Anode side seal for battery cells having porous ceramic layers - Patents.com

Abstract

The present disclosure provides an anode assembly for a battery cell. The battery cell includes a separator layer, an anode layer, an anode current collector, and a seal. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer includes a solid-state electrolyte (SSE) having pores. The anode current collector is bonded to the second surface of the anode layer. The seal is substantially impermeable to liquids. The present disclosure also provides a method of forming an anode assembly for a battery cell.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 63 / 283,149, filed November 24, 2021, the disclosure of which is incorporated herein by reference in its entirety.

[0002] The present invention relates to an anode assembly for a battery cell and a method for forming the same. [Background technology]

[0003] A solid-state battery generally includes one or more battery cells that include a cathode current collector, a cathode layer, a solid electrolyte separator, an anode layer, and an anode current collector. The battery cell may further include a catholyte on the cathode side. The catholyte promotes liquid-solid contact and provides an improved interface for ion transfer, thereby improving ionic conductivity and lowering the impedance of the battery cell. Catholytes may be advantageous over gels and / or solid catholytes because they allow for a single electrolyte filling step during battery cell fabrication and allow flexibility in cell design for various application conditions, such as high energy density, improved safety, or operation over a wide temperature range. However, leakage of catholyte to the anode side of the battery cell (e.g., anode layer) is undesirable and can be a failure mode for solid-state batteries that include catholyte.

[0004] Thus, a need remains to provide improved anode assemblies for battery cells. Summary of the Invention [Means for solving the problem]

[0005] In one aspect, the present invention provides an anode assembly for a battery cell. The battery cell includes a separator layer, an anode layer, an anode current collector, and a seal. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer includes a solid-state electrolyte (SSE) having pores. The anode current collector is bonded to the second surface of the anode layer. The seal is at least partially disposed on the outer surface of the anode layer and includes a sealant material. The seal is substantially impermeable to liquids.

[0006] In some embodiments, the separator layer is substantially free of pores. In some embodiments, the separator layer comprises an SSE material. In some embodiments, the SSE material of the separator layer comprises a polymer, a sulfide, an oxide, a chalcogenide, or any combination thereof.

[0007] In some embodiments, the separator layer defines a recess and the seal is disposed within the recess.

[0008] In some embodiments, the separator layer has a thickness of about 1 μm to about 300 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 200 μm. In other embodiments, the separator layer has a thickness of about 1 μm to about 100 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 50 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 20 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 10 μm.

[0009] In some embodiments, the anode assembly further comprises an anode material disposed in at least a portion of the pores of the anode layer. In some embodiments, the anode material comprises lithium metal, sodium metal, magnesium metal, or any combination thereof. In other embodiments, the pores of the anode layer are substantially free of metal material (e.g., lithium metal).

[0010] In some embodiments, the anode layer defines a first porous region and a second porous region. The first porous region is defined between a center and an outer surface of the anode layer. The second porous region is defined between the first porous region and the outer surface of the anode layer.

[0011] In some embodiments, the pores of the first porous region are substantially free of sealant material, in some embodiments, at least some of the pores of the second porous region include sealant material, and in some embodiments, the seal is at least partially disposed on an exterior surface of the anode layer and within the pores of the second porous region.

[0012] In some embodiments, the anode layer has a thickness of about 1 μm to about 500 μm. In some embodiments, the anode layer has a thickness of about 1 μm to about 200 μm. In other embodiments, the anode layer has a thickness of about 1 μm to about 100 μm. In some embodiments, the anode layer has a thickness of about 1 μm to about 50 μm. In some embodiments, the anode layer has a thickness of about 1 μm to about 20 μm.

[0013] In some embodiments, the anode current collector comprises a metal foil. In other embodiments, the metal foil comprises copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof. Also, in some embodiments, the metal foil has a tab configured to connect to an external circuit.

[0014] In some embodiments, the seal is disposed at least partially on the separator layer, hi some embodiments, the seal is disposed at least partially on the anode current collector.

[0015] In some embodiments, the separator layer has a front surface facing the anode layer, a back surface facing away from the anode layer, and an exterior surface extending from the front surface to the back surface, hi other embodiments, the anode current collector has an inner surface facing the anode layer, an outer surface facing away from the anode layer, and an outer surface extending from the inner surface to the outer surface.

[0016] In some embodiments, the seal is at least partially disposed on the outer surface of the separator layer. In other embodiments, the seal is disposed over substantially the entire outer surface of the separator layer. In some embodiments, the seal is at least partially disposed on the rear surface of the separator layer. In some embodiments, the seal is at least partially disposed on the front surface of the separator layer.

[0017] In some embodiments, the seal is at least partially disposed on the outer surface of the anode current collector. In other embodiments, the seal is disposed over substantially the entire outer surface of the anode current collector. In some embodiments, the seal is at least partially disposed on the outer surface of the anode current collector. In other embodiments, the seal is disposed over substantially the entire outer surface of the anode current collector. In some embodiments, the seal is at least partially disposed on the inner surface of the anode current collector. Also, in some embodiments, a seal is at least partially disposed on each of the outer surface of the anode layer, the outer surface of the separator layer, and the outer surface of the anode current collector.

[0018] In some embodiments, the sealant material comprises a non-conductive polymer, a non-conductive glass, or any combination thereof, and in some embodiments, the sealant material comprises polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof.

[0019] In some embodiments, the anode assembly further comprises a housing having a plurality of interior walls defining an interior. The separator layer, the anode layer, the anode current collector, and the seal are disposed within the housing. In some embodiments, the seal extends from an outer surface of the anode layer to at least one of the plurality of interior walls of the housing.

[0020] In some embodiments, the housing further comprises a first projection and a second projection extending from at least one of the plurality of inner walls to an interior of the housing. The first projection and the second projection define a cavity. The seal extends from an outer surface of the anode layer into the cavity.

[0021] In some embodiments, at least a portion of the seal has a thickness of about 1 μm to about 50 μm. In some embodiments, at least a portion of the seal has a thickness of about 1 μm to about 20 μm. In other embodiments, at least a portion of the seal has a thickness of about 1 μm to about 10 μm. In some embodiments, at least a portion of the seal has a thickness of about 1 μm to about 5 μm.

[0022] In some embodiments, the seal is gas permeable.

[0023] In another aspect, the present invention provides a multi-layer anode assembly. The multi-layer anode assembly includes a first separator layer, a second separator layer, a first anode layer, a second anode layer, an anode current collector, and a seal. The second separator layer is spaced apart from the first separator layer. The first anode layer is at least partially disposed on the first separator layer. The first anode layer has a first surface facing the first separator layer, a second surface facing away from the first separator layer, and an outer surface extending from the first surface to the second surface. The first anode layer includes an SSE having pores. The second anode layer is at least partially disposed on the second separator layer. The second anode layer has a first surface facing the second separator layer, a second surface facing away from the second separator layer, and an outer surface extending from the first surface to the second surface. The second anode layer includes a SSE having pores. An anode current collector is bonded to a second surface of the first and second anode layers. A seal is at least partially disposed on an outer surface of the first and second anode layers. The seal includes a sealant material. And, the seal is substantially impermeable to liquids.

[0024] In another aspect, the present invention provides a battery cell. The battery cell includes a separator layer, an anode layer, an anode current collector, a cathode layer, a cathode current collector, and a seal. The separator layer has a front surface, a back surface spaced from the front surface, and an exterior surface extending from the front surface to the back surface. The anode layer is at least partially disposed on the front surface of the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an exterior surface extending from the first surface to the second surface. The anode layer includes an SSE having pores. The anode current collector is bonded to the second surface of the anode layer. The cathode layer is at least partially disposed on the back surface of the separator layer. The cathode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an exterior surface extending from the first surface to the second surface. The cathode current collector is bonded to the second surface of the cathode layer. A seal is disposed at least partially on an outer surface of the anode layer, the seal includes a sealant material, and the seal is substantially impermeable to liquids.

[0025] In some embodiments, the battery cell further comprises a housing having a plurality of interior walls defining an interior within which the separator layer, the anode layer, the anode current collector, the cathode layer, the cathode current collector, and the seal are disposed.

[0026] In some embodiments, the anode current collector has an inner surface facing the anode layer, an outer surface facing away from the anode layer, and an outer surface extending from the inner surface to the outer surface, hi some embodiments, the cathode current collector has an inner surface facing the cathode layer, an outer surface facing away from the cathode layer, and an outer surface extending from the inner surface to the outer surface.

[0027] In some embodiments, the seal is at least partially disposed on each of an outer surface of the anode layer, an outer surface of the separator layer, and an inner surface of the anode and cathode current collectors, hi some embodiments, the cathode current collector defines an opening configured to allow the cathode layer to be filled with catholyte.

[0028] In some embodiments, the seal is at least partially disposed on each of the outer surface of the anode layer, the outer surface of the separator layer, the inner surface of the cathode current collector, and the outer and outer surfaces of the anode current collector. In some embodiments, the cathode current collector defines an opening configured to allow the cathode layer to be filled with catholyte.

[0029] In some embodiments, the battery cell further comprises a catholyte disposed within the cathode layer, hi some embodiments, the seal is substantially impermeable to the catholyte.

[0030] In some embodiments, the sealant material comprises a non-conductive polymer, a non-conductive glass, or any combination thereof, and in some embodiments, the sealant material comprises polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof.

[0031] In another aspect, the present invention provides a method of forming the anode assembly described herein.

[0032] The following figures are illustrative and do not limit the scope of the claimed invention. [Brief description of the drawings]

[0033] [Figure 1] Figure 1A is a cross-sectional view of a first exemplary embodiment of an anode assembly for a battery cell. Figure 1B is a cross-sectional view of an exemplary embodiment of a multi-layer anode assembly including two anode assemblies of Figure 1A, the anode assemblies sharing a common anode current collector. Figure 1C is a front view of the anode assembly of Figure 1A. [Diagram 2] Figure 2A is a cross-sectional view of a second exemplary embodiment of an anode assembly for a battery cell. Figure 2B is an enlarged view of a portion of the anode assembly of Figure 2A according to one embodiment. Figure 2C is an enlarged view of a portion of the anode assembly of Figure 2A according to another embodiment. Figure 2D is an enlarged view of a portion of the anode assembly of Figure 2A according to a further embodiment. Figure 2E is an enlarged view of a portion of the anode assembly of Figure 2A according to yet another embodiment. [Diagram 3]Figure 3A is a cross-sectional view of a third exemplary embodiment of an anode assembly for a battery cell. Figure 3B is a cross-sectional view of an exemplary embodiment of a multi-layer anode assembly including two anode assemblies of Figure 3A, the anode assemblies sharing a common anode current collector. Figure 3C is a front view of the anode assembly of Figure 3A. [Figure 4] FIG. 13 is a cross-sectional view of a fourth exemplary embodiment of an anode assembly for a battery cell. [Diagram 5] Figure 5A is a cross-sectional view of a fifth exemplary embodiment of an anode assembly for a battery cell. Figure 5B is a cross-sectional view of an exemplary embodiment of a multi-layer anode assembly including two anode assemblies of Figure 5A, the anode assemblies sharing a common anode current collector and a common seal. Figure 5C is a front view of the anode assembly of Figure 5A. [Figure 6] Figure 6A is a cross-sectional view of a sixth exemplary embodiment of an anode assembly for a battery cell. Figure 6B is a cross-sectional view of an exemplary embodiment of a multi-layer anode assembly including two anode assemblies of Figure 6A, the anode assemblies sharing a common anode current collector. Figure 6C is a front view of the anode assembly of Figure 6A. [Figure 7-1] 7A and 7B are a cross-sectional view and a front view, respectively, of a first exemplary embodiment of a battery cell. [Figure 7-2] 7C is a cross-sectional view of a second exemplary embodiment of a battery cell, and FIG 7D is a front view of the battery cell of FIG 7C. [Figure 8] Figure 8A is a cross-sectional view of a seventh exemplary embodiment of an anode assembly for a battery cell, and Figure 8B is a cross-sectional view of an exemplary embodiment of a multi-layer anode assembly including two anode assemblies of Figure 8A, the anode assemblies sharing a common anode current collector and a common seal. [Figure 9-1] 9A and 9B are a cross-sectional view and a front view, respectively, of a third exemplary embodiment of a battery cell. [Figure 9-2]9C is a cross-sectional view of a fourth exemplary embodiment of a battery cell, and FIG 9D is a front view of the battery cell of FIG 9C. [Figure 10-1] 10A and 10B are a cross-sectional view and a front view, respectively, of a fifth exemplary embodiment of a battery cell. [Figure 10-2] Figure 10C is a cross-sectional view of a sixth exemplary embodiment of a battery cell, and Figure 10D is a front view of the battery cell of Figure 10C. [Figure 11-1] 11A and 11B are cross-sectional views of a first and second exemplary embodiment of an electrode pair assembly. [Figure 11-2] 11C and 11D are cross-sectional views of a third and fourth exemplary embodiment of an electrode pair assembly. [Figure 11-3] FIG. 11E is a cross-sectional view of a fifth exemplary embodiment of an electrode pair assembly. [Figure 12-1] 12A and 12B are cross-sectional views of a sixth and seventh exemplary embodiment of an electrode pair assembly. [Figure 12-2] 12C and 12D are cross-sectional views of an eighth and a ninth exemplary embodiment of an electrode pair assembly. [Figure 13] FIG. 23 is a cross-sectional view of a tenth exemplary embodiment of an electrode pair assembly. [Figure 14] 4 is a flow chart of a method of forming an anode assembly, according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] Like reference symbols in the various drawings refer to like elements, for example, the separator layer may be referred to as 102 in Figure 1A, 602 in Figure 6A, and 1202a, 1202a' in Figure 12A.

[0035] The present invention provides an anode assembly for a battery cell, a battery cell including such an anode assembly, a method of forming such an anode assembly, a multi-layer anode assembly, and an electrode pair assembly.

[0036] As used herein, the following definitions shall apply unless otherwise indicated.

[0037] I. Definition The terms used herein are for the purpose of describing particular example configurations only and are not intended to be limiting. As used herein, the singular forms "a," "an," and "the" may be intended to include the plural unless the context dictates otherwise. The terms "comprises," "comprising," and "having" are inclusive and thus specify the presence of features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The steps, processes, and operations of the methodologies described herein should not be construed as necessarily having to be performed in the particular order described or illustrated, unless specifically designated as an order of execution. Additional or alternative steps may be employed.

[0038] In this specification, terms such as first, second, third, etc. may be used to describe various elements, components, regions, layers, and / or sections. These elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may only be used to distinguish one element, component, region, layer, or section from another region, layer, or section. Terms such as "first", "second", and other numerical terms do not imply any order or sequence unless clearly indicated by the context. Thus, a first element, component, region, layer, or section described below can be referred to as a second element, component, region, layer, or section without departing from the teachings of the example configuration.

[0039] As used herein, when an element is described as being "on," "engaged," "connected," "attached," or "coupled" to another element, the element may be directly on, engaged, connected, attached, or coupled to the other element, or there may be intervening elements. In contrast, when an element is described as being "directly on," "directly engaged," "directly connected," "directly attached," or "directly coupled" to another element, there may not be intervening elements or layers. Other words used to describe relationships between elements should be interpreted similarly (e.g., "between" and "directly between," "adjacent" and "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0040] As used herein, the term "battery cell" refers to a rechargeable secondary battery. In some embodiments, the battery cell may be a solid-state lithium-ion battery cell.

[0041] As used herein, the term "anode assembly" refers to an assembly comprising a separator layer, an anode layer, and an anode current collector.

[0042] As used herein, the term "separator layer" refers to a layer disposed between an anode layer and a cathode layer in a battery cell, allowing cations (e.g., lithium cations) to flow between the anode layer and the cathode layer. In some embodiments, the separator layer is substantially free of pores (e.g., has an apparent porosity of less than 50%, has an apparent porosity of less than 40%, has an apparent porosity of less than 30%, has an apparent porosity of less than 20%, has an apparent porosity of less than 15%, has an apparent porosity of less than 10%, has an apparent porosity of less than 5%, or has an apparent porosity of less than 1%). Also, in some embodiments, the separator layer is free of pores.

[0043] As used herein, the term "anode layer" refers to the negative electrode layer from which electrons flow during the discharge phase of a battery cell. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer and a second surface facing away from the separator layer. The anode layer includes a solid-state electrolyte (SSE) having micropores.

[0044] As used herein, the term "bilayer" refers to an anode layer disposed on a separator layer.

[0045] As used herein, the term "anode current collector" refers to a current collector coupled to an anode layer. The anode current collector is configured to be electrically coupled to the anode layer during operation of the battery cell (e.g., during charging and / or discharging of the battery cell). In some embodiments, the anode current collector comprises a metal foil. In other embodiments, the anode current collector comprises a tab configured to connect to an external circuit.

[0046] As used herein, the term "cathode layer" refers to the positive electrode layer into which electrons flow during the discharging phase of a battery cell.

[0047] As used herein, the term "cathode current collector" refers to a current collector coupled to a cathode layer. The cathode current collector is configured to be electrically coupled to the cathode layer during operation of the battery cell (e.g., during charging and / or discharging of the battery cell). In some embodiments, the cathode current collector comprises a metal foil. In other embodiments, the cathode current collector comprises a tab configured to connect to an external circuit.

[0048] As used herein, the term "seal" refers to a layer that is substantially impermeable to liquid (e.g., catholyte) and restricts the inflow of liquid to the anode layer. As used herein, the term "substantially impermeable" means that the seal resists penetration of liquid. In other words, liquid cannot pass freely through the seal. The seal can restrict the flow of catholyte (e.g., catholyte) to the anode layer. In this manner, the seal can reduce the likelihood of battery cell failure caused by catholyte leaking into the anode layer. In some embodiments, the seal is permeable to gas.

[0049] As used herein, the term "apparent porosity" refers to open (or accessible) porosity (i.e., porosity excluding the volume of sealed or closed pores, cells, or voids). Apparent porosity can be expressed as the ratio or percentage of the volume of open pores, cells, or voids to the total volume.

[0050] II. Anode Assembly In one aspect, the present invention provides an anode assembly for a battery cell.

[0051] As shown in FIG. 1A, the anode assembly 100 includes a separator layer 102, an anode layer 104, an anode current collector 106, and a seal 108.

[0052] A. Separator layer The separator layer may be composed of any suitable material that allows for the flow of cations (e.g., lithium cations) between the anode layer and the cathode layer during operation of the battery cell. In some embodiments, the separator layer comprises a solid-state electrolyte (SSE) material. For example, the SSE material of the separator layer comprises a polymer, a sulfide, an oxide, a chalcogenide, or any combination thereof. For example, the SSE material may comprise a sulfide. In some embodiments, the SSE material comprises LSS, LTS, LXPS, LXPSO, LATS, lithium garnet, or any combination thereof, where X is Si, Ge, Sn, As, Al, or any combination thereof, S is S, Si, or any combination thereof, and T is Sn.

[0053] As used herein, "LSS" refers to lithium silicon sulfide, which can be described as Li2S-SiS2, Li-SiS2, Li-S-Si, or an SSE material containing Li, S, and Si. In some embodiments, LSS is Li x S y S z where 0.33≦x≦0.5, 0.1≦y≦0.2, and 0.4≦z≦0.55. In some embodiments, the LSS may include up to 10 atomic % oxygen. In other embodiments, the LSS may include SSE materials including Li, Si, and S. In some embodiments, the LSS includes a mixture of Li2S and SiS2. In some embodiments, the molar ratio of Li2S:SiS2 is 90:10, 85:15, 80:20, 75:25, 70:30, 2:1, 65:35, 60:40, 55:45, or 50:50. In some embodiments, the LSS includes Li x PO y , Li x BO y , Li4SiO4, Li3MO4, Li3MO3, PS, and / or lithium halides, including but not limited to LiI, LiCl, LiF, or LiBr, where 0 <x≦5かつ0<y≦5である。

[0054] As used herein, "LTS" refers to a lithium tin sulfide compound, which can be described as Li2S-SnS2, Li2S-SnS, Li-S-Sn, or an SSE material containing Li, S, and Sn. In some embodiments, LTS is Li x Sn y S z (0.25≦x≦0.65, 0.05≦y≦0.2, and 0.25≦z≦0.65). In some embodiments, the LTS may include a mixture of Li2S and SnS2 in a molar ratio of 80:20, 75:25, 70:30, 2:1, or 1:1 (i.e., Li2S:SnS2). In some embodiments, the LTS may include up to 10 atomic % oxygen. In other embodiments, the LTS may be doped with Bi, Sb, As, P, B, Al, Ge, Ga, In, or any combination thereof. As used herein, "LATS" refers to LTS as used above, further including arsenic (As).

[0055] As used herein, "LXPS" refers to a compound of formula Li a MP b S c "LSPS" refers to a material characterized by the formula L a SiP b S c (2≦a≦8, 0.5≦b≦2.5, 4≦c≦12).

[0056] When M is Sn and Si (i.e., when both Sn and Si are present), the LXPS material is referred to as "LSTPS". As used herein, "LSTPSO" refers to an LSTPS that is doped with, has O, or has O present. In some embodiments, "LSTPSO" is an LSTPS material with an oxygen content of 0.01-10 atomic %. As used herein, "LSPS" refers to an electrolyte material with chemical components of Li, Si, P, and S. As used herein, "LSTPS" refers to an electrolyte material with chemical components of Li, Si, P, Sn, and S. As used herein, "LSPSO" refers to an LSPS that is doped with, has O, or has O present. In some embodiments, "LSPSO" is an LSPS material with an oxygen content of 0.01-10 atomic %. As used herein, "LATP" refers to an electrolyte material with chemical components of Li, As, Sn, and P. As used herein, "LAGP" refers to an electrolyte material having a chemical composition of Li, As, Ge, and P. As used herein, "LXPSO" refers to an electrolyte material having a chemical composition of Li a MP b S c O d where M is Si, Ge, Sn, Al, or any combination thereof, and 2≦a≦8, 0.5≦b≦2.5, 4≦c≦12, and d<3. LXPSO refers to LXPS as defined above, having an oxygen doping of 0.1 to about 10 atomic %. As used herein, "LPS" refers to an electrolyte material comprising Li2S-P2S5. As used herein, "LPSO" refers to LPS as defined herein, further including an oxygen doping of 0.1 to about 10 atomic %.

[0057] In some embodiments, the SSE material of the separator layer comprises a polymer. For example, the polymer may comprise polyolefin, natural rubber, synthetic rubber, polybutadiene, polyisoprene, epoxidized natural rubber, polyisobutylene, polypropylene oxide, polyacrylate, polymethacrylate, polyester, polyvinyl ester, polyurethane, styrenic polymer, epoxy resin, epoxy polymer, poly(bisphenol A-co-epichlorohydrin), vinyl polymer, polyvinyl halide, polyvinyl alcohol, polyethyleneimine, poly(maleic anhydride), silicone polymer, siloxane polymer, polyacrylonitrile, polyacrylamide, polychloroprene, polyvinylidene fluoride, polyvinylpyrrolidone, polyepichlorohydrin, mixtures thereof, or copolymers thereof. In some embodiments, the polymer is a polyolefin. In some embodiments, the polymer is a natural rubber. In some embodiments, the polymer is a synthetic rubber. In some embodiments, the polymer is a polybutadiene. In some embodiments, the polymer is a polyisoprene. In some embodiments, the polymer is an epoxidized natural rubber. In other embodiments, the polymer is a polyisobutylene. In some embodiments, the polymer is a polypropylene oxide. In some embodiments, the polymer is a polyacrylate. In some embodiments, the polymer is a polymethacrylate. In some embodiments, the polymer is a polyester. In other embodiments, the polymer is a polyvinyl ester. In some embodiments, the polymer is a polyurethane. In some embodiments, the polymer is a styrenic polymer. In some embodiments, the polymer is an epoxy resin. In some embodiments, the polymer is an epoxy polymer. In some embodiments, the polymer is poly(bisphenol A-co-epichlorohydrin). In some embodiments, the polymer is a vinyl polymer. In some embodiments, the polymer is a polyvinyl halide. In some embodiments, the polymer is a polyvinyl alcohol. In some embodiments, the polymer is a polyethyleneimine. In other embodiments, the polymer is poly(maleic anhydride). In some embodiments, the polymer is a silicone polymer. In some embodiments, the polymer is a siloxane polymer.In some embodiments, the polymer is polyacrylonitrile. In some embodiments, the polymer is polyacrylamide. In some embodiments, the polymer is polychloroprene. In some embodiments, the polymer is polyvinylidene fluoride. In some embodiments, the polymer is polyvinylpyrrolidone. In some embodiments, the polymer is polyepichlorohydrin. In some embodiments, the molecular weight of the polymer is greater than about 50,000 g / mol.

[0058] In some embodiments, the polymer is preformed and is selected from the group consisting of polypropylene, polyethylene, polybutadiene, polyisoprene, epoxidized natural rubber, poly(butadiene-co-acrylonitrile), polyethyleneimine, polydimethylsiloxane, and poly(ethylene-co-vinyl acetate). In other embodiments, the molecular weight of the polymer is greater than about 50,000 g / mol.

[0059] When the SSE material includes a polymer, the SSE material may further include a metal salt (eg, a lithium salt (eg, LiPF6)).

[0060] In some embodiments, the SSE material of the separator layer is a lithium perovskite material, Li3N, Li-β-alumina, lithium superionic conductor (LISICON), Li 2.88 PO 3.86 N 0.14 (LiPON), Li9AlSiO8, Li 10 GeP2S 12 , a lithium garnet SSE material, a doped lithium garnet SSE material, a lithium garnet composite material, or any combination thereof. In various embodiments, the lithium garnet SSE material is a cation doped Li5La3M 1 2O 12 (M 1 is Nb, Zr, Ta, or any combination thereof), cation-doped Li6La2BaTa2O 12 , cation-doped Li7La3Zr2O 12 , and cation-doped Li6BaY2M 1 2O12 where the cation dopant is barium, yttrium, zinc, or a combination thereof. In various other embodiments, the lithium garnet SSE material is Li5La3Nb2O 12 , Li5La3Ta2O 12 , Li7La3Zr2O 12 , Li6La2SrNb2O 12 , Li6La2BaNb2O 12 , Li6La2SrTa2O 12 , Li6La2BaTa2O 12 , Li7Y3Zr2O 12 , Li 6.4 Y3Zr 1.4 Ta 0.6 O 12 , Li 6.5 La 2.5 Ba 0.5 TaZrO 12 , Li6BaY2M 1 2O 12 , Li7Y3Zr2O 12 , Li 6.75 BaLa2Nb 1.75 Zinc 0.25 O 12 , Li 6.75 BaLa2Ta 1.75 Zinc 0.25 O 12 , or any combination thereof.

[0061] In some embodiments, the SSE material of the separator layer and the SSE material of the anode layer are the same (e.g., the SSE material of the separator layer can be any SSE material described herein for the anode layer), while in other embodiments, the SSE material of the separator layer and the SSE material of the separator layer are different.

[0062] In some embodiments, the separator layer is substantially free of pores (e.g., has an apparent porosity of less than 50%, has an apparent porosity of less than 40%, has an apparent porosity of less than 30%, has an apparent porosity of less than 20%, has an apparent porosity of less than 15%, has an apparent porosity of less than 10%, has an apparent porosity of less than 5%, or has an apparent porosity of less than 1%). Also, in some embodiments, the separator layer is free of pores.

[0063] In some embodiments, the separator layer has a thickness of about 1 μm to about 300 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 200 μm. In other embodiments, the separator layer has a thickness of about 1 μm to about 100 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 50 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 20 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 10 μm.

[0064] Referring again to FIG. 1A, the separator layer has a front surface 110 facing the anode layer, a back surface 112 facing away from the anode layer, and an exterior surface 114 extending from the front surface to the back surface.

[0065] In some embodiments, the separator layer may define recesses 216b, 216c, as shown in Figures 2B and 2C. The separator layer recesses may be defined on the front, back, and / or outer surface of the separator layer. For example, the back surface 212b of the separator layer may define a recess, as shown in Figure 2B. In other embodiments, the back and outer surfaces 214c of the separator layer define a recess, as shown in Figure 2C.

[0066] When the separator layer defines a recess, the seal may be disposed within the recess. Without wishing to be bound by theory, it is believed that the recess increases the surface area to which the seal bonds. Additionally, it is believed that placing the seal in a recess in the separator layer creates a more tortuous path that liquid must follow to penetrate the anode layer.

[0067] B. Anode layer 1A, the anode layer is at least partially disposed on the separator layer. In some embodiments, the anode layer has a first surface 118 facing the separator layer, a second surface 120 facing away from the separator layer, and an exterior surface 122 extending from the first surface to the second surface. The anode layer comprises a SSE having pores.

[0068] In some embodiments, the anode layer is disposed on the entire surface of the separator layer, in other embodiments, the anode layer is disposed on substantially the entire surface (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%) of the separator layer, and in other embodiments, the anode layer is disposed on only a portion of the surface of the separator layer.

[0069] In some embodiments, the anode layer has an apparent porosity of about 20% to about 80%. In other embodiments, the anode layer has an apparent porosity of about 35% to about 75%. In some embodiments, the anode layer has an apparent porosity of about 45% to about 65%. In some embodiments, the anode layer has an apparent porosity of about 50% to about 60%. In some embodiments, the anode layer has an apparent porosity of about 60% to about 80%. In some embodiments, the anode layer has an apparent porosity of about 20% to about 95%. In some embodiments, the anode layer has an apparent porosity of about 50% to about 90%.

[0070] In some embodiments, the SSE material of the anode layer and the SSE material of the separator layer are the same. In other embodiments, the SSE material of the anode layer and the SSE material of the separator layer are different. In some embodiments, the SSE material comprises a lithium conductor, a sodium conductor, or a magnesium conductor. In some embodiments, the SSE material comprises a lithium conductor. In other embodiments, the SSE material comprises a sodium conductor. And, in some embodiments, the SSE material comprises a magnesium conductor.

[0071] In some embodiments, the SSE material of the anode layer may include a garnet material. Non-limiting examples of garnet materials include lithium garnet materials, doped lithium garnet materials, lithium garnet composite materials, and combinations thereof. Non-limiting examples of lithium garnet materials include Li3-phase lithium garnet SSE materials (e.g., Li3M 1 Te2O 12 , where M 1 is a lanthanide such as Y, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Zr, Ta, or a combination thereof, and Li 3+x Nd3Te 2-x O 12 , where x is 0.05 to 1.5), Li5-phase lithium garnet SSE materials (e.g., Li5La3M 2 2O 12 , where M 2 is Nb, Zr, Ta, Sb, or a combination thereof, cation-substituted Li5La3M 2 2O 12 , for example Li6M 1 La3M 2 2O 12 , where M 1 is Mg, Ca, Sr, Ba, or a combination thereof, and Li7La3M 2 2O 12 , where M 2 Zr, Sn, or a combination thereof), Li6-phase lithium garnet SSE materials (e.g., Li6M 1 La2M 2 2O 12 , where M 1 is Mg, Ca, Sr, Ba, or a combination thereof, and M 2 is Nb, Ta, or a combination thereof), cation-doped Li6La2BaTa2O 12 , cation-doped Li6BaY2M 2 2O 12 , where M 2is Nb, Ta, or a combination thereof, and the cation dopant is barium, yttrium, zinc, or a combination thereof, Li7 phase lithium garnet SSE materials (e.g., cubic Li7La3Zr2O 12 and Li7Y3Zr2O 12 ), cation-doped Li7La3Zr2O 12 , Li 5+2x La3, Ta 2-x O2, where x is 0.1 to 1, Li 6.8 (La 2.95 , Ca 0.5 )(Zr 1.75 , Nb 0.25 )O 12 (LLCZN), Li 6.4 Y3Zr 1.4 Ta 0.6 O 12 , Li 6.5 La 2.5 Ba 0.5 TaZrO 12 , Li6BaY2M 1 2O 12 , Li7Y3Zr2O 12 , Li 6.75 BaLa2Nb 1.75 Zinc 0.25 O 12 , or Li 6.75 BaLa2Ta 1.75 Zinc 0.25 O 12 ), lithium garnet composites (e.g., lithium garnet composites with a conductive carbon matrix or other materials). Other examples of lithium ion conducting SSE materials include 3 mol% YSZ doped Li 7.6 La3Zr 1.94 Y 0.06 O 12 and 8mol% YSZ doped Li 7.16 La3Zr 1.94 Y 0.06 O 12 Further examples of suitable lithium garnet SSE materials include cubic garnet type materials such as Li5La3Nb2O 12 , Li5La3Ta2O 12 , Li7La3Zr2O 12 , Li6La2SrNb2O12 , Li6La2BaNb2O 12 , Li6La2SrTa2O 12 , Li6La2BaTa2O 12 , Li7Y3Zr2O 12 , Li 6.4 Y3Zr 1.4 Ta 0.6 O 12 , Li 6.5 La 2.5 Ba 0.5 TaZrO 12 , Li7Y3Zr2O 12 , Li 6.75 BaLa2Nb 1.75 Zinc 0.25 O 12 , or Li 6.75 BaLa2Ta 1.75 Zinc 0.25 O 12 In some embodiments, the garnet material may be, for example, Li 7-x La 3-y M 1 y Zr 2-z M 2 z O 12 where x is greater than 0 and less than 2; M 1 is selected from Ba, Ca, Y, and combinations thereof; M 2 is selected from Nb, Ta, and combinations thereof. In some embodiments, the garnet material is 6.75 La3Zr 1.75 Ta 0.25 O 12 (LLZT), Li 6.75 La 2.75 Zr 1.75 Ca 0.25 Nb 0.25 O 12 (LLZCN), Li5La3Nb2O 12 (LLZNO), Li7La3Zr2O 12 (LLZ), Li5La3Ta2O 12 , Li6La2SrNb2O 12 , Li6La2BaNb2O 12 , Li6La2SrTa2O 12, Li6La2BaTa2O 12 , Li7Y3Zr2O 12 , Li 6.4 Y3Zr 1.4 Ta 0.6 O 12 , Li 6.5 La 2.5 Ba 0.5 TaZrO 12 , Li6BaY2M 1 2O 12 , Li 6.75 BaLa2Nb 1.75 Zinc 0.25 O 12 , Li 6.75 BaLa2Ta 1.75 Zinc 0.25 O 12 , or any combination thereof.

[0072] In some embodiments, the garnet material comprises a composition of formula (I). M1 7-x D1 a M2 3-y D2 b M3 2-z D3 c O 12-w D4 d (I) During the ceremony, M1 is Li, M2 is La, M3 is Zr, D1 is H, Be, B, Al, Fe, Zn, Ga, Ge, or any combination thereof; D2 is Na, K, Ca, Rb, Sr, Y, Ag, Ba, Bi, Pr, Nd, Pm, Sm, Gd, Tb, Dy, Ho, Er, Tm, Zn, Ce, or any combination thereof; D3 is Mg, Si, Sc, Ti, V, Cr, Mn, Co, Ni, Cu, Ge, As, Se, Nb, Mo, Tc, Ru, Rh, Pd, Cd, In, Sn, Sb, Hf, Ta, W, Ir, Pt, Au, Hg, Tl, Pb, Ce, Eu, Te, Y, Sr, Ca, Ba, Gd, Ge, or any combination thereof; D4 is F, Cl, Br, I, S, Se, Te, N, P, or any combination thereof. however, 0≦w≦2, -0.5 <x≦3、 0≦y≦3, 0≦z≦2, 0≦a≦2, 0≦b≦3, 0≦c≦2, and 0≦d≦2, where at least one of a, b, c, and d is greater than 0.

[0073] In some embodiments, the anode layer further comprises an anode material disposed in at least some of the pores of the anode layer. In some embodiments, the anode material comprises a lithium-containing material, a magnesium-containing material, a sodium-containing material, or any combination thereof. In other embodiments, the anode material comprises lithium metal, sodium metal, magnesium metal, or any combination thereof. In some embodiments, the anode material comprises lithium metal. In other embodiments, the anode material comprises sodium metal. And, in some embodiments, the anode material comprises magnesium metal.

[0074] In some embodiments, the pores of the anode layer are substantially free of anode material (e.g., the pores contain less than 1%, less than 0.5%, less than 0.25%, less than 0.1%, less than 0.01%, or less than 0.001% anode material by volume of the pores). In the context of the present disclosure, when reference is made to the "substantially free" or "absent" of anode material in the pores of the anode layer, it will be understood that the pores of the anode layer are substantially free or absent of anode material prior to operation of the battery cell, i.e., immediately after manufacture of the battery cell and prior to operation of the battery cell (e.g., charging / discharging the battery cell). In some embodiments, the pores of the anode layer are substantially free of lithium metal, sodium metal, magnesium metal, or any combination thereof. In other embodiments, the pores of the anode layer are substantially free of lithium metal, sodium metal, magnesium metal, or any combination thereof. In some embodiments, the pores of the anode layer are substantially free of lithium metal. Also, in some embodiments, the pores of the anode layer are substantially free of lithium metal.

[0075] 3A, in some embodiments, the anode layer defines a first porous region 324 and a second porous region 326. The first porous region is defined between a center 328 and an outer surface of the anode layer. The second porous region is defined between the first porous region and the outer surface of the anode layer.

[0076] In some embodiments, the pores of the first porous region are substantially free of sealant material (e.g., the pores contain less than 1%, less than 0.5%, less than 0.25%, less than 0.1%, less than 0.01%, or less than 0.001% sealant material by volume of the pores). In other embodiments, the pores of the first porous region are free of sealant material.

[0077] In some embodiments, as shown in FIG. 3A, at least a portion of the pores of the second porous region comprise a sealant material.

[0078] 2D and 2E, the anode layer may define recesses 230d, 230e. The recesses of the anode layer may be defined on the first surface, the second surface, and / or the outer surface of the anode layer. For example, as shown in FIG. 2D, the second surface 220d and the outer surface 222d of the anode layer may define the recesses. In some embodiments, as shown in FIG. 2E, the first surface 218e, the second surface 220e, and the outer surface 222e of the anode layer define the recesses. In other embodiments, only the outer surface defines the recesses. In some embodiments, only the second surface defines the recesses. Also, in some embodiments, only the first surface defines the recesses.

[0079] When the anode layer defines a recess, the seal may be disposed within the recess, as shown in Figures 2D and 2E. Without wishing to be bound by theory, it is believed that the recess increases the surface area to which the seal bonds. Additionally, it is believed that disposing the seal in the recess of the anode layer creates a more tortuous path that liquid must follow to penetrate the anode layer.

[0080] In some embodiments, the anode layer has a thickness of about 1 μm to about 500 μm. In some embodiments, the anode layer has a thickness of about 1 μm to about 200 μm. In other embodiments, the anode layer has a thickness of about 1 μm to about 100 μm. In some embodiments, the anode layer has a thickness of about 1 μm to about 50 μm. In some embodiments, the anode layer has a thickness of about 1 μm to about 20 μm.

[0081] C. Anode current collector The anode current collector is bonded to the anode layer. Referring again to Figure 1A, the anode current collector is bonded to the second surface of the anode layer. In some embodiments, the anode current collector has an inner surface 132 facing the anode layer, an outer surface 134 facing away from the anode layer, and an outer surface 136 extending from the inner surface to the outer surface.

[0082] In some embodiments, the anode current collector is at least partially disposed on the second surface of the anode layer. In some embodiments, the anode current collector is disposed over the entire second surface of the anode layer. In other embodiments, the anode current collector is disposed over substantially the entire second surface of the anode layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). In other embodiments, the anode current collector is disposed over only a portion of the second surface of the anode layer.

[0083] In some embodiments, the anode current collector comprises a metal foil 138, as shown in Figures 1A and 1C. In such embodiments, the metal foil is at least partially disposed on the second surface of the anode layer. In some embodiments, the metal foil is disposed over the entire second surface of the anode layer. In other embodiments, the metal foil is disposed over substantially the entire second surface of the anode layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). And in other embodiments, the metal foil is disposed over only a portion of the second surface of the anode layer.

[0084] In some embodiments, the metal foil has a tab 140 configured to connect to an external circuit, as shown in Figure 1C. In the illustrated embodiment, the tab is integral with the metal foil. In other embodiments, the tab is bonded (e.g., welded) to the metal foil.

[0085] In some embodiments, the anode current collector includes a tab configured to connect to an external circuit. In such embodiments, the anode current collector may include only the tab, rather than a metal foil. For example, the anode current collector may include a tab, and the tab may be coupled to (e.g., disposed within) the seal.

[0086] The anode current collector may be constructed from any suitable material. In some embodiments, the anode current collector (e.g., metal foil and / or tab) comprises copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof. In some embodiments, the anode current collector comprises copper. In other embodiments, the anode current collector comprises a copper alloy. In some embodiments, the anode current collector comprises nickel. In other embodiments, the anode current collector comprises a nickel alloy. In some embodiments, the anode current collector comprises titanium. In some embodiments, the anode current collector comprises a titanium alloy. In some embodiments, the anode current collector comprises stainless steel. Also, in some embodiments, the anode current collector comprises a stainless steel alloy.

[0087] In some embodiments, the anode current collector comprises a conductive film. For example, the conductive film may comprise a polymeric material and a conductive material. For example, the conductive material may be a metallic material. In some embodiments, the conductive material comprises copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof. In some embodiments, the polymer comprises polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof.

[0088] In some embodiments, a conductive tape couples the anode current collector to the anode layer. During operation of the battery cell (e.g., during charging and / or discharging of the battery cell), the conductive tape can electrically couple the anode current collector to the anode layer.

[0089] D. Seal The seal comprises a sealant material. The seal is substantially liquid impermeable. In some embodiments, the seal is substantially liquid impermeable and gas permeable. When the seal is substantially liquid impermeable and gas permeable, the seal can restrict the flow of liquid (e.g., catholyte) to the anode layer while allowing evacuation of gas from the anode layer.

[0090] In some embodiments, the seal is at least partially disposed on the outer surface of the anode layer. In some embodiments, the seal 108 is disposed over the entire outer surface of the anode layer, as shown in FIG. 1A. In other embodiments, the seal is disposed over substantially the entire outer surface of the anode layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). And in other embodiments, the seal 408 is disposed over only a portion of the outer surface of the anode layer, as shown in FIG. 4.

[0091] In some embodiments, the seal 208, 508, 608 is at least partially disposed on the separator layer, as shown in Figures 2A, 5A, and 6A. In some embodiments, the seal is at least partially disposed on the outer surface of the separator layer. In some embodiments, the seal 508, 608 is disposed on the entire outer surface of the separator layer, as shown in Figures 5A and 6A. In other embodiments, the seal is disposed on substantially the entire outer surface of the separator layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). Also, in some embodiments, the seal is disposed on only a portion of the outer surface of the separator layer.

[0092] In some embodiments, the seal is at least partially disposed on the back surface of the separator layer. In other embodiments, the seal is disposed over substantially the entire back surface of the separator layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). And in other embodiments, the seal 208, 508, 608 is disposed over only a portion of the back surface of the separator layer, as shown in Figures 2A, 5A, and 6A.

[0093] In some embodiments, the seal is at least partially disposed on the front surface of the separator layer. In other embodiments, the seal is disposed over substantially the entire front surface of the separator layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). And in other embodiments, the seal 208e is disposed over only a portion of the front surface of the separator layer, as shown in FIG. 2E.

[0094] In some embodiments, the seal 508, 608 is at least partially disposed on the outer surface and rear surface of the separator layer, as shown in Figures 5A and 6A. In the illustrated embodiment, the seal is disposed on the entire outer surface and only a portion of the rear surface of the separator layer. In other embodiments, the seal 208e is at least partially disposed on the outer surface, front surface, and rear surface of the separator layer, as shown in Figure 2E. As shown, the seal is disposed on the entire outer surface of the separator layer and only a portion of the front and rear surfaces.

[0095] In other embodiments, the separator layer is free of seals, i.e., no seals are disposed on any surface (e.g., the front, back, and / or exterior surface) of the separator layer.

[0096] In some embodiments, the seal 108, 508, 608 is at least partially disposed on the anode current collector, as shown in Figures 1A, 5A, and 6A. In some embodiments, the seal is at least partially disposed on the outer surface of the anode current collector. In some embodiments, the seal 508 is disposed over the entire outer surface of the anode current collector, as shown in Figure 5A. In other embodiments, the seal is disposed over substantially the entire outer surface of the anode current collector (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). Also, in some embodiments, the seal is disposed over only a portion of the outer surface of the anode current collector.

[0097] In some embodiments, the seal is disposed at least partially on the inner surface of the anode current collector. In other embodiments, the seal is disposed over substantially the entirety (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%) of the inner surface of the anode current collector. In other embodiments, the seal 108, 608 is disposed over only a portion of the inner surface of the anode current collector, as shown in Figures 1A and 6A.

[0098] In some embodiments, the seal is disposed at least partially on the outer surface of the anode current collector. In some embodiments, the seal 708, 708' is disposed over the entire outer surface of the anode current collector, as shown in Figures 7A and 7C. In other embodiments, the seal is disposed over substantially the entire outer surface of the anode current collector (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). And in other embodiments, the seal is disposed over only a portion of the outer surface of the anode current collector.

[0099] In some embodiments, the seal 708, 708' is at least partially disposed on the outer surface and exterior of the anode current collector, as shown in Figures 7A and 7C. In the illustrated embodiment, the seal is disposed over the entire outer surface and exterior of the anode current collector.

[0100] In other embodiments, the anode current collector is free of a seal, i.e., no seal is disposed on any surface (e.g., the interior surface, the exterior surface, and / or the exterior surface) of the anode current collector.

[0101] In some embodiments, seal 508 is at least partially disposed on each of the outer surface of the anode layer, the outer surface of the separator layer, and the outer surface of the anode current collector, as shown in Figure 5A. In other embodiments, seal 708, 708' is at least partially disposed on each of the outer surface of the anode layer, the outer surface of the separator layer, the outer surface of the anode current collector, and the outer surface of the anode current collector, as shown in Figures 7A and 7C. Also, in some embodiments, seal 608 is at least partially disposed on each of the outer surface of the anode layer, the outer surface of the separator layer, and the inner surface of the anode current collector, as shown in Figure 6A.

[0102] 3A, a seal 308 may be disposed on an outer surface of the anode layer and at least partially within the pores of the second porous region of the anode layer. In embodiments in which the seal is disposed within the pores of the anode layer (e.g., some of the pores of the second porous region), the seal may also restrict the flow of the anode active material (e.g., lithium metal) outwardly of the anode layer.

[0103] The sealant material may be any material suitable for restricting the flow of liquid (e.g., catholyte) to the anode layer. In some embodiments, the sealant material comprises a non-conductive (e.g., non-ionically and electronically conductive) polymer, a non-conductive (e.g., non-ionically and electronically conductive) glass, or any combination thereof. In other embodiments, the sealant material comprises a non-conductive polymer. In some embodiments, the sealant material comprises a non-conductive glass. For example, the sealant material may be a glass having a low coefficient of thermal expansion (CTE). As another example, the sealant material may be a glass-ceramic.

[0104] In some embodiments, the sealant material comprises polypropylene, polyethylene, polyimide, polyvinyl chloride (PVC), ethylene vinyl acetate, polyamide, polypropylene, polyurethane, copolymers thereof, or any combination thereof. For example, the sealant material may comprise polypropylene. In some embodiments, the sealant material comprises polyethylene. In other embodiments, the sealant material comprises polyimide. In some embodiments, the sealant material comprises PVC. In some embodiments, the sealant material comprises ethylene vinyl acetate. In other embodiments, the sealant material comprises polyamide. In some embodiments, the sealant material comprises polypropylene. Also, in some embodiments, the sealant material comprises polyurethane.

[0105] In some embodiments, the sealant material comprises polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof. In some embodiments, the sealant material comprises polypropylene. In some embodiments, the sealant material comprises polyethylene. In other embodiments, the sealant material comprises polymethylpentene. In some embodiments, the sealant material comprises polybutene-1. In some embodiments, the sealant material comprises ethylene-octene copolymer. In some embodiments, the sealant material comprises propylene-butane copolymer. In some embodiments, the sealant material comprises polyisobutylene. In some embodiments, the sealant material comprises poly(α-olefin). In some embodiments, the sealant material comprises an ethylene propylene rubber. In other embodiments, the sealant material comprises an ethylene propylene diene monomer rubber. In some embodiments, the sealant material comprises an ethylene vinyl acetate. In some embodiments, the sealant material comprises an ethylene-acrylate copolymer. In other embodiments, the sealant material comprises a polyamide. In some embodiments, the sealant material comprises a polyester. In some embodiments, the sealant material comprises a polyurethane. In some embodiments, the sealant material comprises a styrene block copolymer. In some embodiments, the sealant material comprises a polycaprolactone. In other embodiments, the sealant material comprises a polyimide. In some embodiments, the sealant material comprises a polyvinyl chloride. In some embodiments, the sealant material comprises a polycarbonate. In some embodiments, the sealant material comprises a polyacrylate. In some embodiments, the sealant material comprises a polymethacrylate.In some embodiments, the sealant material comprises a fluoropolymer, in some embodiments, the sealant material comprises an epoxy resin, in other embodiments, the sealant material comprises an epoxy polymer, and in some embodiments, the sealant material comprises a silicone rubber.

[0106] In some embodiments, the seal may further include a conductive material. For example, the conductive material may be a metallic material. In some embodiments, the conductive material includes copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof.

[0107] In some embodiments, at least a portion of the seal has a thickness of about 1 μm to about 50 μm. In some embodiments, at least a portion of the seal has a thickness of about 1 μm to about 20 μm. In other embodiments, at least a portion of the seal has a thickness of about 1 μm to about 10 μm. In some embodiments, at least a portion of the seal has a thickness of about 1 μm to about 5 μm.

[0108] Without wishing to be bound by theory, it is believed that an anode layer including a SSE having pores allows a seal to be placed on the exterior surface of the anode layer, the anode current collector, and / or the ceramic separator layer, thereby restricting the flow of liquid (e.g., catholyte) to the anode layer. Specifically, unlike other solid anode assemblies, the volume of the anode layer described herein remains substantially constant during cycling, and the distance between the anode layer and the anode current collector remains substantially stationary during cycling. This allows for sealing of the exterior surface of the anode layer, the anode current collector, and / or the ceramic separator layer without the risk of fatigue failure due to changes in the volume of the anode assembly during cycling.

[0109] E. Housing 4 and 8A, the anode assembly further comprises a housing 442, 842 having a plurality of interior walls 444, 844 defining an interior 446, 846. The separator layer, anode layer, anode current collector, and seal are disposed within the housing.

[0110] 4, when the anode assembly includes a housing, the seal 408 may extend from the outer surface 422 of the anode layer to at least one of the interior walls of the housing. In the illustrated embodiment, the seal contacts at least one (e.g., two or more) of the interior walls. In other embodiments, the seal is spaced from at least one of the interior walls.

[0111] 8, the housing may further include a first protrusion 848 and a second protrusion 850 extending from at least one of the interior walls into the interior of the housing. The first and second protrusions define a cavity 852. In some embodiments, the seal extends from an outer surface of the anode layer into the cavity.

[0112] In some embodiments, the seal may extend from the outer surface of the separator layer to at least one of the inner walls of the housing. In such embodiments, the outer surface of the anode layer may be free of a seal. In other words, a seal may not be disposed on any surface (e.g., the first surface, the second surface, and / or the outer surface) of the anode layer.

[0113] In another aspect, the present invention provides an anode assembly for a battery cell. The battery cell includes a separator layer, an anode layer, an anode current collector, and a seal. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer includes a solid-state electrolyte (SSE) having pores. The anode current collector is bonded to the second surface of the anode layer. The seal is disposed over substantially the entire outer surface of the anode layer and includes a sealant material. The seal is substantially impermeable to liquids.

[0114] In a further aspect, the present invention provides an anode assembly for a battery cell. The battery cell includes a separator layer, an anode layer, an anode current collector, and a seal. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer includes a solid-state electrolyte (SSE) having pores. The anode current collector is bonded to the second surface of the anode layer. A seal is disposed on at least a portion of the anode layer and the separator layer. The seal is substantially impermeable to liquids.

[0115] In one aspect, the present invention provides an anode assembly for a battery cell. The battery cell includes a separator layer, an anode layer, an anode current collector, and a seal. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer includes a solid-state electrolyte (SSE) having pores. The anode current collector is bonded to the second surface of the anode layer. A seal is disposed on at least a portion of the anode layer and the anode current collector. The seal is substantially impermeable to liquids.

[0116] In yet another aspect, the present invention provides an anode assembly for a battery cell. The battery cell includes a separator layer, an anode layer, an anode current collector, and a seal. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer includes a solid-state electrolyte (SSE) having pores. The anode current collector is bonded to the second surface of the anode layer. A seal is disposed over at least a portion of the anode layer, the separator layer, and the anode current collector. The seal is substantially impermeable to liquids.

[0117] In another aspect, the present invention provides an anode assembly for a battery cell. The battery cell includes a separator layer, an anode layer, an anode current collector, and a seal. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer, a second surface facing away from the separator, and an outer surface extending from the first surface to the second surface. The anode layer includes a solid-state electrolyte (SSE) having pores. The anode current collector is bonded to the second surface of the anode layer. The seal includes a casing that encases the anode layer. The seal is substantially impermeable to liquids. In some embodiments, the casing does not contact the anode layer. For example, the casing may be disposed on the outer surface of the anode current collector and / or the separator layer.

[0118] III. Multi-layer anode assembly Another aspect of the present invention provides a multi-layer anode assembly. The multi-layer anode assembly combines two anode assemblies described herein such that at least one component is common to each anode assembly. For example, referring to Figures 1B, 3B, 5B, 6B, and 8B, the multi-layer anode assembly can include a common anode current collector 106, 306, 506, 606, 806. In some embodiments, the multi-layer anode assembly can include a common seal 508, 808, as shown in Figures 5B and 8B.

[0119] In another aspect, the present invention provides a multi-layer anode assembly. The multi-layer anode assembly includes a first separator layer, a second separator layer, a first anode layer, a second anode layer, an anode current collector, and a seal. The second separator layer is spaced apart from the first separator layer. The first anode layer is at least partially disposed on the first separator layer. The first anode layer has a first surface facing the first separator layer, a second surface facing away from the first separator layer, and an outer surface extending from the first surface to the second surface. The first anode layer includes an SSE having pores. The second anode layer is at least partially disposed on the second separator layer. The second anode layer has a first surface facing the second separator layer, a second surface facing away from the second separator layer, and an outer surface extending from the first surface to the second surface. The second anode layer includes a SSE having pores. An anode current collector is bonded to a second surface of the first and second anode layers. A seal is at least partially disposed on an outer surface of the first and second anode layers. The seal includes a sealant material. And, the seal is substantially impermeable to liquids.

[0120] In yet another aspect, the present invention provides a multi-layer anode assembly. The multi-layer anode assembly includes a first separator layer, a second separator layer, a first anode layer, a second anode layer, an anode current collector, a first seal, and a second seal. The second separator layer is spaced apart from the first separator layer. The first anode layer is at least partially disposed on the first separator layer. The first anode layer has a first surface facing the first separator layer, a second surface facing away from the first separator layer, and an outer surface extending from the first surface to the second surface. The first anode layer includes an SSE having pores. The second anode layer is at least partially disposed on the second separator layer. The second anode layer has a first surface facing the second separator layer, a second surface facing away from the second separator layer, and an outer surface extending from the first surface to the second surface. The second anode layer includes a SSE having pores. An anode current collector is bonded to the second surfaces of the first and second anode layers. A first seal is at least partially disposed on the outer surface of the first anode layer. A second seal is at least partially disposed on the outer surface of the second anode layer. The first and second seals include a sealant material. Additionally, the first and second seals are substantially impermeable to liquids.

[0121] IV. Battery Cell 9A, a battery cell 954 includes a separator layer 902, an anode layer 904, an anode current collector 906, a cathode layer 956, a cathode current collector 958, and a seal 908.

[0122] The separator layer can be any separator layer described herein. For example, the separator layer can have a front surface, a back surface spaced from the front surface, and an outer surface extending from the front surface to the back surface.

[0123] The anode layer can be any anode layer described herein. For example, the anode layer can be at least partially disposed on the front surface of the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer can also include a SSE having pores.

[0124] The anode current collector can be any anode current collector described herein. For example, the anode current collector can be bonded to the second surface of the anode layer.

[0125] A. Cathode layer 9A, the cathode layer is at least partially disposed on the back surface 912 of the separator layer. The cathode layer has a first surface 960 facing the separator layer, a second surface 962 facing away from the separator layer, and an outer surface 964 extending from the first surface to the second surface.

[0126] In some embodiments, the cathode layer is disposed on the entire back surface of the separator layer. In other embodiments, the cathode layer is disposed on substantially the entire (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%) of the back surface of the separator layer. In some embodiments, the cathode layer is disposed on only a portion of the back surface of the separator layer.

[0127] The cathode layer may be composed of any suitable material. In some embodiments, the cathode layer comprises a lithium ion conducting material. For example, the lithium ion conducting material may be LiCoO2, LiNi 1 / 3 Co 1 / 3 Mn 1 / 3 O2, LiNi 0.5 Co 0.2 Mn 0.3 Lithium Nickel Manganese Cobalt Oxide (NMC, LiNi x Mn y Co z O2, where x+y+z=1), LiMn2O4, LiNi 0.5 Mn 1.5Lithium manganese oxides (LMOs) such as LiFePO4, LiMnPO4, LiCoPO4, lithium iron phosphates (LFPs) such as Li2MMn3O8, where M is selected from Fe, Co, or any combination thereof. In some embodiments, the ion-conducting cathode material is a high energy ion-conducting cathode material such as Li2MMn3O8, where M is selected from Fe, Co, or any combination thereof.

[0128] In some embodiments, the cathode comprises a sodium ion conducting material. For example, the sodium ion conducting material is Na2V2O5, P2-Na 2 / 3 Fe 1 / 2 Mn 1 / 2 O2, Na3V2(PO4)3, NaMn 1 / 3 Co 1 / 3 Ni 1 / 3 PO4, or any composite thereof (e.g., composite with carbon black) (e.g., Na 2 / 3 Fe 1 / 2 Mn 1 / 2 O2@graphene composite).

[0129] In some embodiments, the cathode layer comprises a magnesium ion conducting material. For example, the magnesium ion conducting material may be a doped manganese oxide (e.g., Mg x MnO 2·y H2O).

[0130] In some embodiments, the cathode layer comprises an organic sulfide or polysulfide. For example, the organic sulfide or polysulfide can be carbyne polysulfide and copolymerized sulfur.

[0131] In some embodiments, the cathode layer includes an air electrode, which can be, for example, a mixture of high surface area carbon particles (e.g., Super P (i.e., conductive carbon black)) and catalyst particles (e.g., alpha-MnO2 nanorods) bound together with a mesh (e.g., a polymer binder such as a PVDF binder).

[0132] In some embodiments, the battery cell further includes a catholyte (e.g., catholyte) disposed within the cathode layer. In such embodiments, the seal is substantially impermeable to the cathode layer. The catholyte may include any material suitable for promoting liquid-solid contact and / or providing an improved interface for ion transfer. For example, the catholyte may include a lithium salt, a linear carbonate, a cyclic carbonate, an ionic liquid, or any combination thereof. For example, the catholyte may include a mixture of lithium bis(fluorosulfonyl)imide and N-propyl-N-methylpyrrolidinium bis(fluorosulfonyl)imide. In other embodiments, the catholyte includes a mixture of lithium hexafluorophosphate, ethylene carbonate, and ethyl methyl carbonate.

[0133] In some embodiments, the cathode layer has a thickness of about 1 μm to about 500 μm. In some embodiments, the cathode layer has a thickness of about 1 μm to about 200 μm. In other embodiments, the cathode layer has a thickness of about 1 μm to about 100 μm. In some embodiments, the cathode layer has a thickness of about 1 μm to about 50 μm. In some embodiments, the cathode layer has a thickness of about 1 μm to about 20 μm. In some embodiments, the cathode layer has a thickness of about 10 μm to about 150 μm. In other embodiments, the cathode layer has a thickness of about 40 μm to about 100 μm. In some embodiments, the cathode layer has a thickness of about 60 μm to about 80 μm.

[0134] B. Cathode current collector The cathode current collector is bonded to the cathode layer. Referring again to Figure 9A, the cathode current collector is bonded to a second surface of the cathode layer. In some embodiments, the cathode current collector has an inner surface 966 facing the cathode layer, an outer surface 968 facing away from the cathode layer, and an outer surface 970 extending from the inner surface to the outer surface.

[0135] In some embodiments, the cathode current collector is at least partially disposed on the second surface of the cathode layer. In some embodiments, the cathode current collector is disposed over the entire second surface of the cathode layer. In other embodiments, the cathode current collector is disposed over substantially the entire second surface of the cathode layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). And in other embodiments, the cathode current collector is disposed over only a portion of the second surface of the cathode layer.

[0136] In some embodiments, the cathode current collector includes a metal foil 972, as shown in Figures 9A and 9B. In such embodiments, the metal foil is at least partially disposed on the second surface of the cathode layer. In some embodiments, the metal foil is disposed over the entire second surface of the cathode layer. In other embodiments, the metal foil is disposed over substantially the entire second surface of the cathode layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). And in other embodiments, the metal foil is disposed over only a portion of the second surface of the cathode layer.

[0137] In some embodiments, the metal foil has a tab 974 configured to connect to an external circuit, as shown in Figure 9B. In the embodiment shown, the tab is integral with the metal foil. In other embodiments, the tab is bonded (e.g., welded) to the metal foil.

[0138] The cathode current collector may be constructed from any suitable material. In some embodiments, the cathode current collector (e.g., metal foil and / or tab) comprises aluminum, stainless steel, alloys thereof, or any combination thereof. In some embodiments, the cathode current collector comprises aluminum. In some embodiments, the cathode current collector comprises an aluminum alloy. In other embodiments, the cathode current collector comprises stainless steel. Also, in some embodiments, the cathode current collector comprises a stainless steel alloy.

[0139] In some embodiments, the cathode current collector comprises a conductive film. For example, the conductive film can comprise a polymeric material and a conductive material. For example, the conductive material can be a metallic material. In some embodiments, the conductive material comprises aluminum, stainless steel, an alloy thereof, or any combination thereof.

[0140] In some embodiments, a conductive tape couples the cathode current collector to the cathode layer. During operation of the battery cell (e.g., during charging and / or discharging of the battery cell), the conductive tape can electrically couple the cathode current collector to the cathode layer.

[0141] In some embodiments, as shown in Figures 9A and 9B, the cathode current collector defines an opening 976 configured to allow the cathode layer to be filled with catholyte. In the illustrated embodiment, the outer surface of the cathode current collector defines an opening configured to allow the cathode layer to be filled with catholyte. In other embodiments, as shown in Figures 10C and 10D, the outer surface and exterior surface of the cathode current collector define an opening 1076' configured to allow the cathode layer to be filled with catholyte.

[0142] In some embodiments, the cross-sectional width of the cathode current collector is greater than the cross-sectional width of the cathode layer, as shown in Figures 7A, 9A, and 10 A. In other embodiments, the cross-sectional width of the cathode current collector is substantially the same as the cross-sectional width of the cathode layer, as shown in Figures 7C and 9C.

[0143] C. Seal The seal comprises a sealant material. The seal is substantially impermeable to liquids. The seal may be any seal described herein.

[0144] In some embodiments, the seal is gas permeable, hi some embodiments, the seal is disposed at least partially on an outer surface of the anode layer.

[0145] In some embodiments, the seal is at least partially disposed on the cathode layer. For example, as shown in Figures 9A, 9C, 10A, and 10C, the seal may be at least partially disposed on the outer surface of the cathode layer. In the illustrated embodiment, the seal is disposed on the entire outer surface of the cathode layer. In other embodiments, the seal is disposed on substantially the entire outer surface of the cathode layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). Also, in some embodiments, the seal is disposed on only a portion of the outer surface of the cathode layer.

[0146] In some embodiments, the seal is at least partially disposed on the cathode current collector. For example, as shown in Figures 9C and 10C, the seal may be at least partially disposed on the exterior surface of the cathode current collector. In other embodiments, the seal is disposed on substantially the entire exterior surface (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%) of the cathode current collector. Also, in some embodiments, the seal is disposed on only a portion of the exterior surface of the cathode current collector.

[0147] In some embodiments, the seal is disposed at least partially on the inner surface of the cathode current collector, as shown in Figures 9A and 10A. In other embodiments, the seal is disposed over substantially the entirety (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%) of the inner surface of the cathode current collector. Also, in some embodiments, the seal is disposed over only a portion of the inner surface of the cathode current collector, as shown in Figures 9A and 10A.

[0148] In some embodiments, the seal is at least partially disposed on each of the outer surface of the anode layer, the outer surface of the separator layer, the outer surface of the separator layer, and the inner surfaces of the anode and cathode current collectors. For example, as shown in Figures 9A and 10A, the seal may be disposed on the entire outer surface of the anode layer, the entire outer surface of the separator layer, and only a portion of the inner surfaces of the anode and cathode current collectors.

[0149] In some embodiments, the seal may be at least partially disposed on each of the outer surface of the anode layer, the outer surface of the separator layer, the inner surface of the cathode current collector, and the outer and exterior surfaces of the anode current collector, as shown in Figure 7 A. In the illustrated embodiment, the seal may be disposed on the entire outer surface of the anode layer, the entire outer surface of the separator layer, only a portion of the inner surface of the cathode current collector, and the entire outer and exterior surfaces of the anode current collector.

[0150] In some embodiments, the seal is at least partially disposed on each of the outer surface of the anode layer, the outer surface of the separator layer, the outer surface of the cathode layer, and the inner surfaces of the anode and cathode current collectors. For example, as shown in Figures 9A and 10A, the seal may be disposed on the entire outer surface of the anode layer, the entire outer surface of the separator layer, the entire outer surface of the cathode layer, and only a portion of the inner surfaces of the anode and cathode current collectors.

[0151] In some embodiments, the seal may be at least partially disposed on each of the outer surface of the anode layer, the outer surface of the separator layer, the outer surface of the cathode layer, the inner surface of the cathode current collector, and the outer and exterior surfaces of the anode current collector. For example, as shown in Figure 7A, the seal may be disposed on the entire outer surface of the anode layer, the entire outer surface of the separator layer, the entire outer surface of the cathode layer, only a portion of the inner surface of the cathode current collector, and the entire outer and exterior surfaces of the anode current collector.

[0152] In some embodiments, the seal may be at least partially disposed on each of the outer surface of the anode layer, the outer surface of the separator layer, the outer surface of the cathode layer, the outer surface of the cathode current collector, and the outer and exterior surface of the anode current collector, as shown in Figure 7C. In the illustrated embodiment, the seal is disposed on the entire outer surface of the anode layer, the entire outer surface of the separator layer, the entire outer surface of the cathode layer, the entire outer surface of the cathode current collector, and the entire outer and exterior surface of the anode current collector.

[0153] In some embodiments, the seal may be at least partially disposed on each of the outer surface of the anode layer, the outer surface of the separator layer, the outer surface of the cathode layer, the outer surface of the cathode current collector, and the inner surface of the anode current collector. For example, as shown in Figure 9C, the seal may be disposed on the entire outer surface of the anode layer, the entire outer surface of the separator layer, the entire outer surface of the cathode layer, the entire outer surface of the cathode current collector, and only a portion of the inner surface of the anode current collector.

[0154] In some embodiments, the seal is at least partially disposed over the anode layer and the separator layer, in other embodiments, the seal is at least partially disposed over the anode layer and the anode current collector, and in some embodiments, the seal is at least partially disposed over the anode layer, the anode current collector, and the separator layer.

[0155] The sealant material may be any sealant material described herein. In some embodiments, the sealant material includes polypropylene, polyethylene, polyimide, polyvinyl chloride (PVC), ethylene vinyl acetate, polyamide, polypropylene, polyurethane, copolymers thereof, or any combination thereof. For example, the sealant material may include polypropylene. In some embodiments, the sealant material includes polyethylene. In other embodiments, the sealant material includes polyimide. In some embodiments, the sealant material includes PVC. In some embodiments, the sealant material includes ethylene vinyl acetate. In other embodiments, the sealant material includes polyamide. In some embodiments, the sealant material includes polypropylene. Also, in some embodiments, the sealant material includes polyurethane.

[0156] Also, in some embodiments, the sealant material comprises polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof. In some embodiments, the sealant material comprises polypropylene. In some embodiments, the sealant material comprises polyethylene. In other embodiments, the sealant material comprises polymethylpentene. In some embodiments, the sealant material comprises polybutene-1. In some embodiments, the sealant material comprises ethylene-octene copolymer. In some embodiments, the sealant material comprises propylene-butane copolymer. In some embodiments, the sealant material comprises polyisobutylene. In some embodiments, the sealant material comprises a poly(α-olefin). In some embodiments, the sealant material comprises an ethylene propylene rubber. In other embodiments, the sealant material comprises an ethylene propylene diene monomer rubber. In some embodiments, the sealant material comprises an ethylene vinyl acetate. In some embodiments, the sealant material comprises an ethylene-acrylate copolymer. In other embodiments, the sealant material comprises a polyamide. In some embodiments, the sealant material comprises a polyester. In some embodiments, the sealant material comprises a polyurethane. In some embodiments, the sealant material comprises a styrene block copolymer. In some embodiments, the sealant material comprises a polycaprolactone. In other embodiments, the sealant material comprises a polyimide. In some embodiments, the sealant material comprises a polyvinyl chloride. In some embodiments, the sealant material comprises a polycarbonate. In some embodiments, the sealant material comprises a polyacrylate. In some embodiments, the sealant material comprises a polymethacrylate.In some embodiments, the sealant material comprises a fluoropolymer, in some embodiments, the sealant material comprises an epoxy resin, in other embodiments, the sealant material comprises an epoxy polymer, and in some embodiments, the sealant material comprises a silicone rubber.

[0157] In some embodiments, at least a portion of the seal has a thickness of about 1 μm to about 50 μm. In some embodiments, at least a portion of the seal has a thickness of about 1 μm to about 20 μm. In other embodiments, at least a portion of the seal has a thickness of about 1 μm to about 10 μm. In some embodiments, at least a portion of the seal has a thickness of about 1 μm to about 5 μm.

[0158] D. Housing In some embodiments, the battery cell further comprises a housing. The housing may be any housing described herein. For example, the housing may comprise a plurality of interior walls defining an interior. Disposed within the housing may be a separator layer, an anode layer, an anode current collector, a cathode layer, a cathode current collector, and a seal.

[0159] V. Electrode Pair Assembly In another aspect, the present invention provides an electrode pair assembly. Referring to Figure 11A, an electrode pair assembly 1178a comprises a first separator layer 1102a, a first anode layer 1104a, a first anode current collector 1106a, a first cathode layer 1156a, a first cathode current collector 1158a, and a first seal 1108a. The electrode pair assembly further comprises a second separator layer 1102a', a second anode layer 1104a', and a second cathode layer 1156a'.

[0160] The first and second separator layers can each be any separator layer described herein. In some embodiments, the first separator layer and the second separator layer are different. In other embodiments, the first separator layer and the second separator layer are the same.

[0161] The first and second anode layers may each be any anode layer described herein. In some embodiments, the first and second anode layers are different. In other embodiments, the first and second anode layers are the same.

[0162] The first and second cathode layers may each be any cathode layer described herein. In some embodiments, the first and second cathode layers are different. In other embodiments, the first and second cathode layers are the same.

[0163] The first anode current collector may be any anode current collector described herein. In some embodiments, the first anode current collector 1106a, 1106b serves as a common current collector for the first and second anode layers, as shown in FIGS. 11A and 11B. In other embodiments, the electrode pair assembly further comprises a second anode current collector 1106c', 1106d', as shown in FIGS. 11C and 11D. The second anode current collector may be any anode current collector described herein. In some embodiments, the first anode current collector and the second anode current collector are different. In other embodiments, the first anode current collector and the second anode current collector are the same.

[0164] The first cathode current collector may be any of the cathode current collectors described herein. In some embodiments, the first cathode current collector serves as a common current collector for the first and second cathode layers. In other embodiments, the electrode pair assembly further comprises a second cathode current collector 1158a', 1158b', 1158c', 1158d', as shown in Figures 11A, 11B, 11C, and 11D. The second cathode current collector may be any of the cathode current collectors described herein. In some embodiments, the first cathode current collector and the second cathode current collector are different. In other embodiments, the first cathode current collector and the second cathode current collector are the same.

[0165] In some embodiments, as shown in FIG. 11C, an outer surface 1168c of a first cathode current collector is disposed on an outer surface 1168c' of a second cathode current collector.

[0166] 11C, where the first and second cathode current collectors define openings 1176c, 1176c' configured to allow the first and second cathode layers to be filled with catholyte, the openings may be spaced apart from one another such that the opening in the first cathode current collector is sealed by the second cathode current collector and the opening in the second cathode current collector is sealed by the first cathode current collector. In other embodiments, the openings 1276b, 1276b' may be substantially aligned such that the first and second cathode layers are in fluid communication with one another, as shown in FIG.

[0167] The first seal may be any seal described herein. In some embodiments, as shown in FIG. 11E, the first seal 1108e serves as a common seal for at least the first and second anode layers (e.g., the first seal is at least partially disposed on an outer surface of the first and second anode layers). In other embodiments, the electrode pair assembly further comprises a second seal 1108a′ as shown in FIG. 11A. The second seal may be any seal described herein. In some embodiments, the first seal and the second seal are different. In other embodiments, the first seal and the second seal are the same.

[0168] 11A, the electrode pair assembly 1178a may include a first separator layer 1102a, a second separator layer 1102a', a first anode layer 1104a, a second anode layer 1104a', a first cathode layer 1156a, a second cathode layer 1156a', a first anode current collector 1106a, a first cathode current collector 1158a, a second cathode current collector 1158a', a first seal 1108a, and a second seal 1108a'. The first anode current collector is a current collector common to the first and second anode layers. A first seal is at least partially disposed on each of the outer surface of the first anode layer, the outer surface of the first separator layer, the back surface of the first separator layer, the outer surface of the first cathode layer, the inner surface of the first cathode current collector, and the inner surface of the first anode current collector. A second seal is at least partially disposed on each of the outer surface of the second anode layer, the outer surface of the second separator layer, the back surface of the second separator layer, the outer surface of the second cathode layer, the inner surface of the second cathode current collector, and the outer surface of the first anode current collector.

[0169] 11B, an electrode pair assembly 1178b differs from the electrode pair assembly 1176a of FIG. 11A in that the first seal 1108b and the second seal 1108b' are at least partially disposed on the outer surfaces of the first and second cathode current collectors 1158b, 1158b', respectively, rather than on the inner surfaces of the first and second cathode current collectors. The cross-sectional widths of the first and second cathode current collectors are substantially the same as the cross-sectional widths of the first and second cathode layers.

[0170] Referring to FIG. 11C, the electrode pair assembly 1178c may include a first separator layer 1102c, a second separator layer 1102c', a first anode layer 1104c, a second anode layer 1104c', a first cathode layer 1156, a second cathode layer 1156c', a first anode current collector 1106c, a second anode current collector 1106c', a first cathode current collector 1158c, a second cathode current collector 1158c', a first seal 1108c, and a second seal 1108c'. The first seal is at least partially disposed on each of the outer surface of the first anode layer, the outer surface of the first separator layer, the back surface of the first separator layer, the outer surface of the first cathode layer, the inner surface of the first cathode current collector, and the inner surface of the first anode current collector. The second seal is at least partially disposed on each of the outer surface of the second anode layer, the outer surface of the second separator layer, the back surface of the second separator layer, the outer surface of the second cathode layer, the inner surface of the second cathode current collector, and the inner surface of the second anode current collector. The outer surface of the first cathode current collector is disposed on the outer surface of the second cathode current collector. The first and second current collectors define openings 1176c, 1176c', respectively. The openings are spaced apart from one another such that the openings in the first cathode current collector are sealed by the second cathode current collector and the openings in the second cathode current collector are sealed by the first cathode current collector. Thus, each of the first and second cathode layers can be filled with catholyte prior to assembling the electrode pair assembly.

[0171] 11D, the electrode pair assembly 1178d differs from the electrode pair assembly 1178c of FIG. 11C in that the first seal 1108d and the second seal 1108d' are at least partially disposed on the outer surfaces of the first and second cathode current collectors 1158d, 1158d', respectively, rather than on the inner surfaces of the first and second cathode current collectors. The cross-sectional widths of the first and second cathode current collectors are substantially the same as the cross-sectional widths of the first and second cathode layers. The first and second seals define a gap 1180d. This gap may allow for the first and second cathode layers to be filled with catholyte after the electrode pair assembly is assembled.

[0172] 11E, an electrode pair assembly 1178e differs from the electrode pair assembly 1178d of FIG. 11D in that it includes only a first seal 1108e and does not include a second seal. A first seal is at least partially disposed on each of the outer surface of the first anode layer, the outer surface of the first separator layer, the back surface of the first separator layer, the outer surface of the first cathode layer, the outer surface of the first cathode current collector, the inner surface of the first anode current collector, the outer surface of the second anode layer, the outer surface of the second separator layer, the back surface of the second separator layer, the outer surface of the second cathode layer, the outer surface of the second cathode current collector, and the inner surface of the second anode current collector.

[0173] 12A, the electrode pair assembly 1278a may include a first separator layer 1202a, a second separator layer 1202a', a first anode layer 1204a, a second anode layer 1204a', a first cathode layer 1256a, a second cathode layer 1256a', a first anode current collector 1206a, a first cathode current collector 1258a, a second cathode current collector 1258a', a first seal 1208a, and a second seal 1208a'. The first anode current collector is a current collector common to the first and second anode layers. A first seal is at least partially disposed on each of the outer surface of the first anode layer, the outer surface of the first separator layer, the back surface of the first separator layer, the outer surface of the first cathode layer, the inner surface of the first cathode current collector, and the inner surface of the first anode current collector. A second seal is at least partially disposed on each of the outer surface of the second anode layer, the outer surface of the second separator layer, the back surface of the second separator layer, the outer surface of the second cathode layer, the inner surface of the second cathode current collector, and the outer surface of the first anode current collector. The first and second current collectors each define an opening.

[0174] Referring to FIG. 12C, the electrode pair assembly 1278c differs from the electrode pair assembly 1278a of FIG. 12A in that the outer surfaces and exterior faces of the first and second cathode current collectors 1258c, 1258c' define respective openings 1276c, 1276c', rather than just the outer surfaces of the first and second cathode current collectors.

[0175] Referring to FIG. 12B, the electrode pair assembly 1278B may include a first separator layer 1202b, a second separator layer 1202b', a first anode layer 1204b, a second anode layer 1204b', a first cathode layer 1256b, a second cathode layer 1256b', a first anode current collector 1206b, a second anode current collector 1206b', a first cathode current collector 1258b, a second cathode current collector 1258b', a first seal 1208b, and a second seal 1208b'. The first seal is at least partially disposed on each of the outer surface of the first anode layer, the outer surface of the first separator layer, the back surface of the first separator layer, the outer surface of the first cathode layer, the inner surface of the first cathode current collector, and the inner surface of the first anode current collector. The second seal is at least partially disposed on each of the outer surface of the second anode layer, the outer surface of the second separator layer, the back surface of the second separator layer, the outer surface of the second cathode layer, the inner surface of the second cathode current collector, and the inner surface of the second anode current collector. The outer surface of the first cathode current collector is disposed on the outer surface of the second cathode current collector. The first and second current collectors each define an opening 1276b, 1276b'. The openings are substantially aligned such that the first and second cathode layers are in fluid communication with each other.

[0176] Referring to FIG. 12D, electrode pair assembly 1278d differs from electrode pair assembly 1278b of FIG. 12B in that the outer surfaces and exterior faces of the first and second cathode current collectors 1258d, 1258d' define respective openings 1276d, 1276d', rather than just the outer surfaces of the first and second cathode current collectors.

[0177] 13, the electrode pair assembly 1378 includes a first anode current collector 1306, a first anode layer 1304, a first seal 1308, a first separator layer 1302, a first cathode layer 1356, a first cathode current collector 1358, a second cathode layer 1356', a second separator layer 1302', a second anode layer 1304', a second seal 1308', a second anode current collector 1358 ... separator layer 1302', a second anode current collector 1358', a second anode current collector 1358', a second separator layer 1302', a second anode current collector 1358', a second anode current collector 1358', a second separator layer 1302', a second anode current collector 1358', a second anode current collector 1358', a second separator layer 1302', a second anode current collector 1358', a second anode current collector 1358', a second anode current collector 1358', a second separator layer 1302', a second anode current collector 1358', a second anode current collector 1358', a second anode current collector 1358', a second anode current The cathode current collector 1304'' may comprise a first body 1306', a third anode layer 1304'', a third seal 1308'', a third separator layer 1302'', a third cathode layer 1356'', a second cathode current collector 1358', a fourth cathode layer 1356''', a fourth separator layer 1302''', a fourth anode layer 1304'''', a fourth seal 1308''', and a third anode current collector 1306''. The first cathode current collector is a current collector common to the first and second cathode layers. The second anode current collector is a current collector common to the second and third cathode layers. The second cathode current collector is a current collector common to the third and fourth cathode layers. The first seal is at least partially disposed on an outer surface of the first anode layer. The second seal is at least partially disposed on an outer surface of the second anode layer. The third seal is at least partially disposed on an outer surface of the third anode layer. The fourth seal is at least partially disposed on an outer surface of the fourth anode layer. The electrode pair assembly may be disposed in the housing 1382.

[0178] VI. Method of Forming the Anode Assembly Another aspect of the present invention provides a method of forming an anode assembly. Referring to Figure 14, a flow chart is provided illustrating an exemplary embodiment of forming an anode assembly for a battery cell. The method includes: (a) a separator layer; an anode layer at least partially disposed on the separator layer and having a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface, the anode layer including a solid-state electrolyte (SSE) having pores; an anode current collector bonded to the second surface of the anode layer; (1402) to provide (b) forming a seal at least partially on an exterior surface of the anode layer, the seal being substantially impermeable to liquid (1404); Includes.

[0179] The separator layer may be any separator layer described herein. The anode layer may be any anode layer described herein. The anode current collector may be any anode current collector described herein.

[0180] In some embodiments, the forming of step (b) includes forming a seal from the sealant material by cold pressing, hot pressing, melting, 3D printing, or any combination thereof, at least partially on the exterior surface of the anode layer. In some embodiments, the forming of step (b) includes forming a seal from the sealant material by cold pressing the sealant material at least partially on the exterior surface of the anode layer. In other embodiments, the forming of step (b) includes forming a seal from the sealant material by hot pressing the sealant material at least partially on the exterior surface of the anode layer. In some embodiments, the forming of step (b) includes forming a seal from the sealant material by melting the sealant material at least partially on the exterior surface of the anode layer. Also, in some embodiments, the forming of step (b) includes forming a seal from the sealant material by 3D printing the sealant material at least partially on the exterior surface of the anode layer.

[0181] In some embodiments, the forming step (b) includes forming a seal from the sealant material by mechanically applying the sealant material at least partially on the outer surface of the anode layer. For example, the forming step (b) may include forming a seal from the sealant material by applying the sealant material at least partially on the outer surface of the anode layer using a paint brush, a roller, a plastic applicator, a metal applicator, a mold tool, a syringe dispenser, a dispenser valve, or any combination thereof. In some embodiments, the forming step (b) includes forming a seal from the sealant material by applying the sealant material at least partially on the outer surface of the anode layer with a paint brush. In other embodiments, the forming step (b) includes forming a seal from the sealant material by applying the sealant material at least partially on the outer surface of the anode layer with a roller. In some embodiments, the forming step (b) includes forming a seal from the sealant material by applying the sealant material at least partially on the outer surface of the anode layer with a plastic applicator. In some embodiments, the forming step (b) includes forming a seal from the sealant material by applying the sealant material at least partially onto the exterior surface of the anode layer with a metal applicator. In other embodiments, the forming step (b) includes forming a seal from the sealant material by applying the sealant material at least partially onto the exterior surface of the anode layer with a molding tool. In some embodiments, the forming step (b) includes forming a seal from the sealant material by applying the sealant material at least partially onto the exterior surface of the anode layer with a syringe dispenser. Also, in some embodiments, the forming step (b) includes forming a seal from the sealant material by applying the sealant material at least partially onto the exterior surface of the anode layer with a dispenser valve.

[0182] In some embodiments, forming step (b) includes forming a seal from the sealant material by injection molding, in-line extrusion, spray depositing, 3D printing, wrapping, or any combination thereof, of the sealant material at least partially on the exterior surface of the anode layer. In some embodiments, forming step (b) includes forming a seal from the sealant material by injection molding at least partially on the exterior surface of the anode layer. In other embodiments, forming step (b) includes forming a seal from the sealant material by in-line extruding at least partially on the exterior surface of the anode layer. In some embodiments, forming step (b) includes forming a seal from the sealant material by spray depositing at least partially on the exterior surface of the anode layer. In some embodiments, forming step (b) includes forming a seal from the sealant material by 3D printing at least partially on the exterior surface of the anode layer. Also, in some embodiments, forming step (b) includes forming a seal from the sealant material by wrapping at least partially on the exterior surface of the anode layer.

[0183] The temperature and / or application pressure of the sealant material may be selected to provide suitable sealant material flow and coverage without damaging other components of the anode assembly. In embodiments in which the sealant material is disposed at least partially on the exterior surface of the anode layer and within the pores of the second porous region, the temperature and / or application pressure of the sealant material may be sufficient to allow a desired level of penetration into the pores of the second porous region. Similarly, the location of the sealant material, the amount of sealant material, the application rate of the sealant material, and the cooling scheme of the seal may be tailored for each particular embodiment of the seal.

[0184] The sealant material may be any sealant material described herein. For example, the sealant material may include polypropylene, polyethylene, polyimide, polyvinyl chloride (PVC), ethylene vinyl acetate, polyamide, polypropylene, polyurethane, copolymers thereof, or any combination thereof. For example, the sealant material may include polypropylene. In some embodiments, the sealant material includes polyethylene. In other embodiments, the sealant material includes polyimide. In some embodiments, the sealant material includes PVC. In some embodiments, the sealant material includes ethylene vinyl acetate. In other embodiments, the sealant material includes polyamide. In some embodiments, the sealant material includes polypropylene. Also, in some embodiments, the sealant material includes polyurethane.

[0185] Also, in some embodiments, the sealant material comprises polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof. In some embodiments, the sealant material comprises polypropylene. In some embodiments, the sealant material comprises polyethylene. In other embodiments, the sealant material comprises polymethylpentene. In some embodiments, the sealant material comprises polybutene-1. In some embodiments, the sealant material comprises ethylene-octene copolymer. In some embodiments, the sealant material comprises propylene-butane copolymer. In some embodiments, the sealant material comprises polyisobutylene. In some embodiments, the sealant material comprises a poly(α-olefin). In some embodiments, the sealant material comprises an ethylene propylene rubber. In other embodiments, the sealant material comprises an ethylene propylene diene monomer rubber. In some embodiments, the sealant material comprises an ethylene vinyl acetate. In some embodiments, the sealant material comprises an ethylene-acrylate copolymer. In other embodiments, the sealant material comprises a polyamide. In some embodiments, the sealant material comprises a polyester. In some embodiments, the sealant material comprises a polyurethane. In some embodiments, the sealant material comprises a styrene block copolymer. In some embodiments, the sealant material comprises a polycaprolactone. In other embodiments, the sealant material comprises a polyimide. In some embodiments, the sealant material comprises a polyvinyl chloride. In some embodiments, the sealant material comprises a polycarbonate. In some embodiments, the sealant material comprises a polyacrylate. In some embodiments, the sealant material comprises a polymethacrylate.In some embodiments, the sealant material comprises a fluoropolymer, in some embodiments, the sealant material comprises an epoxy resin, in other embodiments, the sealant material comprises an epoxy polymer, and in some embodiments, the sealant material comprises a silicone rubber.

[0186] In some embodiments, the forming of step (b) further comprises curing the sealant material. For example, curing the sealant material may comprise curing the sealant material by exposure to radiation (e.g., ultraviolet (UV) radiation). In some embodiments, the curing may be performed by UV radiation from a UV lamp. In other embodiments, the curing of the sealant material comprises an epoxy cure.

[0187] In another aspect, the present invention provides a method of forming an anode assembly, the method comprising: (a-1) a separator layer; an anode layer at least partially disposed on the separator layer and having a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface, the anode layer including a solid-state electrolyte (SSE) having pores; an anode current collector bonded to the second surface of the anode layer; and (b-2) forming a seal at least partially on an outer surface of the anode layer, the seal being substantially impermeable to liquid; Includes.

[0188] VII. Examples In order that the invention described herein may be more fully understood, the following examples are set forth herein to illustrate the methods and anode assemblies provided herein, and should not be construed as limiting the scope thereof in any way.

[0189] Example 1. Epoxy seal In a fume hood at normal pressure and room temperature, a 5 mL mixing syringe was attached to the end of an epoxy gun (Nordson TAH manual dispensing gun or 3M dual cartridge dispensing gun). The plunger was removed from the 5 mL syringe and a 20 gauge blunt tip needle was attached via a luer lock connection. Using the epoxy gun with the mixing syringe attached, 1-3 mL of epoxy was directly loaded into the 5 mL syringe (T = 0 min). A plunger back was added into the syringe to evacuate any air remaining in the syringe. At T = 30 min, the epoxy-based material (Hysol E 120 HP from Henkel, Rocky Hill, CT) was introduced into the glove box using a small vacuum antechamber by pulling a vacuum for 1.5 min and refilling the chamber (repeated for 3 cycles).

[0190] An anode assembly was provided. The anode assembly consisted of a 1 cm x 1 cm ceramic bilayer with a metallized current collecting layer disposed on the face of the porous (i.e., anode) layer opposite the dense (i.e., separator) layer. The metallized current collecting layer was adhered to the anode current collector using a conductive adhesive material.

[0191] The porous (i.e., anode) layer was oriented face down on the work surface. At T=60 min, while holding the assembly with tweezers, a layer of epoxy was applied around the edges of the anode assembly using a syringe. A layer of epoxy was applied to the surface of the dense (i.e., separator) layer of the ceramic bilayer on the side perpendicular to the plane of the electrode pair (i.e., the outer surface of the anode layer and separator layer), with a certain amount of epoxy overlapping. Additional epoxy was applied where gaps and / or air bubbles appeared. The epoxy was applied slowly and carefully to prevent the formation of air bubbles. Once the seal deposition (i.e., epoxy layer) was completed, the anode assembly was suspended using a binder clip attached to a ring stand to prevent the assembly from curing to the surface. The appropriate epoxy curing schedule was followed. The curing schedule was 20 hours at room temperature.

[0192] Example 2. Polyethylene (LDPE) seal A clean sheet of aluminum foil was placed on top of the hot plate and pressed against the hot plate in a shape that minimized the gap between the hot plate surface and the aluminum foil.

[0193] Using tweezers, a thin LDPE strip was placed in a square around the periphery of the anode assembly (i.e., an anode assembly substantially similar to that of Example 1 above). The strip overlapped the surface of the ceramic bilayer by 0.5-1.5 mm and extended to the anode current collector. Once the LDPE strip was in place, the hot plate was heated to 150°C. The LDPE strip was allowed to melt completely. After the LDPE strip had melted, any visible gaps were filled with additional LDPE strip, which was also allowed to melt. Using a cold glass slide (maintained at room temperature), light pressure was applied to the seal by quickly tracing the tweezers around the seal on the glass slide. The hot plate was turned off and the anode assembly was allowed to cool until its temperature was below 80°C.

[0194] Equivalence and Scope In the claims, articles such as "a," "an," and "the" may mean one or more, unless indicated to the contrary or the context clearly indicates otherwise. A claim or description including "or" between one or more members of a group is considered to be satisfied if one, more than one, or all of the members of the group are present, employed, or relevant in a given product or process, unless indicated to the contrary or the context clearly indicates otherwise. The invention includes embodiments in which exactly one member of a group is present, employed, or relevant in a given product or process. The invention includes embodiments in which more than one, or all of the members of a group are present, employed, or relevant in a given product or process.

[0195] Furthermore, the present invention encompasses all variations, combinations, and substitutions in which one or more limitations, elements, clauses, and descriptive terms from one or more of the enumerated claims are introduced into another claim. For example, any claim that is dependent on another claim can be amended to include one or more limitations found in any other claim that is dependent on the same base claim. When elements are presented as a list, e.g., in Markush group format, each subgroup of elements is also disclosed, and any element(s) may be removed from this group. Of course, when the invention, or aspects of the invention, are generally referred to as comprising certain elements and / or features, a particular embodiment of the invention or aspect of the invention consists of or consists essentially of such elements and / or features. For the sake of brevity, those embodiments have not been specifically described verbatim herein. It should also be noted that the terms "comprising" and "containing" are intended to be open-ended and allow for the inclusion of additional elements or steps. When ranges are given, the endpoints are included. Furthermore, unless otherwise indicated or clear from the context and the understanding of one of ordinary skill in the art to mean otherwise, values ​​expressed as ranges can be considered to be any particular value or subrange within the stated ranges of different embodiments of the invention, down to one tenth of the unit of the lower limit of the range, unless clearly meant otherwise by the context.

[0196] This application refers to various issued patents, published patent applications, journal articles, and other publications, all of which are incorporated herein by reference. In the event of a conflict between any of the incorporated references and this specification, this specification shall control. Furthermore, any particular embodiment of the present invention within the prior art may be expressly excluded from any one or more of the claims. Such embodiments may be excluded even if the exclusion is not expressly set forth herein, since they are deemed known to those of ordinary skill in the art. Any particular embodiment of the present invention may be excluded from any claim for any reason, whether related to the existence of prior art or not.

[0197] Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation many equivalents to the specific embodiments described herein. The scope of the present embodiments described in the present invention is not intended to be limited to the above specification, but is as set forth in the appended claims. It will be apparent to those skilled in the art that various changes and modifications to this description can be made without departing from the spirit or scope of the present invention, as defined in the following claims.

Claims

1. 1. An anode assembly for a battery cell, comprising: a separator layer; an anode layer at least partially disposed on the separator layer, the anode layer having a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface, the anode layer comprising a solid electrolyte (SSE) having micropores; an anode current collector bonded to the second surface of the anode layer; a seal disposed at least partially on the outer surface of the anode layer, the seal comprising a sealant material, the seal being substantially impermeable to liquids; Equipped with the anode layer defines a first porous region between a center of the anode layer and the outer surface and a second porous region between the first porous region and the outer surface of the anode layer, the pores of the first porous region being substantially free of the sealant material and at least some of the pores of the second porous region containing the sealant material.

2. 10. The anode assembly of claim 1, wherein the separator layer is substantially pore-free.

3. 10. The anode assembly of claim 1, wherein the separator layer comprises a SSE material, the SSE material comprising a polymer, a sulfide, an oxide, a chalcogenide, or any combination thereof.

4. the separator layer defines a recess; The anode assembly of claim 1 , wherein the seal is disposed within the recess in the separator layer. (i) the separator layer has a thickness of about 1 μm to about 300 μm, and / or (ii) the anode layer has a thickness of about 1 μm to about 500 μm; and / or 10. The anode assembly of claim 1, wherein (iii) at least a portion of the seal has a thickness of from about 1 μm to about 50 μm.

6. 10. The anode assembly of claim 1, further comprising an anode material disposed in at least some of the pores of the anode layer, the anode material comprising lithium metal, sodium metal, magnesium metal, or any combination thereof.

7. The anode assembly of claim 1 , wherein the seal is disposed on the outer surface of the anode layer and at least partially within the pores of the second porous region.

8. the outer surface of the anode layer defines a recess; The anode assembly of claim 1 , wherein the seal is disposed within the recess in the anode layer.

9. 10. The anode assembly of claim 1, wherein the anode current collector comprises a metal foil, the metal foil comprising copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof.

10. 10. The anode assembly of claim 9, wherein the metal foil has a tab configured for connection to an external circuit.

11. The anode assembly of claim 1 , wherein the seal is at least partially disposed on the separator layer.

12. The anode assembly of claim 1 , wherein the seal is at least partially disposed on the anode current collector.

13. the separator layer has a front surface facing the anode layer, a back surface facing away from the anode layer, and an outer surface extending from the front surface to the back surface; 2. The anode assembly of claim 1, wherein the anode current collector has an inner surface facing the anode layer, an outer surface facing away from the anode layer, and an outer surface extending from the inner surface to the outer surface.

14. (i) the seal is at least partially disposed on the outer surface of the separator layer; and / or (ii) the seal is disposed over substantially the entire outer surface of the separator layer; and / or (iii) the seal is at least partially disposed on the back surface of the separator layer; and / or (iv) the seal is at least partially disposed on the front surface of the separator layer; and / or (v) the seal is disposed at least partially on the exterior surface of the anode current collector; and / or (vi) the seal is disposed over substantially the entire exterior surface of the anode current collector; and / or (vii) the seal is at least partially disposed on the outer surface of the anode current collector; and / or (viii) the seal is disposed over substantially the entire outer surface of the anode current collector; and / or (ix) the seal is at least partially disposed on the interior surface of the anode current collector; and / or 14. The anode assembly of claim 13, wherein (x) the seal is at least partially disposed on each of the outer surface of the anode layer, the outer surface of the separator layer, and the outer surface of the anode current collector.

15. The anode assembly of claim 1 , wherein the sealant material comprises a non-conductive polymer, a non-conductive glass, or any combination thereof.

16. 10. The anode assembly of claim 1, wherein the sealant material comprises polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof.

17. a housing having a plurality of interior walls defining an interior; The anode assembly of claim 1 , wherein the separator layer, the anode layer, the anode current collector, and the seal are disposed within the interior of the housing.

18. 18. The anode assembly of claim 17, wherein the seal extends from the outer surface of the anode layer to at least one of the interior walls of the housing.

19. the housing further includes a first protrusion and a second protrusion extending from at least one of the plurality of inner walls to the interior of the housing; the first protrusion and the second protrusion define a cavity; 18. The anode assembly of claim 17, wherein the seal extends from the outer surface of the anode layer into the cavity.

20. The anode assembly of claim 1 , wherein the seal is gas permeable.

21. 1. A multi-layer anode assembly comprising:

21. The anode assembly of any one of claims 1 to 20, wherein the separator layer is further defined as a first separator layer and the anode layer is further defined as a first anode layer; and a second separator layer spaced apart from the first separator layer; a second anode layer disposed at least partially on the second separator layer, the second anode layer having a first surface facing the second separator layer, a second surface facing away from the second separator layer, and an outer surface extending from the first surface to the second surface, the second anode layer including a solid electrolyte (SSE) having micropores; Equipped with the anode current collector is bonded to the second surface of the first anode layer and the second anode layer; The seal is at least partially disposed on the outer surface of the second anode layer.

22. A battery cell, An anode assembly according to any one of claims 1 to 20; a cathode layer at least partially disposed on the back surface of the separator layer, the cathode layer having a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface; a cathode current collector bonded to the second surface of the cathode layer; and A battery cell comprising:

23. a housing having a plurality of interior walls defining an interior; 23. The battery cell of claim 22, wherein the separator layer, anode layer, anode current collector, cathode layer, cathode current collector, and the seal are disposed within the interior of the housing.

24. the anode current collector has an inner surface facing the anode layer, an outer surface facing away from the anode layer, and an outer surface extending from the inner surface to the outer surface; 23. The battery cell of claim 22, wherein the cathode current collector has an inner surface facing the cathode layer, an outer surface facing away from the cathode layer, and an outer surface extending from the inner surface to the outer surface. (i) the seal is at least partially disposed on each of the outer surface of the anode layer, the outer surface of the separator layer, and the inner surfaces of the anode current collector and the cathode current collector; 25. The battery cell of claim 24, wherein (ii) the seal is at least partially disposed on each of the outer surface of the anode layer, the outer surface of the separator layer, the inner surface of the cathode current collector, and the outer surface and exterior surface of the anode current collector.

26. 26. The battery cell of claim 25, wherein the cathode current collector defines an opening configured to allow the cathode layer to be filled with catholyte.

27. further comprising a catholyte disposed within the cathode layer; 23. The battery cell of claim 22, wherein the seal is substantially impervious to the catholyte.

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