment. At the top and bottom of the electrochemical stack 2430 are anode current collectors 1055. Adjacent to the anode 1055 and inside the anode current collector 1055 as part of the electrochemical stack 2430 are anode supports 1065. Inside the anode support 1065 in the electrochemical stack 2430 is a separator 1075. Inside the separator 1075 is a cathode frame 1085. Finally, at the center of the electrochemical stack 2430 is a cathode current collector 1095 which works with both anodes 1055. Depending on the embodiment, the cathode current collector 1095 may be fitted within the cathode frame 1085.

[0190]

[0202] FIG. 10D is a high level exploded view of a prismatic frame 2400 in a pouch containing unit cells such as those depicted in FIG. 10C according to one embodiment. In the embodiment of FIG. 10D, four unit cells 2430 are assembled to form an eight-layer unit stack 2435. In a different embodiment, there can be an adhesive layer (not shown) between adjacent unit cells 2430 to facilitate maintaining the unit cells 2430 in alignment with one another. In a different embodiment, the unit cells 2430 can be assembled without an adhesive layer using pressure of the remaining portions of the prismatic frame 2400 in the pouch, such as drawing a vacuum inside the pouch, where the upper and lower stacked portions contact the top and bottom of the frame and the electrochemical stack assembly to maintain the unit cells 2430 in alignment with one another.

[0191]

[0203] 10D, laminate preforms 2410, 2450 form the upper and lower portions of laminate pouch assembly 2400. Below laminate preform 2410 is spacer block 2410a and compressible sheet 2415a, shown as rubber according to one embodiment, and above laminate preform 2450 is spacer block 2410b and compressible sheet 2415b. In one embodiment, spacer block 2410b and compressible sheet 2415b are inside frame 2420. Below compressible sheet 2415 is 8 layer unit stack 2435a and above compressible sheet 2415b is 8 layer unit stack 2435b. At the center of the laminate pouch is a frame portion 2440 having a central plate or surface 2440a and edges 2441-2444 extending upwardly from the central surface 2440a to form a tray 2445. Bonding layers 2446 may be provided on either side to adhere each eight-ply stack 2435a, 2435b to the central surface 2440a. In different embodiments, the spacer blocks 2410a and 2410b may be compressible.

[0192]

[0204] FIG. 10D depicts an 8-layer unit stack 2435a, 2435b for a total of 16 cells. In some embodiments, there can be a different number of layers and a different number of unit cells to form the unit stack. For example, there can be two 8-layer stacks on either side of the central surface 2440a for a total of 32 cells. Or, there can be three 8-layer stacks on either side of the central surface 2440a for a total of 48 cells. In some embodiments, there can be a different number of 8-layer stacks on either side of the central surface 2440a. The number of unit cells in the stack can also vary. As described elsewhere, there can be as many as 100 unit cells in the stack. Depending on the embodiment, all anode electrodes in the unit stack can be secured together, for example by welding, and the same can be said for the cathode electrodes, depending on the embodiment as well.

[0193]

[0205] Some examples, including any of the above, include a solid electrolyte separator that includes a lithium-filled garnet electrolyte.

[0194]

[0206] In some examples, including any of the above, the negative electrode includes lithium metal.

[0195]

[0207] In some examples, including any of the above, the electrochemical stack further includes a central wall.

[0196]

[0208] In some examples, including any of the above, the electrochemical stack further includes a central wall, as shown in numerous figures, such as Figures 2B, 3A-3D, 5A, and 5B.

[0197]

[0209] In some examples, including any of the above, the electrochemical stack further includes a center wall mounted on one half of the frame.

[0198]

[0210] In some examples, including any of the above, the central wall is attached to either the positive or negative electrode of the electrochemical stack.

[0199]

[0211] In some examples, including any of the above, the center wall is attached to either the positive or negative electrode of the electrochemical stack using a pressure sensitive adhesive.

[0200]

[0212] In some examples, including any of the above, the frame includes a surface that is parallel to a major surface of the electrochemical stack.

[0201]

[0213] In some examples, including any of the above, the frame is attached to either the positive or negative electrode of the electrochemical stack using a pressure sensitive adhesive.

[0202]

[0214] 11A-11D are views of frame assemblies according to different embodiments. FIG 11A is an exploded view of a frame assembly 1110 including a first frame section 1111 and a second frame section 1115. In one embodiment, the frame section 1115 can be nested within the frame section 1111. In one embodiment, the frame section 1111 can be nested within the frame section 1115. In one embodiment, the frame section 1111 can be a suitable plastic and the insert 1115 can be a suitable metal.

[0203]

[0215] 11A, tabs 1112, 1113 are mounted over openings 1118 in frame sections 1111 and 1115. In one embodiment, these tabs 1112, 1113 contact the cathode and anode, respectively, in an electrochemical stack that is within the frame 1110.

[0204]

[0216] FIG. 11B is an assembled view of frame assembly 1110 with frame portions 1111 and 1115 nested one within the other, with tabs 1112, 1113 inserted into openings in frame portions 1111 and 1115.

[0205]

[0217] 11C and 11D show two embodiments of the outer portion of the frame assembly. In FIG. 11C, the outer frame portion 1130 has four different types of protrusions. Protrusion 1131 has tabs extending from a rectangular portion 1135. These tabs have holes through them. Protrusion 1132 is a tab with a recess therein. Protrusion 1133 is a tab with a cylindrical portion extending upward. Depending on the embodiment, the extensions can have different cross sections. For example, protrusion 1134 is a tab with a protrusion of a rectangular cross section extending upward. All of these configurations can be useful when attaching laminate pouches to each other or inside an area that can hold one or more laminate pouches. FIG. 11C also has openings 1138 that can connect to each of the cathodes and anodes in an electrochemical stack that is placed within the frame assembly.

[0206]

[0218] In Figure 11D, outer frame portion 1140 has a flange-type portion 1141 that extends outwardly around most of the periphery of a rectangular portion 1145 that surrounds the electrochemical stack. A protrusion 1142 also extends from rectangular portion 1145. Figure 11D also has openings 1148 that are connectable to each of the cathodes and anodes in an electrochemical stack that is disposed within the frame assembly.

[0207]

[0219] FIG. 12 shows an exploded view of the assembly 1200. The assembly 1200 includes upper and lower laminate parts 1210, 1250, which may include flexible layered polymers, which may be similar to the materials described with respect to other embodiments. Inside the laminate parts 1210, 1250 are two stacks of cells 1230a, 1230b. The cell layers 1230a, 1230b are placed on either side of a central plate 1245, which is part of a metal frame 1240. When assembled, the cells 1230a, 1230b are encapsulated inside a pouch formed by the upper and lower laminate parts 1210, 1250. When the pouch is vacuum sealed (i.e., when a vacuum is drawn inside the pouch), the cells 1230a, 1230b can be tightly packed together on either side of the central plate 1245.

[0208]

[0220] When fully discharged, all the Li in the cell is in the cathode. The cell itself has no Li in the anode. As a result, the cell is in its most compressed state. In this state, the face of the cell is slightly below the frame 1240, in some embodiments, 1 or 2 mm below. As each cell is charged and the anode of each cell layer is plated with Li, each cell stack expands. The flexible packaging material expands with the stack, eventually flush with the cell frame.

[0209]

[0221] In one embodiment, when each cell is charged, the anode of each layer is plated with pure Li, which causes the layers to expand and the respective stack to expand. As the layers expand, the outer walls of each cell 1230a, 1230b expand with them, eventually reaching the end of the frame 1240. This frame 1240 protects the ends of each cell and allows the cells to be tightly packed together without the expansion of one cell affecting the next. When each cell is discharged, the layers contract back into their respective cells. As a result, the assembly 1200 can be seen to breathe during each cell cycle.

[0210]

[0222] As a result of the structures described in the various embodiments, the cells that are part of the stack on the frame assembly can dissipate excess heat during charging, such as fast charging. The cells can function with or without externally applied pressure.

[0211]

[0223] The exterior walls of each cell 1230a, 1230b can expand, but the center plate 1245 can transfer heat away from the center of the stack above the frame assembly and carry heat from the interior of each cell up to the frame 1240. The frame 1240 can then be cooled from the top, bottom, or sides depending on the pack configuration. In connection with the cooling functions described herein, it should be noted that pure Li is a much better thermal conductor than the graphite in conventional EV batteries.

[0212]

[0224] In some examples, including any of the above, the thickness of the center plate (variously referred to as the center plate, center surface, center wall, and in some cases the junction plate, as described above) may be 0.3 mm. In some examples, including any of the above, the thickness of the center plate (variably referred to as the center plate, center surface, center wall, and in some cases the junction plate, as described above) may be 0.4 mm. In some examples, including any of the above, the thickness of the center plate (variably referred to as the center plate, center surface, center wall, and in some cases the junction plate, as described above) may be 0.5 mm. In some examples, including any of the above, the thickness of the center plate (variably referred to as the center plate, center surface, center wall, and in some cases the junction plate, as described above) may be 0.6 mm. In some examples, including any of the above, the thickness of the center plate (variably referred to as the center plate, center surface, center wall, and in some cases the junction plate, as described above) may be 0.7 mm. In some examples, including any of the above, the thickness of the center plate (variously referred to as the center plate, center surface, center wall, and in some cases the junction plate, as described above) may be 0.8 mm. In some examples, including any of the above, the thickness of the center plate (variably referred to as the center plate, center surface, center wall, junction plate, as described above) may be 0.9 mm. In some examples, including any of the above, the thickness of the center plate (variably referred to as the center plate, center surface, center wall, junction plate, as described above) may be 1.0 mm. In some examples, including any of the above, the thickness of the center plate (variably referred to as the center plate, center surface, center wall, junction plate, as described above) may be 1.1 mm. In some examples, including any of the above, the thickness of the center plate (variably referred to as the center plate, center surface, center wall, junction plate, as described above) may be 1.2 mm. In some examples, including any of the above, the thickness of the center plate (variously referred to as the center plate, center face, center wall, plate, and in some cases the joint plate, as described above) may be 1.3 mm. In some examples, including any of the above, the thickness of the center plate (variably referred to as the center plate, center face, center wall, plate, and in some cases the joint plate, as described above) may be 1.4 mm.In some examples, including any of the above, the thickness of the center plate (variously referred to as the center plate, center face, center wall, plate, and in some cases the joint plate, as described above) may be 1.5 mm. In some examples, including any of the above, the thickness of the center plate (variably referred to as the center plate, center face, center wall, plate, and in some cases the joint plate, as described above, also referred to as the plate) may be 1.6 mm.

[0213]

[0225] 13A-13C show diagrams of a half-stack flat plate design of an electrochemical stack assembly 1300 according to one embodiment. In one embodiment, an active cell stack 1320 sits on one surface 1340a of a flat plate 1340 and is surrounded by a frame 1350. The opposite surface 1340b of the flat plate 1340 is the bottom-facing side of this design according to one embodiment. Unlike previous embodiments where a central plate or wall has cell stacks on opposite sides, according to one embodiment as in FIGs. 13A-13C, only one active cell stack sits on the flat plate 1340, so that the opposite surface 1340b only conducts heat from that active cell stack 1320. A laminate pouch (not shown) surrounds the frame 1350, the flat plate 1340, and the active cell stack. With this type of configuration, cooling is more efficient because not only is one cell stack cooled instead of two, but the opposing surface 1340b within the laminate pouch (not shown) can also be easily mounted, for example, onto the surface of the device being powered, thereby providing additional heat transfer capabilities.

[0214]

[0226] In one embodiment, two electrochemical stack assemblies such as those shown in Figures 13A-13C can be positioned such that the opposing surfaces 1340b of the plates 1340 in each assembly face each other and can be joined together. A laminating pouch (not shown) surrounds the two electrochemical stack assemblies.

[0215]

[0227] In one embodiment, electrodes 1360 protrude near the opposing surface. Electrodes 1360 can be soldered without the need for special bending. Overall, the configuration according to the described embodiment allows for easy mounting of the resulting pack and promotes heat transfer as previously discussed.

[0216]

[0228] In some examples, including any of the above, the half-stack plate described immediately above can be placed inside the laminate pouch as described above in various ways. In some examples, including any of the above, two half-stack plates can be placed back-to-back, with their respective plates facing or in contact with each other, and the two plates can form a central wall, or central plate, or central surface of a prismatic frame in the overall pouch. Those skilled in the art will recognize that the thicknesses of the central wall / plate / surface described above can be applied to the plates.

[0217] Method for manufacturing electrochemical stacks in pouches

[0229] Described herein is a novel method of protecting prismatic battery cells with a surrounding (mechanical structure) frame. Prismatic battery cells are evacuated, seams are sealed, and present in a stack of cells in a laminate pouch. The laminate pouch can have electrical terminals protruding outside of the laminate pouch. The resulting prismatic frame in the pouch protects the prismatic battery cells.

[0218]

[0230] In some embodiments, cells including solid cathodes are packaged in the electrochemical stacks disclosed herein.

[0219]

[0231] In some embodiments, a cell including a cathode, where the cathode comprises a solid catholyte, is packaged in an electrochemical stack as disclosed herein.

[0220]

[0232] In one example, an electrochemical stack is provided that includes a series of electrochemical cells arranged in series.

[0221]

[0233] In one other example, an electrochemical stack is provided that includes a series of electrochemical cells arranged in parallel.

[0222]

[0234] In some examples, including any of the above, the electrochemical cell includes a lithium metal negative electrode.

[0223]

[0235] In some examples, including any of the above, the electrochemical cell includes a solid electrolyte.

[0224]

[0236] In some examples, including any of the above, the electrochemical cell includes a solid electrolyte separator that includes a lithium-loaded garnet.

[0225]

[0237] A positive terminal is attached to the electrochemical stack.

[0226]

[0238] A negative terminal is attached to the electrochemical stack.

[0227]

[0239] The electrochemical stack is bonded via pressure sensitive adhesive to a bonding plate that is also part of one half of the frame.

[0228]

[0240] In one example, the electrochemical stack is attached to a surface on a frame via a pressure sensitive adhesive (PSA) material at either the top major surface 101 or the bottom major surface 102. The PSA holds the stack against the surface, either via the top major surface 101 or the bottom major surface 102, from moving within the frame during charging and discharging. The PSA keeps the minor surfaces of the electrochemical stack from contacting the frame. In one example, the top major surface 101 is bonded to the frame at a central wall, shown at 302 in FIG. 3A. In one example, the bottom major surface 102 is bonded to the frame at a central wall, shown at 302 in FIG. 3A.

[0229]

[0241] The other half of the frame is connected and attached to the one half of the frame.

[0230]

[0242] The laminate is manufactured in a molded shape, which in some instances corresponds to the shape of the electrochemical stack.

[0231]

[0243] In some examples, including any of the above, the laminate has multiple layers. In some examples, the laminate has five layers. In some of these examples, the multiple layers include a polyester (PET) layer adjacent to an oriented nylon (ONy) layer. The ONy layer is adjacent to an aluminum layer. The aluminum layer is adjacent to a non-adhesive sealable chemically bonded polyphthalamide (PPa) layer. The PPa layer is adjacent to a polypropylene (PP) layer. In some examples, the order of these layers may vary. In some examples, including any of the above, there may be six or more layers, some or all of which may be one or more of the five materials listed immediately above. In some examples, including any of the above, there may be fewer than five layers, some or all of which may be one or more of the five materials listed immediately above.

[0232]

[0244] In some examples, including any of the foregoing, the polymeric material on either side of the aluminum can include one or more of polypropylene (PP), polyphthalamide (PPa), polyethylene terephthalate (PET), and oriented nylon (ONy).

[0233]

[0245] In some examples, including any of the above, the thickness of the PP layer is 10 μm. In some examples, including any of the above, the thickness of the PP layer is 20 μm. In some examples, including any of the above, the thickness of the PP layer is 30 μm. In some examples, including any of the above, the thickness of the PP layer is 40 μm. In some examples, including any of the above, the thickness of the PP layer is 50 μm. In some examples, including any of the above, the thickness of the PP layer is 60 μm. In some examples, including any of the above, the thickness of the PP layer is 70 μm. In some examples, including any of the above, the thickness of the PP layer is 80 μm. In some examples, including any of the above, the thickness of the PP layer is 90 μm. In some examples, including any of the above, the thickness of the PP layer is 100 μm.

[0234]

[0246] In some examples, including any of the above, the thickness of the PPa layer is 10 μm. In some examples, including any of the above, the thickness of the PPa layer is 20 μm. In some examples, including any of the above, the thickness of the PPa layer is 30 μm. In some examples, including any of the above, the thickness of the PPa layer is 40 μm. In some examples, including any of the above, the thickness of the PPa layer is 50 μm. In some examples, including any of the above, the thickness of the PPa layer is 60 μm. In some examples, including any of the above, the thickness of the PPa layer is 70 μm. In some examples, including any of the above, the thickness of the PPa layer is 80 μm. In some examples, including any of the above, the thickness of the PPa layer is 90 μm. In some examples, including any of the above, the thickness of the PPa layer is 100 μm.

[0235]

[0247] In some examples, including any of the above, the layer of ONy is 10 μm thick. In some examples, including any of the above, the layer of ONy is 20 μm thick. In some examples, including any of the above, the layer of ONy is 30 μm thick. In some examples, including any of the above, the layer of ONy is 40 μm thick. In some examples, including any of the above, the layer of ONy is 50 μm thick. In some examples, including any of the above, the layer of ONy is 60 μm thick. In some examples, including any of the above, the layer of ONy is 70 μm thick. In some examples, including any of the above, the layer of ONy is 80 μm thick. In some examples, including any of the above, the layer of ONy is 90 μm thick. In some examples, including any of the above, the layer of ONy is 100 μm thick.

[0236]

[0248] In some examples, including any of the above, the thickness of the layer of PET is 10 μm. In some examples, including any of the above, the thickness of the layer of PET is 20 μm. In some examples, including any of the above, the thickness of the layer of PET is 30 μm. In some examples, including any of the above, the thickness of the layer of PET is 40 μm. In some examples, including any of the above, the thickness of the layer of PET is 50 μm. In some examples, including any of the above, the thickness of the layer of PET is 60 μm. In some examples, including any of the above, the thickness of the layer of PET is 70 μm. In some examples, including any of the above, the thickness of the layer of PET is 80 μm. In some examples, including any of the above, the thickness of the layer of PET is 90 μm. In some examples, including any of the above, the thickness of the layer of PET is 100 μm.

[0237]

[0249] In some examples, including any of the above, the PET layer is about 12 μm thick. In some examples, including any of the above, the ONy layer is about 25 μm thick. In some examples, including any of the above, the aluminum layer is about 40 μm thick. In some examples, including any of the above, the aluminum layer is about 80 μm thick. In some examples, including any of the above, the PPa layer is about 30 μm thick. In some examples, including any of the above, the PP layer is about 30 μm thick.

[0238]

[0250] In some examples, including any of the above, the PET layer is about 12 μm thick. In some examples, including any of the above, the ONy layer is about 25 μm thick. In some examples, including any of the above, the aluminum layer is about 40 μm thick. In some examples, including any of the above, the aluminum layer is about 60 μm thick. In some examples, including any of the above, the PPa layer is about 40 μm thick. In some examples, including any of the above, the PP layer is about 40 μm thick.

[0239]

[0251] The PP layers are layered from one laminate form to another to form a laminate pouch. The sheets of the laminate are placed face to face so that the PP layers of each sheet are in contact. Heat is then applied to the areas to be joined. The PP layers melt together, thereby forming a pouch.

[0240] In some examples, including any of the above, the thickness of the laminate including all layers is 100-200 μm. In some examples, including any of the above, the thickness of the laminate including all layers is 140-190 μm. In some examples, including any of the above, the thickness of the laminate including all layers is 150-175 μm. In some examples, including any of the above, the thickness of the laminate including all layers is 160-185 μm.

[0241]

[0252] In some examples, including any of the above, the thickness of the laminate, including all layers, is 140 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 141 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 142 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 143 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 144 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 145 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 146 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 147 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 148 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 149 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 150 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 151 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 152 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 153 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 154 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 155 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 156 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 157 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 158 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 159 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 160 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 161 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 162 μm.In some examples, including any of the above, the thickness of the laminate, including all layers, is 163 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 164 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 165 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 166 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 167 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 168 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 169 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 170 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 171 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 172 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 173 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 174 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 175 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 176 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 177 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 178 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 179 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 180 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 181 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 182 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 183 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 184 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 185 μm.In some examples, including any of the above, the thickness of the laminate, including all layers, is 186 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 187 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 188 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 189 μm. In some examples, including any of the above, the thickness of the laminate, including all layers, is 190 μm. The laminate is sealed to another laminate to form a pouch.

[0242]

[0253] The laminate is manufactured from a flat sheet form. The form is placed in a pneumatic press. A die and a cavity are used to convert the flat sheet into a preformed shape. This includes debossing the form to raise a portion of the laminate up away from the laminate surface, and embossing the form to press a portion of the laminate down away from the laminate surface. A combination of debossing and embossing is used to form a shape in the laminate. By forming a shape in the laminate, when a vacuum is pulled on the sealed laminate, the laminate does not have to deform against either major surface of the electrochemical stack. Thus, the laminate is prestressed during its manufacture, so that there is no stress concentration on the electrochemical stack when the laminate is stretched on the frame. Because the laminate is pulled on the frame, there is a draft angle when it is stretched on the frame. In part, this draft angle creates a space between the laminate and the electrochemical stack, so that the laminate only contacts one or both major surfaces of the electrochemical stack.

[0243]

[0254] In some examples, including any of those mentioned above, a pneumatic press machine having a forming die and a cavity is used.

[0244]

[0255] The laminate is sealed. The bonded seal is formed by a heat sealing process. Some heat sealing processes involve simultaneously pressing two hot metal bars against the two laminate pouch parts until the polymer layers on each laminate melt and the two sheets are bonded (e.g., welded) together.

[0245]

[0256] By drawing a vacuum on the sealed laminate, the draft angle collapses relative to the frame but not to the subsurface. After a vacuum is drawn through the sealed laminate, the preformed portion of the laminate takes the shape of the frame. EXAMPLES

[0246] Example 1 - Vibration Testing - Prophetic Example

[0257] Vibration testing is used to ensure that the electrochemical stack does not move laterally within the frame (lateral movement in this example is movement perpendicular to the direction in which expansion and contraction of the electrochemical stack occurs. Lateral movement is movement in the x or y plane where the z direction is taken as being perpendicular to the top or bottom major surfaces 101 and 102 in FIG. 1 ).

[0247]

[0258] An electrochemical stack is provided.

[0248]

[0259] A vibration test according to UN 38.3 is carried out. This test consists of: · 7Hz~200Hz sine sweep; · 3 hours of time on each of the 3 axes; 7~18Hz to 1g; and 18~200Hz to 8g Includes.

[0249]

[0260] This test is based on ST / SG / AC.10 / 11 / Rev.6-Recommendations on the TRANSPORT OF DANGEROUS GOODS,Manual of Tests and Criteria,6 threvised edition, United Nations, New York and Geneva, 2015.

[0250]

[0261] UN 38.3 covers a wide range of "transport of dangerous goods" tests, including: · Advanced simulating; Thermal testing; ·vibration; ·impact; External short circuit; Collision and crushing; Overvoltage; and ·Forced discharge.

[0251] Example 2 - Vibration Test - Example

[0262] Vibration testing is used to ensure that the electrochemical stack does not move laterally within the frame (lateral movement in this example is movement perpendicular to the direction in which expansion and contraction of the electrochemical stack occurs. Lateral movement is movement in the x or y plane where the z direction is taken as being perpendicular to the top or bottom major surfaces 101 and 102 in FIG. 1 ).

[0252]

[0263] The Laminate on Frame (LOF) Laminate Sheet Tester is a machine that replicates the forces and movements of a preformed laminate sheet in a manner that simulates how the laminate responds to a 20% z-increment of an actual LOF battery during charge and discharge cycles. The tester simulates the expansion and contraction of an electrochemical stack using a plunger that exerts approximately 75 pounds of force against the inside of the laminate. This laminate tester simplifies the process of evaluating different laminate configurations and manufacturing layered adhesive technologies.

[0253]

[0264] In one example test, the laminate included a layer of aluminum 40 μm thick. In a second example test, the laminate included a layer of aluminum 80 μm thick.

[0254]

[0265] At 1000 cycles, the 40 μm aluminum exhibited fatigue failure and was rejected. The 80 μm aluminum thickness specimen survived 1000 cycles.

[0255]

[0266] Fatigue failure was confirmed by inspecting the laminate for fatigue failure with high resolution (VHX-6000 Camera) while illuminating it from behind (backlighting).

[0256]

[0267] A dummy electrochemical cell was used with the plunger device described above as a surrogate for an electrochemical cell undergoing expansion and contraction. A frame and laminate pouch according to one embodiment shown in FIG. 2A were provided. The frame included a central wall to which the plunger was attached with a pressure sensitive adhesive. The plunger was cycled 2.5 mm to simulate a "z" volume change. The cycles were performed at 5 minutes per cycle. The laminate pouch was sealed under vacuum (15 PSI). The pouch was D-EL80 6PH(3). Unexpectedly, no signs of degradation were observed after 1000 cycles for the laminate with an 80 μm aluminum layer.

[0257]

[0268] Another dummy electrochemical cell was provided in which the plunger device was a substitute for an electrochemical cell in which expansion and contraction occurred. A frame and laminate pouch according to one embodiment shown in FIG. 2A were provided. The frame included a central wall to which the plunger was attached with a pressure sensitive adhesive. The plunger was cycled 2.5 mm to simulate a "z" volume change. The cycles were performed at 30 seconds per cycle. The laminate pouch was sealed under vacuum (15 PSI). The pouch was D-EL80 6PH(3). Unexpectedly, no signs of degradation were observed after 5000 cycles.

[0258]

[0269] Aspects of the present invention are described in the following clauses: Clause 1. An electrochemical stack assembly comprising: one or more electrochemical cells, each electrochemical cell including a solid electrolyte and forming at least one electrochemical stack having two major surfaces and four minor surfaces; a frame surrounding the at least one electrochemical stack, the frame having a space between the frame and each of the four minor surfaces; a lamination pouch surrounding the frame and the at least one electrochemical stack and contacting one or both of the two major surfaces; an electrochemical stack assembly comprising:

[0259] Clause 2. The electrochemical stack assembly of clause 1, further comprising a central wall and an adhesive for adhering said central wall to one of said two major surfaces, said laminate pouch contacting the other of said two major surfaces.

[0260] Clause 3. The electrochemical stack assembly of clause 2, wherein the adhesive comprises a pressure sensitive adhesive.

[0261] Clause 4. The electrochemical stack assembly of clause 2 or clause 3, wherein the central wall comprises a thermally conductive material.

[0262] Clause 5. The electrochemical stack assembly of any of clauses 2-4, wherein the one or more electrochemical cells form at least two electrochemical stacks, each having two major surfaces and four minor surfaces, each of the at least two electrochemical stacks having one of the two major surfaces adhered to the central wall.

[0263] Clause 6. The electrochemical stack assembly of any of clauses 1-5, further comprising at least one positive terminal and at least one negative terminal.

[0264] Clause 7. The electrochemical stack assembly of any of clauses 1 to 6, wherein the frame is at a negative or positive potential.

[0265] Clause 8. The electrochemical stack assembly of any of clauses 1 to 6, wherein the frame is at a positive potential.

[0266] Clause 9. The electrochemical stack assembly of any of clauses 1-8, further comprising an insulating material for insulating the frame.

[0267] Clause 10. The electrochemical stack assembly of any of clauses 1-9, wherein the frame comprises a material selected from the group consisting of plastic, plastic with thermal additives, rubber, ceramic, clay, glass, reinforced glass, thermoplastic, carbon fiber, metal-plastic composite, aluminum, anodized aluminum, magnesium, magnesium-copper alloy, or aluminum-copper alloy, or a combination thereof.

[0268] Clause 11. The electrochemical stack assembly of any of clauses 1-10, wherein a space between the frame and the four minor surfaces of the at least one electrochemical stack, or each of the at least two electrochemical stacks, prevents application of forces by the laminate pouch against the four minor surfaces of the at least one electrochemical stack, or each of the at least two electrochemical stacks, during charge and discharge cycles of the at least one electrochemical stack, or each of the at least two electrochemical stacks, thereby preventing deformation, cracking, or other damage to the solid electrolyte in each of the one or more electrochemical cells.

[0269] Clause 12. The electrochemical stack assembly of any of clauses 1-11, wherein an interior of the lamination pouch is under a vacuum whereby the lamination pouch contacts one or both of the two major surfaces of the at least one electrochemical stack.

[0270] Clause 13. The electrochemical stack assembly of any of clauses 1-12, wherein an interior of the laminate pouch is under a vacuum whereby the laminate pouch contacts one of the two major surfaces of each of the at least two electrochemical stacks.

[0271] Clause 14. The electrochemical stack assembly of any of clauses 1-13, wherein an interior of the laminate pouch is under a vacuum whereby the laminate pouch contacts both of the two major surfaces of the at least one electrochemical stack.

[0272] Clause 15. The electrochemical stack assembly of any of clauses 1-14, wherein the space between the frame and the at least one electrochemical stack or the at least two electrochemical stacks provides room for the at least one electrochemical stack or the at least two electrochemical stacks to expand and contract during charge and discharge cycles without causing deformation, cracking, or other damage to the solid electrolyte in each of the one or more electrochemical cells.

[0273] Clause 16. The electrochemical stack assembly of any of clauses 1-14, wherein the space between the frame and the at least one electrochemical stack provides room for expansion of the at least one electrochemical stack during a charging cycle without causing deformation, cracking, or other damage to the solid electrolyte in each of the one or more electrochemical cells.

[0274] Clause 17. The electrochemical stack assembly of any of clauses 1-16, wherein the laminate pouch provides for expansion and contraction of about 20% in a direction perpendicular to at least one of the two major surfaces of the at least one electrochemical stack or the at least two electrochemical stacks.

[0275] Clause 18. The distribution of pressure across the two main surfaces of the at least one electrochemical stack or the at least two electrochemical stacks is greater than or equal to 10 mm 2 , 10cm 2 , or 10m 2 18. The electrochemical stack assembly of any of clauses 1-17, wherein the electrochemical stack assembly is uniform across a surface area of ​​the stack.

[0276] Clause 19. The distribution of pressure across the two main surfaces of the at least one electrochemical stack or the at least two electrochemical stacks is greater than or equal to 20 mm 2 , 20cm 2 , or 20m 2 18. The electrochemical stack assembly of any of clauses 1-17, wherein the electrochemical stack assembly is uniform across a surface area of ​​the stack.

[0277] Clause 20. The distribution of pressure across the two main surfaces of the at least one electrochemical stack or the at least two electrochemical stacks is greater than or equal to 30 mm 2 , 30cm 2 , or 30m 2 18. The electrochemical stack assembly of any of clauses 1-17, wherein the electrochemical stack assembly is uniform across a surface area of ​​the stack.

[0278] Clause 21. The electrochemical stack assembly of any of clauses 1-20, wherein said laminate pouch fits around said frame.

[0279] Clause 22. The electrochemical stack assembly of any of clauses 1-21, wherein the laminate pouch maintains its shape when the interior of the laminate pouch is under a vacuum.

[0280] Clause 23. The electrochemical stack assembly of any of clauses 1-22, wherein the laminate pouch is sealed and the interior of the laminate pouch is under vacuum.

[0281] Clause 24. The electrochemical stack assembly of any of clauses 1-23, wherein the laminate pouch exerts a force of 78 pounds per unit area on both of the two major surfaces of the at least one electrochemical stack, or on each of the two major surfaces of each of the at least two electrochemical stacks.

[0282] Clause 25. The electrochemical stack assembly of any of clauses 1-24, wherein the vacuum applies an atmospheric pressure of up to 14.7 pounds per square inch (PSI) onto two major surfaces of the at least one electrochemical stack, or onto one of the two major surfaces of each of the at least two electrochemical stacks.

[0283] Clause 26. The electrochemical stack assembly of any of clauses 1-26, wherein the laminate pouch includes a pair of laminate forms having opposing surfaces forming a seam, the opposing surfaces being joined at the seam by a seal.

[0284] Clause 27. The electrochemical stack assembly of any of clauses 1-27, wherein the vacuum in the laminate pouch is less than 10 Torr.

[0285] Clause 28. The electrochemical stack assembly of any of clauses 1-28, wherein the frame comprises a material selected from the group consisting of metal, plastic, rubber, silicone, or combinations thereof.

[0286] Clause 29. The electrochemical stack assembly of any of clauses 1-29, wherein the laminate pouch has a molded shape having two major surfaces.

[0287] Clause 30. The electrochemical stack assembly of clause 29, wherein a ratio of a surface area of ​​each of the two major surfaces of the shaped shape on the laminate pouch to a surface area of ​​each of the two major surfaces of the at least one electrochemical stack or the at least two electrochemical stacks is greater than 1.

[0288] Clause 31. The electrochemical stack assembly of clause 29 or 30, wherein a ratio of a surface area of ​​each of the two major surfaces of the molded shape on the laminate pouch to a surface area of ​​each of the two major surfaces of the at least one electrochemical stack or the at least two electrochemical stacks is greater than 1.1.

[0289] Clause 32. The electrochemical stack assembly of any of clauses 29-31, wherein a ratio of a surface area of ​​each of the two major surfaces of the molded shape on the laminate pouch to a surface area of ​​each of the two major surfaces of the at least one electrochemical stack or the at least two electrochemical stacks is greater than 1.2.

[0290] Clause 33. The electrochemical stack assembly of any of clauses 1-32, wherein each of the two major surfaces of the at least one electrochemical stack is rectangular and has dimensions of 64 mm by 79 mm.

[0291] Clause 34. The electrochemical stack assembly of any of clauses 29-33, wherein a thickness of the formed shape of the laminate pouch is about 20% of a thickness of the at least one electrochemical stack or the at least two electrochemical stacks.

[0292] Clause 35. The electrochemical stack assembly of clause 34, wherein the thickness of the formed shape of the laminate pouch is 13.5 mm.

[0293] Clause 36. The electrochemical stack assembly of any of clauses 6-35, wherein the at least one positive terminal and the at least one negative terminal extend through the frame and the laminate pouch.

[0294] Clause 37. The electrochemical stack assembly of any of clauses 1-36, wherein each electrochemical cell includes a solid electrolyte separator.

[0295] Clause 38. The electrochemical stack assembly of clause 37, wherein the solid electrolyte separator comprises a sintered lithium-filled garnet electrolyte.

[0296] Clause 39. The electrochemical stack assembly of any of clauses 6 to 38, wherein the negative electrode comprises lithium metal.

[0297] Clause 40. The electrochemical stack assembly of any of clauses 2-39, wherein the frame includes a first frame portion and a second frame portion, the second frame portion including a central wall to which one of the two major surfaces of the at least one electrochemical stack, or one of the two major surfaces of each of the at least two electrochemical stacks, is attached.

[0298] Clause 41. The electrochemical stack assembly of any of clauses 2-40, wherein one of the major surfaces of one of the at least two electrochemical stacks is attached to one surface of said central wall and one of the major surfaces of another of said at least two electrochemical stacks is attached to the other surface of said central wall.

[0299] Clause 42. The electrochemical stack assembly of any of clauses 40-41, wherein the central wall is attached to either the positive electrode or the negative electrode of the at least one electrochemical stack.

[0300] Clause 43. The electrochemical stack assembly of any of clauses 40-42, further comprising a pressure sensitive adhesive for attaching said central wall of said frame to either a positive electrode or a negative electrode of said at least one electrochemical stack.

[0301] Clause 44. The electrochemical stack assembly of any of clauses 6-43, further comprising a pressure sensitive adhesive for attaching said frame to either a positive electrode or a negative electrode of said at least one electrochemical stack.

[0302] Clause 45. The electrochemical stack assembly of any of clauses 1 to 44, wherein the frame includes a metal insert and a surrounding plastic portion.

[0303] Clause 46. The electrochemical stack assembly of clause 45, wherein the peripheral plastic portion includes a plurality of protrusions disposed about a periphery of the peripheral plastic portion.

[0304] Clause 47. The electrochemical stack assembly of clause 45, wherein the peripheral plastic portion includes flange portions along at least three sides.

[0305] Clause 48. The electrochemical stack assembly of clause 6, wherein the at least one positive terminal and the at least one negative terminal are flat.

[0306] Clause 49. The electrochemical stack assembly of clause 6, wherein the at least one positive terminal and the at least one negative terminal are bent.

[0307] Clause 50. The electrochemical stack assembly of clause 6, wherein the at least one positive terminal and the at least one negative terminal have a Z-bend.

[0308] Clause 51. The electrochemical stack assembly of clause 6, wherein the at least one positive terminal and the at least one negative terminal are folded.

[0309] Clause 52. The electrochemical stack assembly of any of clauses 2-51, wherein the frame includes a first frame portion including a first central wall to which one of the respective major surfaces of the at least two electrochemical stacks is attached, and a second frame portion including a second central wall to which the other of the other major surfaces of the at least two electrochemical stacks is attached.

[0310] Clause 53. The electrochemical stack assembly of clause 52, wherein the first and second frame portions are positioned relative to one another such that the first and second central walls contact one another.

[0311] Clause 54. The electrochemical stack assembly of clause 52 or 53, wherein the first frame portion is rectangular and includes four ends projecting upwardly from the first central wall to form a first tray that holds a first electrochemical stack, and the second frame portion is rectangular and includes four ends projecting upwardly from the second central wall to form a second tray that holds a second electrochemical stack.

[0312] Clause 55. The electrochemical stack assembly of any of clauses 52-54, wherein one of the four ends of the first tray includes at least a first set of elongated openings and one of the four ends of the second tray includes at least a second set of elongated openings.

[0313] Clause 56. The electrochemical stack assembly of clause 55, further including a first part extending over the first set of elongated openings and a second part extending over the second set of elongated openings.

[0314] Clause 57. The electrochemical stack assembly of clause 55 or clause 56, wherein the anode and cathode of each of the first and second electrochemical stacks extend through a respective pair of the elongated openings.

[0315] Clause 58. The electrochemical stack assembly of any of clauses 52-54, wherein one of the four ends of the first tray includes a first elongated opening and one of the four ends of the second tray includes a second elongated opening.

[0316] Clause 59. The electrochemical stack assembly of clause 58, further including a first part extending over the first elongated opening to define a first set of elongated openings, and a second part extending over the second elongated opening to define a second set of elongated openings.

[0317] Clause 60. The electrochemical stack assembly of clause 58 or clause 59, wherein the anode and cathode of each of the first and second electrochemical stacks extend through a respective set of elongated openings.

[0318] Clause 61. The electrochemical stack assembly of any of clauses 1 to 60, wherein each electrochemical stack includes at least two cells.

[0319] Clause 62. The electrochemical stack assembly of any of clauses 1 to 61, wherein each electrochemical stack includes at least four cells.

[0320] Clause 63. The electrochemical stack assembly of any of clauses 1-62, wherein each electrochemical stack includes at least eight cells.

[0321] Clause 64. The electrochemical stack assembly of any of clauses 1 to 63, wherein each electrochemical stack includes as many as 100 cells.

[0322] Clause 65. The electrochemical stack assembly of any of clauses 2-64, wherein the electrochemical cells on one side of the central wall include a cathode and the electrochemical cells on the other side of the central wall include a second cathode, the cathode being thicker than the second cathode.

[0323] Clause 66. The electrochemical stack assembly of any of clauses 2-64, wherein the electrochemical cells on one side of the central wall include a cathode and the electrochemical cells on the other side of the central wall include a second cathode, the cathode having a higher energy density, higher power output, or higher capacity than the second cathode.

[0324] Clause 67. The electrochemical stack assembly of any of clauses 2-64, wherein the electrochemical cells on one side of the central wall include a cathode and the electrochemical cells on the other side of the central wall include a second cathode, the cathode providing a higher power output than the second cathode.

[0325] Clause 68. The electrochemical stack assembly of clauses 2-64, wherein the electrochemical cells on one side of the central wall include a cathode and the electrochemical cells on the other side of the central wall include a second cathode, the cathode providing a higher capacity than the second cathode.

[0326] Clause 69. A module comprising two or more electrochemical stack assemblies of any one of clauses 1 to 68.

[0327] Clause 70. The module of clause 69, including a positive electrode in each electrochemical cell, wherein a thickness of the positive electrode in at least one or more of the two or more electrochemical stack assemblies is greater than a thickness of the positive electrode in another electrochemical stack assembly.

[0328] Clause 71. The module of clause 69, including a negative electrode in each electrochemical cell, wherein a thickness of the negative electrode in at least one or more of the two or more electrochemical stack assemblies is greater than a thickness of the negative electrode in another electrochemical stack assembly.

[0329] Clause 72. The module of clause 69, including a positive electrode in each electrochemical cell, the positive electrode in at least one or more of the two or more electrochemical stack assemblies having a higher energy density or higher power output than the positive electrode in another electrochemical stack assembly.

[0330] Clause 73. The module of clause 69, including a positive electrode in each electrochemical cell, the positive electrode in at least one or more of the two or more electrochemical stack assemblies having a higher power output than the positive electrode in another electrochemical stack assembly.

[0331] Clause 74. The module of clause 69, including a positive electrode in each electrochemical cell, the positive electrode in at least one or more of the two or more electrochemical stack assemblies having a higher power output than the positive electrode in another of the electrochemical stack assemblies; and further, the positive electrode in at least one or more of another of the two or more electrochemical stack assemblies having a higher energy density than the positive electrode in the electrochemical stack assembly.

[0332] Clause 75. A pack comprising a module, or a combination of modules, said modules being according to any one of clauses 69 to 74.

[0333] Clause 76. An electrochemical stack assembly comprising: a first solid-state electrochemical stack having two major surfaces and four minor surfaces, the first solid-state electrochemical stack including a first electrochemical cell, the cell including a solid electrolyte; a first tray surrounding the first solid-state electrochemical stack, the first tray including a first central surface having four sides and four ends each extending upwardly from a respective one of the four sides, with a space between each of the four ends of the first tray and a respective minor surface of the first solid-state electrochemical stack; a second solid-state electrochemical stack having two major surfaces and four minor surfaces, the second solid-state electrochemical stack including a second electrochemical cell, the cell including a solid electrolyte; a second tray surrounding the second solid-state electrochemical stack, the second tray including a second central surface having four sides and four ends each extending upwardly from a respective one of the four sides, with a space between each of the four ends of the second tray and a respective minor surface of the second solid-state electrochemical stack; a laminate pouch surrounding the first and second solid-state electrochemical stacks in the first and second trays, the laminate pouch contacting one of the two major surfaces of the first solid-state electrochemical stack and one of the two major surfaces of the second solid-state electrochemical stack; an electrochemical stack assembly comprising:

[0334] Clause 77. The electrochemical stack assembly of clause 76, wherein the first and second central surfaces contact each other.

[0335] Clause 78. The electrochemical stack assembly of clause 76, wherein the first and second central surfaces comprise a material selected from the group consisting of plastic, plastic with a thermal additive, rubber, ceramic, clay, glass, tempered glass, aluminum, anodized aluminum, magnesium, magnesium-copper alloy, or aluminum-copper alloy.

[0336] Clause 79. The electrochemical stack assembly of clause 76, wherein the first and second trays comprise a material selected from the group consisting of plastic, plastic with a thermal additive, rubber, ceramic, clay, glass, tempered glass, aluminum, anodized aluminum, magnesium, magnesium-copper alloy, or aluminum-copper alloy.

[0337] Clause 80. The electrochemical stack assembly of any of clauses 76-79, wherein each of the first and second solid-state electrochemical stacks includes two electrochemical cells each having a solid electrolyte.

[0338] Clause 81. The electrochemical stack assembly of any of clauses 76-80, wherein each of said first and second electrochemical stacks includes four electrochemical cells.

[0339] Clause 82. The electrochemical stack assembly of any of clauses 76-81, wherein each of the first and second electrochemical stacks includes eight electrochemical cells each having a solid electrolyte.

[0340] Clause 83. The electrochemical stack assembly of any of clauses 76-82, wherein each of the first and second electrochemical stacks includes 16 electrochemical cells each having a solid electrolyte.

[0341] Clause 84. The electrochemical stack assembly of any of clauses 76-83, wherein each of the first and second electrochemical stacks includes 24 electrochemical cells each having a solid electrolyte.

[0342] Clause 85. The electrochemical stack assembly of any of clauses 76-84, wherein each of the electrochemical cells includes, in order, a first anode current collector, a first anode support, a first separator, a first cathode frame, a first cathode current collector, a second cathode current collector, a second cathode frame, a second separator, a second anode support, and a second anode current collector.

[0343] Clause 86. The electrochemical stack assembly of any of clauses 76-85, further comprising a first spacer block and a first compressible sheet disposed between one of the two major surfaces of the first solid-state electrochemical stack and the laminate pouch, and a second spacer block and a second compressible sheet disposed between one of the two major surfaces of the second solid-state electrochemical stack and the laminate pouch.

[0344] Clause 87. The electrochemical stack assembly of any of clauses 76-86, further comprising a first bonding layer between the first central surface and the first electrochemical stack, and a second bonding layer between the second central surface and the second electrochemical stack.

[0345] Clause 88. The electrochemical stack assembly of any of clauses 76-87, wherein one of the four ends of the first tray includes a first set of elongated openings and one of the four ends of the second tray includes a second set of elongated openings.

[0346] Clause 89. The electrochemical stack assembly of clause 88, further including a first part extending over the first set of elongated openings and a second part extending over the second set of elongated openings.

[0347] Clause 90. The electrochemical stack assembly of clause 88 or clause 89, wherein an anode and a cathode of each of the first and second electrochemical stacks extend through a respective pair of the elongated openings.

[0348] Clause 91. The electrochemical stack assembly of any of clauses 76-90, wherein one of the four ends of the first tray includes a first elongated opening and one of the four ends of the second tray includes a second elongated opening.

[0349] Clause 92. The electrochemical stack assembly of clause 91, further including a first part extending over the first elongated opening to define a first set of elongated openings, and a second part extending over the second elongated opening to define a second set of elongated openings.

[0350] Clause 93. The electrochemical stack assembly of clause 91 or clause 92, wherein the anode and cathode of each of the first and second electrochemical stacks extend through a respective set of elongated openings.

[0351] Clause 94. An electrochemical stack assembly comprising: one or more electrochemical cells, each electrochemical cell including a solid electrolyte and forming an electrochemical stack having two major surfaces and four minor surfaces; a frame surrounding the electrochemical stack, the frame having a space between the frame and each of the four minor surfaces; a laminating pouch surrounding the frame and the electrochemical stack and contacting one or both of the two major surfaces; 1. An electrochemical stack assembly comprising:

[0352] Clause 95. The electrochemical stack assembly of clause 94, wherein the electrochemical stack assembly further includes a central wall, the electrochemical stack assembly further includes an adhesive for adhering the central wall to one of the two major surfaces, and the laminate pouch contacts the other of the two major surfaces.

[0353] Clause 96. The electrochemical stack assembly of clause 95, wherein the adhesive comprises a pressure sensitive adhesive.

[0354] Clause 97. The electrochemical stack assembly of clause 95 or 96, wherein the central wall comprises a thermally conductive material.

[0355] Clause 98. The electrochemical stack assembly of any of clauses 94-97, further comprising at least one positive terminal and at least one negative terminal.

[0356] Clause 99. The electrochemical stack assembly of any of clauses 94-98, wherein the frame is at a negative potential.

[0357] Clause 100. The electrochemical stack assembly of any of clauses 94-98, wherein the frame is at a positive potential.

[0358] Clause 101. The electrochemical stack assembly of any of clauses 94-100, further comprising an insulating material for insulating said frame.

[0359] Clause 102. The electrochemical stack assembly of any of clauses 94-101, wherein the frame comprises a material selected from the group consisting of plastic, plastic with thermal additives, rubber, ceramic, clay, glass, reinforced glass, thermoplastic, carbon fiber, metal-plastic composite, aluminum, anodized aluminum, magnesium, magnesium-copper alloy, or aluminum-copper alloy, or a combination thereof.

[0360] Clause 103. The electrochemical stack assembly of any of clauses 94-102, wherein the space between the frame and the four minor surfaces of the electrochemical stack prevents application of forces by the laminate pouch against the four minor surfaces during charge and discharge cycles of the electrochemical stack, thereby preventing deformation, cracking, or other damage to the solid electrolyte in each of the one or more electrochemical cells.

[0361] Clause 104. The electrochemical stack assembly of any of clauses 94-103, wherein the interior of the laminate pouch is under a vacuum whereby the laminate pouch contacts one or both major surfaces of the electrochemical stack.

[0362] Clause 105. The electrochemical stack assembly of any of clauses 94-104, wherein an interior of the laminate pouch is under a vacuum whereby the laminate pouch is in contact with both major surfaces.

[0363] Clause 106. The electrochemical stack assembly of any of clauses 94-105, wherein the space between the frame and the electrochemical stack provides room for the electrochemical stack to expand and contract during charge and discharge cycles without causing deformation, cracking, or other damage to the solid electrolyte in each of the one or more electrochemical cells.

[0364] Clause 107. The electrochemical stack assembly of any of clauses 94-106, wherein the space between the frame and the electrochemical stack provides room for expansion of the at least one electrochemical stack during a charging cycle without causing deformation, cracking, or other damage to the solid electrolyte in each of the one or more electrochemical cells.

[0365] Clause 108. The electrochemical stack assembly of any of clauses 94-107, wherein the laminate pouch provides for expansion and contraction of about 20% in a direction perpendicular to at least one of the two major surfaces.

[0366] Article 109. The distribution of pressure across the two main surfaces is less than 10mm 2 , 10cm 2 , or 10m 2 The electrochemical stack assembly of any of clauses 94-108, wherein the surface area of ​​the electrochemical stack assembly is uniform.

[0367] Clause 110. The distribution of pressure across the two main surfaces is less than 20mm 2 , 20cm 2 , or 20m 2 The electrochemical stack assembly of any of clauses 94-108, wherein the surface area of ​​the electrochemical stack assembly is uniform.

[0368] Clause 111. The distribution of pressure across the two main surfaces is less than 30mm 2 , 30cm 2 , or 30m 2 The electrochemical stack assembly of any of clauses 94-108, wherein the surface area of ​​the electrochemical stack assembly is uniform.

[0369] Clause 112. The electrochemical stack assembly of any of clauses 94-111, wherein said laminate pouch fits around said frame.

[0370] Clause 113. The electrochemical stack assembly of any of clauses 94-112, wherein the laminate pouch maintains its shape when the interior of the laminate pouch is under a vacuum.

[0371] Clause 114. The electrochemical stack assembly of any of clauses 94-113, wherein the laminate pouch is sealed and the interior of the laminate pouch is under vacuum.

[0372] Clause 115. The electrochemical stack assembly of any of clauses 94-114, wherein the laminate pouch exerts a force of 78 pounds per unit area on the two major surfaces of the electrochemical stack.

[0373] Clause 116. The electrochemical stack assembly of any of clauses 113-115, wherein the vacuum applies an atmospheric pressure of up to 14.7 pounds per square inch (PSI) onto the two major surfaces of the electrochemical stack.

[0374] Clause 117. The electrochemical stack assembly of any of clauses 94-116, wherein said laminate pouch includes a pair of laminate forms having opposing surfaces forming a seam, said opposing surfaces being joined at said seam by a seal.

[0375] Clause 118. The electrochemical stack assembly of any of clauses 94-117, wherein the vacuum in said laminate pouch is less than 10 Torr.

[0376] Clause 119. The electrochemical stack assembly of any of clauses 94-118, wherein the frame comprises a material selected from the group consisting of metal, plastic, rubber, silicone, or combinations thereof.

[0377] Clause 120. The electrochemical stack assembly of any of clauses 94-119, wherein the laminate pouch has a molded shape having two major surfaces.

[0378] Clause 121. The electrochemical stack assembly of any clause 120, wherein a ratio of a surface area of ​​one of the two major surfaces of the shaped shape on the laminate pouch to a surface area of ​​one of the two major surfaces of the electrochemical stack is greater than 1.

[0379] Clause 122. The electrochemical stack assembly of clause 121, wherein a ratio of a surface area of ​​one of said two major surfaces of said shaped shape on said laminate pouch to a surface area of ​​one of said two major surfaces of said electrochemical stack is greater than 1.1.

[0380] Clause 123. The electrochemical stack assembly of clause 121 or 122, wherein a ratio of a surface area of ​​one of the two major surfaces of the shaped shape on the laminate pouch to a surface area of ​​one of the two major surfaces of the electrochemical stack is greater than 1.2.

[0381] Clause 124. The electrochemical stack assembly of any of clauses 94-123, wherein one of the major surfaces of the electrochemical stack is rectangular and has dimensions of 64 mm by 79 mm.

[0382] Clause 125. The electrochemical stack assembly of any of clauses 121-124, wherein a thickness of the formed shape of the laminate pouch is about 20% of a thickness of the electrochemical stack.

[0383] Clause 126. The electrochemical stack assembly of any of clauses 121-124, wherein the formed shape of the laminate pouch has a thickness of 13.5 mm.

[0384] Clause 127. The electrochemical stack assembly of any of clauses 98-125, wherein the at least one positive terminal and the at least one negative terminal extend through the frame and the laminate pouch.

[0385] Clause 128. The electrochemical stack assembly of any of clauses 98-124, wherein each electrochemical cell includes a solid electrolyte separator.

[0386] Clause 129. The electrochemical stack assembly of clause 128, wherein the solid electrolyte separator comprises a sintered lithium-filled garnet electrolyte.

[0387] Clause 130. The electrochemical stack assembly of any of clauses 94-129, wherein the negative electrode comprises lithium metal.

[0388] Clause 131. The electrochemical stack assembly of any of clauses 95-130, wherein the central wall is attached to either the positive electrode or the negative electrode of the electrochemical stack.

[0389] Clause 132. The electrochemical stack assembly of clause 131, further comprising a pressure sensitive adhesive for attaching the central wall of the frame to either the positive electrode or the negative electrode of the electrochemical stack.

[0390] Clause 133. The electrochemical stack assembly of clause 131 or clause 132, further comprising a pressure sensitive adhesive for attaching the frame to either the positive electrode or the negative electrode of the electrochemical stack.

[0391] Clause 134. The electrochemical stack assembly of any of clauses 94 to 133, wherein the frame includes a metal insert and a surrounding plastic portion.

[0392] Clause 135. The electrochemical stack assembly of clause 134, wherein the peripheral plastic portion includes a plurality of protrusions disposed about a periphery of the peripheral plastic portion.

[0393] Clause 136. The electrochemical stack assembly of clause 134 or clause 135, wherein the peripheral plastic portion includes flange portions along at least three sides.

[0394] Clause 137. The electrochemical stack assembly of clause 98, wherein the at least one positive terminal and the at least one negative terminal are flat.

[0395] Clause 138. The electrochemical stack assembly of clause 98, wherein the at least one positive terminal and the at least one negative terminal are bent.

[0396] Clause 139. The electrochemical stack assembly of clause 98, wherein the at least one positive terminal and the at least one negative terminal have a Z-bend.

[0397] Clause 140. The electrochemical stack assembly of clause 98, wherein the at least one positive terminal and the at least one negative terminal are folded.

[0398] Clause 141. A module including two or more electrochemical stack assemblies of any one of clauses 76 to 140.

[0399] Clause 142. The module of clause 138, including a positive electrode in each electrochemical cell, wherein a thickness of the positive electrode in at least one or more of the two or more electrochemical stack assemblies is greater than a thickness of the positive electrode in another electrochemical stack assembly.

[0400] Clause 143. The module of clause 138, including a negative electrode in each electrochemical cell, wherein a thickness of the negative electrode in at least one or more of the two or more electrochemical stack assemblies is greater than a thickness of the negative electrode in another electrochemical stack assembly.

[0401] Clause 144. The module of clause 138, including a positive electrode in each electrochemical cell, the positive electrode in at least one or more of the two or more electrochemical stack assemblies having a higher energy density than the positive electrode in another electrochemical stack assembly.

[0402] Clause 145. The module of clause 138, including a positive electrode in each electrochemical cell, the positive electrode in at least one or more of the two or more electrochemical stack assemblies having a higher power output than the positive electrode in another electrochemical stack assembly.

[0403] Clause 146. The module of clause 138, comprising a positive electrode in each electrochemical cell, wherein the positive electrode in at least one or more of the two or more electrochemical stack assemblies has a higher power output than the positive electrode in another of the electrochemical stack assemblies; and further, another positive electrode in at least one or more others of the two or more electrochemical stack assemblies has a higher energy density than the positive electrode in another of the electrochemical stack assemblies.

[0404] Clause 147. A pack comprising a module or a combination of modules, said modules being according to any one of clauses 141 to 146.

[0405] Clause 148. An electric vehicle comprising an electrochemical stack assembly according to any of clauses 1 to 140; a module according to any of clauses 141 to 146; or a pack according to clause 147.

[0406]

[0270] The above embodiments and examples are intended to be merely illustrative and non-limiting. Those skilled in the art will recognize, or be able to ascertain, with no more than routine experimentation, numerous equivalents to the specific compounds, materials, and procedures. All such equivalents are considered to be within the scope of the present invention and are encompassed by the appended claims.

Claims

1. 1. An electrochemical stack assembly comprising: one or more electrochemical cells, each electrochemical cell including a solid electrolyte and forming at least two electrochemical stacks, each stack having two major surfaces and four minor surfaces; a frame surrounding the at least two electrochemical stacks, the frame having a space between the frame and each of the four minor surfaces of each of the at least two electrochemical stacks; a flat plate attached to or integral with the frame, wherein each of the at least two electrochemical stacks has one of the two major surfaces adhered to a respective side of the flat plate; a laminate pouch surrounding the frame and the at least two electrochemical stacks, the laminate pouch contacting one of the two major surfaces of each of the at least two electrochemical stacks; an electrochemical stack assembly comprising:

2. An electrochemical stack assembly as described in claim 1, further comprising an adhesive for adhering the flat plate to one of the two major surfaces of each of the at least two electrochemical stacks, and the laminate pouch contacts the other of the two major surfaces of each of the at least two electrochemical stacks.

3. An electrochemical stack assembly as described in claim 1 or 2, wherein the laminate pouch fits around the frame.

4. 3. The electrochemical stack assembly of claim 1 or 2, wherein the frame includes a first frame portion and a second frame portion, and the flat plate is attached to both the first frame portion and the second frame portion.

5. The plate comprises: a) a thermally conductive material; or b) a material selected from the group consisting of metal, plastic, plastic with thermal additives, rubber, silicone, ceramic, clay, glass, tempered glass, thermoplastic, carbon fiber, metal-plastic composite, aluminum, anodized aluminum, magnesium, magnesium-copper alloy, or aluminum-copper alloy, or a combination thereof; 3. The electrochemical stack assembly of claim 1 or 2, comprising:

6. The frame: a) a negative or positive potential; or b) the electrochemical stack assembly of claim 1 or 2, comprising a material selected from the group consisting of metal, plastic, plastic with thermal additives, rubber, silicone, ceramic, clay, glass, tempered glass, thermoplastic, carbon fiber, metal-plastic composite, aluminum, anodized aluminum, magnesium, magnesium-copper alloy, or aluminum-copper alloy, or a combination thereof.

7. a) the space between the frame and the four minor surfaces of each of the at least two electrochemical stacks prevents the application of forces by the laminate pouch against the four minor surfaces of each electrochemical stack during charge and discharge cycles of each electrochemical stack without causing deformation, cracking, or other damage to the solid electrolyte in each of the one or more electrochemical cells; or b) the interior of the laminate pouch is under vacuum, whereby the laminate pouch contacts one of the two major surfaces of each of the at least two electrochemical stacks; or c) the space between the frame and the four minor surfaces of each of the at least two electrochemical stacks provides room for the at least two electrochemical stacks to expand or contract during charge or discharge without causing deformation, cracking, or other damage to the solid electrolyte in each of the one or more electrochemical cells.

8. The method of claim 7, wherein the laminate pouch provides expansion and contraction of about 20% in a direction perpendicular to at least one of the two major surfaces of the at least two electrochemical stacks; or b) the distribution of pressure across the two major surfaces of each electrochemical stack is uniform over a surface area of ​​10 mm 2 , 20 mm 2 , 30 mm 2 , 10 cm 2 , 20 cm 2 , 30 cm 2 , 10 m 2 , 20 m 2 , or 30 m 2 ; or 3. The electrochemical stack assembly of claim 1 or 2, wherein the laminate pouch applies a force of 78 pounds per unit area on both of the two major surfaces of each of the at least two electrochemical stacks.

9. a) the laminate pouch comprises a set of laminated forms having opposing surfaces forming a seam, the opposing surfaces being joined at the seam by a seal; b) the laminate pouch has a formed shape with two major surfaces; or 3. The electrochemical stack assembly of claim 1 or 2, wherein c) the thickness of the formed shape of the laminate pouch is about 20% of the thickness of the at least two electrochemical stacks.

10. a) an insulating material for insulating the frame; or b) at least one positive terminal and at least one negative terminal; or c) a first spacer block and a first compressible sheet disposed between one of the two major surfaces of the at least one electrochemical stack or one of the at least two electrochemical stacks and the laminate pouch; 3. The electrochemical stack assembly of claim 1 or 2, further comprising:

11. 3. The electrochemical stack assembly of claim 1 or 2, wherein each electrochemical cell comprises a sintered lithium-filled garnet electrolyte.

12. 3. The electrochemical stack assembly of claim 1, wherein the flat plate is attached to either the positive or negative electrodes of the at least two electrochemical stacks, and further comprising a pressure sensitive adhesive for attaching the frame or the flat plate to either the positive or negative electrodes of the at least two electrochemical stacks.

13. 3. The electrochemical stack assembly of claim 1, wherein the frame includes a first frame portion including a first flat plate to which one of the main surfaces of each of the at least two electrochemical stacks is attached, and a second frame portion including a second flat plate to which the other of the main surfaces of the other of the at least two electrochemical stacks is attached.

14. A method for manufacturing a semiconductor device comprising: a) each electrochemical stack including at least two cells, at least four cells, at least eight cells, at least sixteen cells, at least twenty-four cells, or as many as one hundred cells; or b) the electrochemical cell on one side of the plate includes a cathode and the electrochemical cell on the other side of the plate includes a second cathode, the cathode having a higher energy density or higher power output or higher capacity than the second cathode; or c) each of said electrochemical cells comprises, in order, a first anode current collector, a first anode support, a first separator, a first cathode frame, a first cathode current collector, a second cathode current collector, a second cathode frame, a second separator, a second anode support, and a second anode current collector; or d) The electrochemical stack assembly of claim 1 or 2, wherein the frame comprises a metal insert and a surrounding plastic portion.

15. A module comprising two or more electrochemical stack assemblies according to claim 1 or 2.

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