Single pouch battery cells and methods of manufacture therefor

Abstract

To cope with a problem of defect propagation during manufacturing or operation of a battery, a problem of fire hazard induced by a large amount of electrolyte in each battery cell, and a problem of metal contamination caused during welding processes.SOLUTION: An electrochemical cell includes a first current collector coupled to a first portion of a pouch, the first current collector having a first electrode material disposed thereon, a second current collector coupled to a second portion of the pouch, the second current collector having a second electrode material disposed thereon, and a separator disposed between the first electrode material and the second electrode material. The first portion of the pouch is coupled to the second portion of the pouch to enclose the electrochemical cell.SELECTED DRAWING: Figure 1B

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[1001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62 / 181,385, entitled "Single Pouch Battery Cells and Methods of Manufacture," filed June 18, 2015, the entire disclosure of which is incorporated herein by reference.

[0002]

[1002] FIELD OF THE INVENTION Embodiments described herein relate generally to the manufacture of battery cells, and more particularly to systems and methods for manufacturing and using single pouch battery cells in battery modules. [Background technology]

[0003]

[1003] Lithium-ion electrochemical (battery) cells typically contain alternating anode and cathode layers separated by a separator. The combination of one anode and one cathode with a separator separating them is sometimes referred to as a stack. Multiple stacks, typically connected in parallel, are inserted into a pouch to form a battery cell. The number of stacks in a battery cell (and thus in a pouch) is typically relatively high (e.g., greater than 20) to increase capacity. The pouch also contains an electrolyte (e.g., an organic solvent and dissolved lithium salt), which is typically introduced in a closely controlled environment and serves as a medium for lithium-ion transport. The amount of electrolyte in the pouch is proportional to the number of stacks in the pouch; more stacks can provide more electrolyte.

[0004]

[1004] In manufacturing, battery cells can be constructed by stacking alternating electrode layers (typical high-performance prismatic cells) or by winding long electrode strips into a "jelly roll" shape (typical cylindrical cells). The electrode stack or roll can be inserted into a rigid case sealed with a gasket (most commercially available cylindrical cells), inserted into a laser-welded rigid case, or enclosed in a foil pouch with heat-sealed seams (commonly referred to as a lithium-ion polymer cell).

[0005]

[1005] One promising application of lithium-ion battery cells is in automotive battery packs, which typically include a large number of battery cells, sometimes hundreds or even thousands, to meet the needs of desired power output and capacity. Each battery cell may further include multiple stacks (i.e., anodes, cathodes, and separators) and electrode leads (i.e., tabs). Typically, several cells are connected via battery tabs and bus bars (i.e., interconnection units) to form a module. A typical battery pack can include dozens of such modules. As a result, a significant amount of welding or other joining is typically required to achieve the desired amount of power output and capacity from a single battery pack. Summary of the Invention

[0006]

[1006] The devices, systems, and methods described herein relate to the manufacture and use of single-pouch battery cells. In some embodiments, the electrochemical cell includes a first current collector coupled to a first portion of the pouch, the first current collector having a first electrode material disposed thereon, a second current collector coupled to a second portion of the pouch, the second current collector having a second electrode material disposed thereon, and a separator disposed between the first and second electrode materials. The first portion of the pouch is coupled to the second portion of the pouch to enclose the electrochemical cell. [Brief explanation of the drawings]

[0007] [Figure 1A]

[1007] A schematic diagram showing a battery cell according to one embodiment. [Figure 1B]

[1008] A schematic diagram illustrating another type of battery cell according to some embodiments. [Figure 1C]

[1009] FIG. 1C is a top view of the battery cell shown in FIG. 1B. [Figure 1D]

[1010] A top view showing another battery cell according to some embodiments. [Figure 1E]

[1011] A schematic diagram showing a type of battery cell made using the concept of self-welding, according to some embodiments. [Figure 1F]

[1012] A photograph of the edge of the battery cell shown in Figure 1E. [Figure 2]

[1013] A schematic diagram showing a battery module including multiple single-pouch battery cells according to some embodiments. [Figure 3]

[1014] FIG. 3 is a schematic diagram illustrating a battery pack including multiple battery modules shown in FIG. 2, according to one embodiment. [Figure 4A]

[1015] A schematic diagram showing the relative dimensions of each component of a single pouch battery cell according to some embodiments. [Figure 4B]

[1016] FIG. 4B is an enlarged view showing a corner of the single pouch battery cell shown in FIG. 4A. [Figure 5]

[1017] A schematic diagram showing a battery module including a single pouch battery cell enclosed in a metal case, according to some embodiments. [Figure 6A]

[1018] FIG. 1 is a side view of a battery module (lid open) including a single pouch battery cell enclosed in a metal case, according to some embodiments. [Figure 6B]

[1019] FIG. 6B is a side view of the battery module shown in FIG. 6A after the lid is closed. [Figure 7A]

[1020] A top view showing a battery module including multiple single-pouch battery cells enclosed in a plastic frame according to some embodiments. [Figure 7B]

[1021] FIG. 7B is a side view of the battery module shown in FIG. 7A, showing the top and bottom lids. [Figure 8A]

[1022] A diagram showing a tab design utilized in a battery module including multiple single-pouch battery cells according to some embodiments. [Figure 8B]

[1023] A diagram showing a spacer with a tab design including a tab connection area of ​​the battery module shown in Figure 8A. [Figure 8C]

[1024] FIG. 8B is a diagram showing a connector portion of the battery module shown in FIG. 8A. [Figure 9]

[1025] A flowchart illustrating a method for manufacturing single pouch battery cells and modules according to some embodiments. [Figure 10A]

[1026] A diagram showing the layout of an anode assembly including multiple anodes arranged on a pouch film, according to some embodiments. [Figure 10B]

[1027] FIG. 10B is a cross-sectional view of the anode assembly shown in FIG. 10A. [Figure 11A]

[1028] A diagram showing the layout of a cathode assembly including multiple cathodes arranged on a pouch film, according to some embodiments. [Figure 11B]

[1029] FIG. 11B is a cross-sectional view of the cathode assembly shown in FIG. 11A. [Figure 12]

[1030] A top view showing an electrode assembly including a cathode assembly and an anode assembly according to some embodiments. [Figure 13A]

[1031] A diagram illustrating the layout of a unit cell assembly including multiple unit cells, according to some embodiments. [Figure 13B]

[1032] FIG. 13B is a cross-sectional view of the unit cell assembly shown in FIG. 13A. [Figure 14]

[1033] A diagram illustrating a method for manufacturing unit cells within individual pouches according to some embodiments. [Figure 15A]

[1034] A diagram illustrating a method for manufacturing a unit cell stack according to some embodiments. [Figure 15B] 1A-1C illustrate methods of fabricating a unit cell stack according to some embodiments. [Figure 16A]

[1035] A top view of a unit cell stack prepared by the method shown in Figures 15A-15B. [Figure 16B] FIG. 15C is a cross-sectional view of a unit cell stack prepared by the method shown in FIGS. 15A and 15B. [Figure 17A]

[1036] A diagram showing a pouch cell having additional portions for venting, resealing and removal during manufacturing of a single pouch battery cell according to some embodiments. [Figure 17B] 1A-1C illustrate pouch cells with additional portions for venting, resealing, and removal during manufacturing of single pouch battery cells, according to some embodiments. [Figure 18]

[1037] A diagram showing an exemplary tab configuration for a single pouch battery cell, according to some embodiments. [Figure 19A]

[1038] A diagram illustrating an exemplary manufacturing method for preparing a single pouch battery cell according to some embodiments. [Figure 19B] 1A-1C illustrate an exemplary manufacturing method for producing a single pouch battery cell, according to some embodiments. [Figure 19C]

[1039] A diagram showing an exemplary manufacturing method for manufacturing a cylindrically configured battery cell according to some embodiments. [Figure 19D] 1A-1C illustrate an exemplary manufacturing method for manufacturing a cylindrically configured battery cell, according to some embodiments. [Figure 19E]

[1040] A diagram showing an exemplary manufacturing method for preparing a battery cell in a prismatic configuration, according to some embodiments. [Figure 19F]1A-1C illustrate an exemplary manufacturing method for preparing a battery cell in a prismatic configuration, according to some embodiments. [Figure 19G] 1A-1C illustrate an exemplary manufacturing method for preparing a battery cell in a prismatic configuration, according to some embodiments. [Figure 20]

[1041] A diagram showing a single pouch battery cell according to some embodiments. [Figure 21]

[1042] Figure 1 shows the capacity retention curves of battery cells fabricated using the method described above. [Figure 22]

[1043] A schematic diagram showing a battery module including an array of single-pouch battery cells according to some embodiments. [Figure 23A]

[1044] An exploded view of a battery module including multiple single-pouch battery modules enclosed within a metal case, according to some embodiments. [Figure 23B] FIG. 1 illustrates a completed view of a battery module including multiple single-pouch battery modules enclosed within a metal case, according to some embodiments. [Figure 24A]

[1045] An exploded view of a battery module including multiple single-pouch battery modules enclosed in a plastic case according to some embodiments. [Figure 24B] FIG. 1 illustrates a completed view of a battery module including multiple single-pouch battery modules enclosed within a plastic case, according to some embodiments. [Figure 25]

[1046] A diagram showing a battery pack including a two-dimensional array of battery modules, according to some embodiments. [Figure 26]

[1047] A diagram showing a battery pack including a one-dimensional array of battery modules, according to some embodiments. [Figure 27A]

[1048] A schematic diagram of a battery pack showing stacking and coupling features of battery modules according to some embodiments. [Figure 27B]1 is a schematic diagram of a battery pack illustrating stacking and interlocking features of battery modules, according to some embodiments. [Figure 27C] 1 is a schematic diagram of a battery pack illustrating stacking and interlocking features of battery modules, according to some embodiments. [Figure 28A]

[1049] A completed view of a battery rack including multiple single-pouch battery modules arranged in a rack configuration, according to some embodiments. [Figure 28B] FIG. 1 is an exploded view illustrating a battery rack including multiple single-pouch battery modules arranged in a rack configuration, according to some embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0008]

[1050] FIELD OF THE INVENTION

[0002] Embodiments described herein relate generally to single-pouch battery cells, and more particularly to systems and methods for manufacturing and using single-pouch battery cells in battery modules or battery packs. In some embodiments, the single-pouch battery cell includes an anode, a cathode, a separator disposed therebetween, and a pouch that houses the anode, cathode, and separator to form the single-pouch battery cell. In some embodiments, the anode and / or cathode include a semi-solid electrode material.

[0009]

[1051] Reducing the amount of non-electrochemically active materials in a battery cell can increase the energy density of a given battery cell. The thickness of the current collector is typically selected to facilitate handling and / or provide mechanical support for the electrodes, rather than based on current density considerations. In other words, current collectors are generally thicker than necessary to accommodate the high current densities generated by the electrochemical reactions in the battery, but thinner current collectors (i.e., optimized for current density) can become very brittle and easily break during the manufacturing process. For example, the 20 μm-thick current collectors currently used in some conventional batteries can easily handle the amount of current generated in conventional batteries, yet only a few μm of current collector is needed to shuttle the electrons.

[0010]

[1052] As described herein, single-pouch cells can enable the use of thinner current collectors while improving other aspects of battery cell construction. For example, the current collectors can be bonded to the pouch, allowing the pouch to provide physical support for the current collectors and improve handling, allowing thinner current collectors to be used for electrical conduction while using the pouch. Some additional benefits of this approach include, but are not limited to, (i) reducing or eliminating defect propagation from one battery cell to one or more adjacent battery cells, (ii) reducing fire and other thermal hazards caused by the large amount of flammable electrolyte in conventional batteries, (iii) reducing or eliminating metal contamination that can be introduced into electrode materials during the welding process in conventional battery manufacturing and can impair battery performance by causing internal short circuits within the battery, and (iv) stacking multiple single-pouch battery cells to form battery modules or (v) improving manufacturing yields by conveniently sorting and rejecting individual pouches when manufacturing multi-pouch or multi-stack batteries (by capacity, thickness, impedance, weight, etc.); (vi) providing a means of supporting the semi-solid electrode material during battery or electrode manufacturing, thereby achieving uniform distribution (e.g., uniform thickness) of the electrode material and preventing leakage of the electrode material from the battery cell; and (vii) reducing or eliminating the fire hazard of wet electrodes during the welding process, where welding sparks could ignite the normally flammable electrolyte. The single-pouch battery cell approach allows all welding processes to be performed after the individual battery cells are contained within the pouch, thereby preventing welding sparks from reaching and igniting the electrolyte, thereby reducing or eliminating such a fire hazard. As used herein, the term "semi-solid" refers to a liquid that has a liquid phase and a solid phase, such as, for example, a particle suspension, a colloidal suspension, an emulsion, a gel, or a micelle. Refers to a material with mixed phases.

[0011]

[1053] As used herein, the term "single pouch battery cell" refers to a battery cell (also referred to herein as an electrochemical cell) that includes a pouch that typically houses one unit cell assembly that includes one anode, one cathode, and one separator. In some cases, as expressly stated herein, a single pouch battery cell can also include two unit cell assemblies.

[0012]

[1054] As used herein, the terms "about" and "approximately" generally include plus or minus 10% of the stated value. For example, "about 5" includes 4.5 to 5.5, "approximately 10" includes 9 to 11, and "about 100" includes 90 to 110.

[0013]

[1055] Typical battery manufacturing requires multiple, sequential, complex, and expensive processes, each of which results in yield loss, capital equipment costs, and operating costs for energy consumption and consumable materials. The battery manufacturing process first involves preparing separate anode and cathode mixtures (also called "slurries"), which are typically mixtures of an electrochemically active ion storage compound, conductive additives, and a polymer binder. This mixture is then coated onto the surface of flexible metal foils to form electrodes (anode and cathode). The formed electrodes are then compressed, typically under high pressure, to increase density and control thickness. These compressed electrode / foil composites are then cut to a size and / or shape appropriate for the particular form factor of the battery being manufactured.

[0014]

[1056] One anode, one cathode, and one separator can be stacked to form a unit cell assembly. Each unit cell assembly also typically includes conductive tabs (also called leads) that connect the electrodes to an external circuit. Multiple unit cell assemblies are then stacked or arranged to form a battery cell. The number of unit cell assemblies in a battery cell can vary depending, for example, on the desired capacity and / or thickness of the resulting battery cell. These stacked unit cell assemblies are electrically parallel, and the tabs of each unit cell assembly are typically welded together by a welding process such as resistance welding, laser welding, ultrasonic welding, seam welding, and electric beam welding, among others. A vacuum pouch sealing process can then be performed to form the battery cell. During the vacuum pouch sealing, an electrolyte is typically injected into the stacked unit cell assemblies, and the unit cell assembly and the electrolyte are sealed within the pouch.

[0015]

[1057] The sealed battery cell is then subjected to a formation process in which an initial charging operation can be performed to create a stable solid electrolyte interface (SEI) that can passivate the electrode / electrolyte interface and prevent side reactions. Cycle charging and discharging is also performed to ensure the battery's capacity meets required specifications. A degassing process is typically performed to release gases introduced during the initial charging stage, called the pre-charging process, or during the electrochemical reactions in the battery formation process. The presence of trapped gas in the electrodes generally reduces the electrode's conductivity and density, limits the amount of active electrochemical material that can be placed in the battery cell, and can lead to the formation of lithium dendrites, which degrade battery performance, such as cycle life and overall safety performance. After the trapped gas is released, a resealing process can be performed to reseal the battery cell.

[0016]

[1058] The above-described manufacturing process and the resulting batteries have several problems. The first problem is defect propagation during the manufacturing or operation of the battery. More specifically, during manufacturing, if there is a problem with one unit cell assembly, it usually leads to the failure of multiple unit cell assemblies. The entire cell, including the assembly, may become defective. Therefore, a defect in one unit cell assembly may propagate, resulting in the discarding of multiple unit cell assemblies within the same battery cell, thereby affecting manufacturing yield. Furthermore, defects may propagate from one unit cell assembly to one or more adjacent unit cell assemblies during battery operation. For example, a typical battery defect is thermal runaway, during which an increase in temperature triggers more vigorous electrochemical reactions, which in turn further increases the temperature, potentially resulting in a positive feedback loop and, potentially, cycle destruction. A thermal runaway reaction in one unit cell assembly within a battery cell is likely to trigger thermal runaway in adjacent unit cell assemblies via various heat transfer mechanisms, such as direct case-to-case contact, impingement of hot vent gases, or impingement of burning vent gases. A chain reaction may occur, destroying the pack within seconds or within hours of using each cell.

[0017]

[1059] A second problem in conventional battery manufacturing is the fire hazard posed by the large amount of electrolyte in each battery cell. In lithium-ion batteries, the electrolyte is typically hydrocarbon-based and typically flammable. The hydrocarbon-based electrolyte in lithium-ion cells means that these cells may behave differently under fire conditions than lead-acid, NiMH, or NiCd cells, which contain aqueous electrolytes. More specifically, leaks or venting in lithium-ion cells can result in the release of flammable vapors. If a cell containing an aqueous electrolyte comes into contact with fire, the water in the cell can absorb heat, reducing the overall heat released by the fire and mitigating the hazard. In contrast, if a lithium-ion cell comes into contact with fire, it can cause the release of flammable electrolyte, thereby increasing the overall heat released by the fire and exacerbating the fire hazard. The amount of electrolyte in a battery cell is roughly proportional to the amount of electrode material in the battery cell. Conventional battery cells containing multiple unit cell assemblies (i.e., multiple anode / cathode stacks) typically contain a correspondingly large amount of electrolyte. Thus, the large amount of electrolyte in each battery cell can pose an increased fire hazard.

[0018]

[1060] A third problem in conventional battery manufacturing is metal contamination that occurs during the welding process. Because welding is typically performed before sealing the entire battery cell, including the multiple electrode stacks, in a pouch, the electrodes are exposed to metal particles that fly off from the weld. If these metal particles adhere near the weld, they can cause an electrical short. Furthermore, these metal particles can disperse into the electrode material during welding, potentially causing an internal short. These contaminating metals within the cell can form metal dendrites, which can lead to short circuits. For example, copper contaminants during welding to the cathode region can electrochemically deposit on the anode side during battery cycling, potentially causing an internal short circuit because copper is unstable at most voltages for cathode materials. Copper dendrites are more robust than lithium dendrites due to their higher melting point.

[0019] Single pouch battery cells and battery modules

[1061] 1A is a schematic diagram illustrating a battery cell that may at least partially address the aforementioned problems of conventional battery manufacturing. The battery cell 100 includes an anode 110 including an anode material 111 disposed on an anode current collector 150 (also referred to herein as "ACC 150"), a cathode 120 including a cathode material 121 disposed on a cathode current collector 160 (also referred to herein as "CCC 160"), and a separator 130 disposed between the anode 110 and the cathode 120. The assembly of the anode 110, cathode 120, and separator 130 is substantially contained within a pouch 140, which isolates the battery cell 100 from one or more adjacent cells in a battery module or pack, thereby reducing defect propagation (e.g., fire hazards) by confining unintentional electrochemical reactions within an individual cell. Optionally, the ACC 150 and The CCC 160 may also be placed inside the pouch 140 prior to assembling the anode 110, cathode 120, or battery cell 100. The use of a pouch may also reduce or eliminate metal contamination of the electrodes during the welding process during construction of the battery module / pack, as the pouch 140 protects the electrodes (i.e., the anode 110 and cathode 120) from metal particles or any other material that could short the battery cell. Optionally, in some embodiments, at least one of the ACC 150 and CCC 160 may include tabs or tab connections (not shown) that act as electrical leads (or connection points) for connecting to one or more external electrical circuits.

[0020]

[1062] In some embodiments, ACC150 and CCC160 (collectively referred to herein as "current collectors") can comprise a conductive material in the form of a substrate, sheet, or foil, or any other form factor. In some embodiments, the current collector can comprise aluminum, copper, lithium, nickel, stainless steel, tantalum, titanium, tungsten, vanadium, or mixtures, combinations, or alloys thereof. In other embodiments, the current collector can also comprise a non-metallic material such as carbon, carbon nanotubes, or a metal oxide (e.g., TiN, TiB2, MoSi2, n-BaTiO3, Ti2O3, ReO3, RuO2, IrO2, etc.). In some embodiments, the current collector can comprise a conductive coating disposed on any of the aforementioned metallic and non-metallic materials. In some embodiments, the conductive coating can comprise a carbon-based material, a conductive metal, and / or a non-metallic material, such as a composite or layered material.

[0021]

[1063] In some embodiments, the current collector includes a base substrate having one or more surface coatings to improve the mechanical, thermal, chemical, or electrical properties of the current collector. In one example, the one or more coatings on the current collector can be configured to reduce corrosion and modify adhesion properties (e.g., hydrophilic or hydrophobic coatings, respectively). In another example, the one or more coatings on the current collector can include a material with high electrical conductivity to improve overall charge transport through the base substrate. In yet another example, the coating can include a material with high thermal conductivity to promote heat dissipation through the base substrate and protect the battery from overheating. In yet another example, the coating can include a heat-resistant or flame-retardant material to prevent fire hazards in the battery. In yet another example, the coating can be configured to be rough to increase surface area and / or enhance adhesion with the electrode materials (e.g., the anode material 111 and the cathode material 121). In yet another example, the coating can include a material with good adhesion or gluing properties with the electrode materials.

[0022]

[1064] In some embodiments, the current collector comprises a conductive substrate, sheet, or foil having a roughened surface to improve mechanical, electrical, and thermal contact between the electrode material and the current collector. The roughened surface of the current collector can increase the physical contact area between the electrode material and the current collector, thereby improving adhesion of the electrode material to the current collector. This increased physical contact area can also improve electrical and thermal contact (e.g., lower electrical and thermal resistance) between the current collector and the electrode material.

[0023]

[1065] In some embodiments, the current collector comprises a porous current collector, such as a wire mesh. A wire mesh (also referred to herein as a mesh) can comprise any number of filament wires that can be assembled into various configurations using a suitable process, such as a regular pattern or structure created by weaving, braiding, knitting, etc., or a more random pattern or structure created by randomly distributing the wires and connecting them by welding, adhesives, or other suitable techniques. Furthermore, the wires comprising the mesh can be any suitable material. For example, in some embodiments, the wires are metal, such as steel, aluminum, copper, titanium, or any other suitable metal. Other embodiments In the present application, the wire can be a conductive non-metallic material, such as carbon nanofiber or any other suitable material. In some embodiments, the wire can include a coating. For example, the coating can be configured to reduce corrosion and improve or reduce adhesion properties (e.g., hydrophilic or hydrophobic coatings, respectively). Examples of porous current collectors are described in U.S. Patent Publication No. US2013 / 0065122, entitled "Semi-Solid Electrode Cell Having A Porous Current Collector and Methods of Manufacture," and U.S. Patent Application No. US15 / 097838, entitled "Semi-Solid Electrodes with Porous Current Collectors and Methods of Manufacture," the disclosures of which are incorporated herein by reference in their entireties.

[0024]

[1066] In some embodiments, the current collector is deposited by deposition methods such as, but not limited to, chemical vapor deposition (CVD) (including initiated CVD, hot wire CVD, plasma enhanced CVD, and other types of CVD), physical vapor deposition, sputter deposition, magnetron sputtering, and radio frequency sputtering. The nanoparticles can be made by any of the coating or deposition techniques such as electroplating, atomic layer deposition, pulsed laser deposition, plating, electroplating, dip coating, brushing, spray coating, sol-gel processes (by dip coating, brushing or spray coating), electrostatic spray coating, 3D printing, spin coating, electrodeposition, powder coating, sintering, self-assembly and any combination of these techniques.

[0025]

[1067] In some embodiments, the properties of a current collector formed by deposition or coating can be optimized by varying the deposition parameters during deposition. Physical properties such as coating texture, coating thickness, thickness uniformity, and surface morphology, such as surface roughness, porosity, and general mechanical properties such as fracture toughness, ductility, and tensile strength, can be optimized by fine-tuning the deposition parameters. Similarly, chemical properties such as chemical and corrosion resistance, as well as specific reactivity, adhesion, and affinity to electrolytes and salts, can be optimized by varying the deposition parameters to create a functional current collector. In some embodiments, various physical and chemical properties of a current collector formed by deposition or coating can be further improved or modified after deposition by subsequent surface or temperature treatments, such as annealing or rapid thermal (flash) annealing, or electrochemical polishing, or using any combination of these techniques.

[0026]

[1068] In some embodiments, the anode current collector 150 can have a thickness in the range of about 1 μm to about 20 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 1 μm to about 18 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 1 μm to about 17 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 1 μm to about 16 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 1 μm to about 15 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 1 μm to about 14 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 1 μm to about 13 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 1 μm to about 12 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 2 μm to about 11 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 3 μm to about 10 μm. In some embodiments, ACC 150 can have a thickness ranging from about 4 μm to about 9 μm. In some embodiments, ACC 150 can have a thickness ranging from about 5 μm to about 8 μm. In some embodiments, ACC 150 can have a thickness ranging from about 6 μm to about 7 μm. In some embodiments, ACC 150 can have a thickness of less than about 1 μm, less than about 2 μm, less than about 3 μm, less than about 4 μm, including all thicknesses between the following values: It can have a thickness of less than about 5 μm, less than about 6 μm, less than about 7 μm, less than about 8 μm, less than about 9 μm, less than about 10 μm, less than about 11 μm, less than about 12 μm, less than about 13 μm, less than about 14 μm, less than about 15 μm, less than about 16 μm, less than about 17 μm, less than about 18 μm, less than about 19 μm, and less than about 20 μm.

[0027]

[1069] The anode material 111 can be selected from a variety of materials. In some embodiments, the anode material 111 includes carbon-based materials such as, but not limited to, hard carbon, carbon nanotubes, carbon nanofibers, porous carbon, and graphene. In some embodiments, the anode material 111 includes, but is not limited to, spinel Li4Ti5O 12 (LTO), titanium dioxide (TiO2, Titanium In some embodiments, the anode material 111 comprises an alloyed or dealloyed material such as, but not limited to, silicon, silicon monoxide (SiO), germanium, or tin oxide (SnO). In some embodiments, the anode material 111 comprises a transition metal compound (e.g., oxide, phosphide, sulfide, nitride, etc.). The general formula for the transition compound is M x N y where M can be selected from iron (Fe), cobalt (Co), copper (Cu), manganese (Mn), and nickel (Ni), and N can be selected from oxygen (O), phosphorus (P), sulfur (S), and nitrogen (N).

[0028]

[1070] In some embodiments, the anode material 111 is amorphous carbon, disordered carbon, graphitic carbon, or metal coated or decorated carbon, graphite, non-graphitic carbon, mesocarbon microbeads, boron carbon alloys, hard or disordered carbon, lithium titanium spinel, or a solid metal or metal alloy or metalloid or metalloid alloy that reacts with lithium to form an electron compound, such as, for example, Si, Ge, Sn, Bi, Zn, Ag, Al, any other suitable metal alloy, metalloid alloy, or combination thereof, or LiAl, LiAl, LiAl, LiZn, LiAg, Li 10 Ag3, Li5B4, Li7B6, Li 12 Si7, Li 21 Si8, Li 13 Si4, Li 21 Si5, Li5Sn2, Li 13 Sn5, Li7Sn2, Li 22The solid may comprise a solid selected from the group consisting of a lithiated metal or metal alloy, such as compounds such as Sn5, Li2Sb, Li3Sb, LiBi, or Li3Bi, or a lithiated or non-lithiated composition, an amorphous metal alloy of any other material or alloy thereof, or any other combination thereof.

[0029]

[1071] In some embodiments, the anode material 111 includes an electron compound. The electron compound can be based on the formula MM′, where M is one metal element and M′ is a different metal element. The electron compound can also include more than two metal elements. The M atom of the electron compound can be, for example, Cu, Li, and Mn, and the M′ element of the electron compound can be, for example, Sb. Exemplary electron compounds are CuSb, LiCuSb, and LiSb, among others. In one example, the electron compound of the anode material 111 can have a fully disordered structure in which the M or M′ atoms are randomly arranged. In another example, the electron compound of the anode material 111 has a partially disordered structure in which the M or M′ atoms in the crystal lattice are non-disordered.

[0030]

[1072] In some embodiments, the anode material 111 can be made porous to increase the surface area and enhance the lithium intercalation rate of the resulting electrode. In one example, the anode material 111 comprises porous MnO, which can be prepared, for example, by pyrolysis of MnCO microspheres. In another example, the anode material 111 comprises porous carbon fibers, prepared, for example, by electrospinning a mixed solution of polyacrylonitrile and poly(l-lactide), followed by carbonization. In some embodiments, the porosity of the anode material 111 can be achieved or enhanced by using a porous current collector. For example, the anode material 111 can include Cu2Sb conformally deposited on a porous foam structure to have a particular porosity.

[0031]

[1073] In some embodiments, the thickness of the anode material 111 is in the range of about 250 μm to about 2000 μm, in the range of about 300 μm to about 2000 μm, in the range of about 350 μm to about 2000 μm, in the range of about 400 μm to about 2000 μm, in the range of about 450 μm to about 2000 μm, in the range of about 500 μm to about 2000 μm, in the range of about 250 μm to about 1500 μm, in the range of about 300 μm to about 1500 μm, in the range of about 350 μm to about 1500 μm, in the range of about 400 μm to about 1500 μm, in the range of about Within the range of 450 μm to about 1500 μm, within the range of about 500 μm to about 1500 μm, within the range of about 250 μm to about 1000 μm, within the range of about 300 μm to about 1000 μm, within the range of about 350 μm to about 1000 μm, within the range of about 400 μm to about 1000 μm, within the range of about 450 μm to about 1000 μm, within the range of about 500 μm to about 1000 μm, within the range of about 250 μm to about 750 μm, within the range of about 300 μm to about 750 μm, within the range of about 350 μm to about 750 μm, within the range of about 400 μm to about 750 μm, within the range of about 450 μm to about 750 μm range, about 500 μm to about 750 μm range, about 250 μm to about 700 μm range, about 300 μm to about 700 μm range, about 350 μm to about 700 μm range, about 400 μm to about 700 μm range, about 450 μm to about 700 μm range, about 500 μm to about 700 μm range, about 250 μm to about 650 μm range, about 300 μm to about 650 μm range, about 350 μm to about 650 μm range, about 400 μm to about 650 μm range, about 450 μm to about 650 μm range, about 500 μm to about 650 μm, about 250 μm to about 600 μm, about 300 μm to about 600 μm, about 350 μm to about 600 μm, about 400 μm to about 600 μm, about 450 μm to about 600 μm, about 500 μm to about 600 μm, about 250 μm to about 550 μm, about 300 μm to about 550 μm, about 350 μm to about 550 μm, about 400 μm to about 550 μm, about 450 μm to about 550 μm, or about 500 μm to about 550 μm.

[0032]

[1074] In some embodiments, cathode 120 includes cathode current collector 160 and cathode material 121. Cathode current collector 160 of cathode 120 is substantially the same as anode current collector 150 of anode 110 described above, and therefore, the same techniques described with respect to the deposition and / or coating techniques for anode current collector 150 may also be applicable to fabricating cathode current collector 160. In some embodiments, cathode current collector 160 can have a thickness in the range of about 1 μm to about 40 μm. In some embodiments, CCC 160 can have a thickness in the range of about 2 μm to about 38 μm. In some embodiments, CCC 160 can have a thickness in the range of about 2 μm to about 36 μm. In some embodiments, CCC 160 can have a thickness in the range of about 2 μm to about 34 μm. In some embodiments, CCC 160 can have a thickness in the range of about 2 μm to about 32 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 30 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 28 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 26 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 24 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 22 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 20 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 18 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 3 μm to about 16 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 4 μm to about 14 μm. In some embodiments, the CCC 160 may have a thickness ranging from about 5 μm to about 12 μm. In some embodiments, the CCC 160 can have a thickness ranging from about 6 μm to about 10 μm. In some embodiments, the CCC 160 can have a thickness ranging from about 7 μm to about 8 μm. In some embodiments, the CCC 160 can have a thickness of less than about 1 μm, less than about 2 μm, less than about 3 μm, less than about 4 μm, less than about 5 μm, less than about 6 μm, less than about 7 μm, less than about 8 μm, less than about 9 μm, less than about 10 μm, less than about 11 μm, less than about 12 μm, less than about 13 μm, less than about 14 μm, less than about 15 μm, less than about 16 μm, less than about 17 μm, less than about 18 μm, less than about 19 μm, less than about 20 μm, including all thicknesses between the following values: The thickness may be less than about 0 μm, less than about 21 μm, less than about 22 μm, less than about 23 μm, less than about 24 μm, less than about 25 μm, less than about 26 μm, less than about 27 μm, less than about 28 μm, less than about 29 μm, less than about 30 μm, less than about 31 μm, less than about 32 μm, less than about 33 μm, less than about 34 μm, less than about 35 μm, less than about 36 μm, less than about 37 μm, less than about 38 μm, less than about 39 μm, and less than about 40 μm.

[0033]

[1075] The cathode material 121 of the cathode 120 may be, for example, nickel cobalt aluminum (NCA), core-shell gradient (CSG), lithium ion spinel (LMO), phosphorus In some embodiments, the cathode material 121 can be nickel, lithium iron oxide (LFP), lithium cobalt ion (LCO), and nickel cobalt manganese (NCM). The cathode material 121 can include solid-state compounds known to those skilled in the art, such as those used in nickel-metal hydride (NiMH) and nickel-cadmium (NiCd) batteries. In some embodiments, the cathode material 121 can include the general family of ordered rock-salt compounds LiMO, such as those having the D-NaFeO structure type (so-called "layered compounds") or orthorhombic LiMnO structure type, or derivatives thereof with different crystal symmetries, atomic orders, or partial substitutions of metal or oxygen. M includes at least one first-row transition metal, but may also include non-transition metals such as, but not limited to, Al, Ca, Mg, or Zr. Examples of such compounds are LiCoO, Mg-doped LiCoO, LiNiO, Li(Ni,Co,Al)O (referred to as "NCA"), and Li(Ni,Mn,Co)O ("NMC"). Other families of exemplary cathode materials 121 include those with spinel structure, such as LiMnO and its derivatives, so-called "layered spinel nanocomposites" whose structures include nanoscopic domains with ordered rocksalt and spinel order, olivine LiMPO (where M includes one or more of Mn, Fe, Co, or Ni) and its derivatives, partially fluorinated compounds such as LiVPOF, other "polyanionic" compounds discussed below, and VO and VO. 11 Vanadium oxide such as V x O y may include:

[0034]

[1076] In some embodiments, the cathode material 121 comprises a transition metal polyanion compound, such as those described in U.S. Patent No. 7,338,734. In some embodiments, the cathode material 121 comprises an alkali metal transition metal oxide or phosphate, such as those described in U.S. Patent No. 7,338,734. x (M' 1-a M” a ) y (XD4) z , A x (M' 1-a M” a ) y (DXD4) z or A x(M' 1-a M” a ) y (X2D7) z wherein x + y(1-a) × (one or more formal valences of M') + ya × (one or more formal valences of M") has a value equal to z × (one or more formal valences of XD4, X2D7 or DXD4 Groups), or the compound has a composition such that (A 1-a M” a ) x M' y (XD4) z , (A 1-a M” a ) x M' y (DXD4) z or (A 1-a M” a ) x M' y (X2D7) z wherein (1-a)x + (amount ax) × (one or more formal valences of M″) + y × (one or more formal valences of M′) has a value equal to z × (formal valences of Group XD4, XD7, or DXD4). In this compound, A is at least one of an alkali metal and hydrogen; M′ is a first row transition metal; X is at least one of phosphorus, sulfur, arsenic, molybdenum, and tungsten; M″ is any of Group IIA, IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB, IIIB, IVB, VB, and VIB metals; and D is at least one of oxygen, nitrogen, carbon, or a halogen. The cathode material 121 can be the olivine structure compound LiMPO4, where M is one or more of V, Cr, Mn, Fe, Co, and Ni, and the compound is optionally doped at the Li, M, or O sites. Deficiencies at the Li sites are compensated by the addition of a metal or metalloid, and deficiencies at the O sites are compensated by the addition of a halogen. In some embodiments, the cathode material 121 has the olivine structure and the chemical formula (Li 1-x Z x)It contains a thermally stable transition metal-doped lithium transition metal phosphate having MPO4. Here, M is one or more of V, Cr, Mn, Fe, Co, and Ni, Z is a non-alkali metal dopant such as one or more of Ti, Zr, Nb, Al, or Mg, and x ranges from 0.005 to 0.05.

[0035]

[1077] In other embodiments, the lithium transition metal phosphate material is Li 1-x-z M 1+z has an overall composition of PO4, where M is at least one first-row transition metal selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, and Ni, x ranges from 0 to 1, and z can be positive or negative. M contains Fe and z is between about 0.15 and 0.15. This material can exhibit a solid solution in the composition range of 0 < x < 0.15, or can exhibit a stable solid solution in the composition range of x between 0 and at least about 0.05, or can exhibit a stable solid solution in the composition range of x between 0 and at least 0.07 at room temperature (22 - 25 °C). This material may also exhibit a solid solution in a regime poor in lithium, for example, x ≥ 0.8, or x ≥ 0.9, or x ≥ 0.95.

[0036]

[1078] In some embodiments, the cathode material 121 includes a metal salt that stores alkali ions by undergoing a substitution or conversion reaction. Examples of such compounds include metal oxides such as CoO, CoO, NiO, CuO, and MnO, which undergo a substitution or conversion reaction with Li to form a mixture of LiO and a metal component in its more reduced oxide form or its metallic form, and are typically used as non-electrodes in lithium batteries. Other examples include metal fluorides such as CuF, FeF, FeF, BiF, CoF, and NiF, which undergo a substitution or conversion reaction to form LiF and a reduced metal component. Such fluorides can be used as positive electrodes in lithium batteries. In other embodiments, the cathode material 121 includes carbon monofluoride or a derivative thereof. In some embodiments, the cathode material 121 that undergoes a substitution or conversion reaction is in the form of particles having an average size of 100 nanometers or less. In some embodiments, the cathode material 121 undergoing the substitution or conversion reaction includes nanocomposites of the cathode material 121 mixed with an inert host, such as, but not limited to, carbon, or a metal, or an electrically conductive, relatively ductile compound such as a metal sulfide. FeS2 and FeF3 can also be used as inexpensive, electrically conductive cathode materials 121 in non-aqueous or aqueous lithium systems. In some embodiments, CF x The FeS electrode, FeS electrode, or MnO electrode is a positive cathode material used in conjunction with a lithium metal negative electrode to make a lithium battery. In some embodiments, such a battery is a primary battery. In some embodiments, such a battery is a storage battery.

[0037]

[1079] In some embodiments, the working ions in the cathode material 121 are Li + , Na + , H + , Mg 2+ , Al 3+ , or Ca 2+ In some embodiments, the working ion is selected from the group consisting of Li + or Na +In some embodiments, the cathode material 121 includes a solid, such as an ion storage compound. In some embodiments, the ion is a proton or a hydroxyl ion, and the cathode material 121 includes those ions used in nickel-cadmium or nickel-metal hydride batteries. In some embodiments, the ion is lithium, and the cathode material 121 is selected from the group consisting of metal fluorides, such as CuF2, FeF2, FeF3, BiF3, CoF2, and NiF2.

[0038]

[1080] In some embodiments, the ions are lithium and the cathode material 121 is selected from the group consisting of metal oxides such as CoO, Co3O4, NiO, CuO, and MnO.

[0039]

[1081] In some embodiments, the ion is lithium and the cathode material 121 has the formula (Li 1-x Z x )MPO4, where M is one or more of V, Cr, Mn, Fe, Co, and Ni, Z is a non-alkali metal dopant such as one or more of Ti, Zr, Nb, Al, or Mg, and x is in the range of 0.005 to 0.05.

[0040]

[1082] In some embodiments, the ion is lithium, and the cathode material 121 comprises an intercalation compound selected from compounds having the formula LiMPO4, where M is one or more of V, Cr, Mn, Fe, Co, and Ni, and the compound is optionally doped at the Li, M, or O site.

[0041]

[1083] In some embodiments, the ions are lithium and the cathode material 121 is A x (M' 1-a M” a ) y (XD4) z , A x(M' 1-a M” a ) y (DXD4) z , and A x (M' 1-a M” a ) y (X2D7) z wherein x + y(1-a) × (one or more formal valences of M') + ya × (one or more formal valences of M") equals z × (the formal valences of Group XD4, X2D7, or DXD4), A is at least one of an alkali metal and hydrogen, M' is a first row transition metal, X is at least one of phosphorus, sulfur, arsenic, molybdenum, and tungsten, M" is any of Group IIA, IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB, IIIB, IVB, VB, and VIB metals, and D is at least one of oxygen, nitrogen, carbon, or a halogen.

[0042]

[1084] In some embodiments, the ions are lithium and the cathode material 121 is (A 1-a M” a ) x M' y (XD4) z , (A 1-a M” a ) x M' y (DXD4) z and (A 1-a M” a ) x M' y (X2D7) zwherein (1-a)x + (amount ax) × (one or more formal valences of M″) + y × (one or more formal valences of M′) equals z × (the formal valences of Group XD4, X2D7, or DXD4), A is at least one of an alkali metal and hydrogen, M′ is a first row transition metal, X is at least one of phosphorus, sulfur, arsenic, molybdenum, and tungsten, M″ is any of Group IIA, IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB, IIIB, IVB, VB, and VIB metals, and D is at least one of oxygen, nitrogen, carbon, or a halogen.

[0043]

[1085] In some embodiments, the ion is lithium, and the cathode material 121 comprises an intercalation compound selected from the group consisting of ordered rock-salt compounds LiMO, such as those having the α-NaFeO and orthorhombic LiMnO structure types, or derivatives thereof with different crystal symmetries, atomic orders, or partial substitution of metal or oxygen, where M includes at least one first-row transition metal, but may also include non-transition metals such as, but not limited to, Al, Ca, Mg, or Zr.

[0044]

[1086] In some embodiments, the cathode material 121 comprises a solid such as amorphous carbon, disordered carbon, graphitic carbon, or metal-coated or metal-decorated carbon.

[0045]

[1087] In some embodiments, the cathode material 121 can include a solid that includes nanostructures such as, for example, nanowires, nanorods, and nanotetrapods.

[0046]

[1088] In some embodiments, the cathode material 121 comprises a solid, such as an organic redox compound.

[0047]

[1089] In some embodiments, the cathode material 121 comprises a solid selected from the group consisting of ordered rock-salt compounds LiMO, such as those having the α-NaFeO and orthorhombic LiMnO structure types, or derivatives thereof with different crystal symmetries, atomic orders, or partial substitutions of metal or oxygen, where M includes at least one first-row transition metal, but may also include non-transition metals such as, but not limited to, Al, Ca, Mg, or Zr.

[0048]

[1090] In some embodiments, the cathode material 121 is A x (M' 1-a M” a ) y (XD4) z , A x (M' 1-a M” a ) y (DXD4) z , and A x (M' 1-a M” a ) y (X2D7) z wherein x + y(1-a) × (one or more formal valences of M') + ya × (one or more formal valences of M") equals z × (the formal valences of Group XD4, X2D7, or DXD4), A is at least one of an alkali metal and hydrogen, M' is a first row transition metal, X is at least one of phosphorus, sulfur, arsenic, molybdenum, and tungsten, M" is any of Group IIA, IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB, IIIB, IVB, VB, and VIB metals, and D is at least one of oxygen, nitrogen, carbon, or a halogen.

[0049]

[1091] In some embodiments, the cathode material 121 may be LiMn2O4 and its derivatives, layered spinel nanocomposites whose structures include nanoscopic domains with ordered rocksalt and spinel ordering, including, but not limited to, LiNi 0.5 Mn1.5 So-called "high voltage spinels" with potentials above 4.3 V (vs. Li / Li+), such as O4, olivine LiMPO4 (where M includes one or more of Mn, Fe, Co, or Ni) and its derivatives, partially fluorinated compounds such as LiVPO4F, other "polyanionic" compounds, and VO and VO 11 Vanadium oxide such as V x O y The compound may include a compound selected from the group consisting of:

[0050]

[1092] In some embodiments, the thickness of the cathode material 121 is in the range of about 250 μm to about 2000 μm, in the range of about 300 μm to about 2000 μm, in the range of about 350 μm to about 2000 μm, in the range of about 400 μm to about 2000 μm, in the range of about 450 μm to about 2000 μm, or in the range of about 500 μm to about 2000 μm, inclusive of all ranges or any other distances between the following values: , in the range of about 250 μm to about 1500 μm, in the range of about 300 μm to about 1500 μm, in the range of about 350 μm to about 1500 μm, in the range of about 400 μm to about 1500 μm, in the range of about 450 μm to about 1500 μm, in the range of about 500 μm to about 1500 μm, in the range of about 250 μm to about 1000 μm, in the range of about 300 μm to about 1000 μm, in the range of about 350 μm to about 1000 μm Within the range of about 400 μm to about 1000 μm, within the range of about 450 μm to about 1000 μm, within the range of about 500 μm to about 1000 μm, within the range of about 250 μm to about 750 μm, within the range of about 300 μm to about 750 μm, within the range of about 350 μm to about 750 μm, within the range of about 400 μm to about 750 μm, within the range of about 450 μm to about 750 μm, within the range of about 500 μm to about 750 μm, Within the range of 250 μm to about 700 μm, within the range of about 300 μm to about 700 μm, within the range of about 350 μm to about 700 μm, within the range of about 400 μm to about 700 μm, within the range of about 450 μm to about 700 μm, within the range of about 500 μm to about 700 μm, within the range of about 250 μm to about 650 μm, within the range of about 300 μm to about 650 μm, within the range of about 350 μm to about 650 μm, within the range of about 400 μm to about The thickness may be within the range of 650 μm, within the range of about 450 μm to about 650 μm, within the range of about 500 μm to about 650 μm, within the range of about 250 μm to about 600 μm, within the range of about 300 μm to about 600 μm, within the range of about 350 μm to about 600 μm, within the range of about 400 μm to about 600 μm, within the range of about 450 μm to about 600 μm, within the range of about 500 μm to about 600 μm, within the range of about 250 μm to about 550 μm, within the range of about 300 μm to about 550 μm, within the range of about 350 μm to about 550 μm, within the range of about 400 μm to about 550 μm, within the range of about 450 μm to about 550 μm, or within the range of about 500 μm to about 550 μm.

[0051]

[1093] In some embodiments, at least one of the anode material or cathode material comprises a semi-solid or concentrated ion-storing liquid reactant. "Semi-solid" means that the material is a mixture of a liquid and a solid phase, such as a semi-solid particle suspension, colloidal suspension, emulsion, gel, or micelle. "Concentrated ion-storing liquid" or "concentrated liquid" means that the liquid is not simply a solvent, as in the case of a catholyte or anolyte in an aqueous flow cell, but that the liquid itself is redox-active. Such liquid forms can be diluted or mixed with another non-redox-active liquid, which is a diluent or solvent, for example, to form a lower-melting liquid phase, such as the ion-storing liquid, an emulsion, or a micelle. The cathode or anode material can be a flowable semi-solid or concentrated liquid composition. The flowable anodic semi-solid (referred to herein as "anolyte") and / or the flowable cathodic semi-solid ("catholyte") are comprised of a suspension of electrochemically active materials (anode particles and / or cathode particles) and, optionally, conductive particles. The cathode particles and conductive particles are suspended together in an electrolyte to form the catholyte semi-solid. The anode particles and conductive particles are suspended together in an electrolyte to form the anolyte semi-solid. These semi-solids can be made to flow by applied pressure, gravity, or other fields that exert a force on the semi-solid, and optionally with the aid of mechanical vibration. Examples of battery architectures utilizing semi-solid suspensions are described in International Patent Publication WO 2012 / 024499, entitled "Stationary, Fluid Redox Electrode," and International Patent Publication WO 2012 / 088442, entitled "Semi-Solid Filled Battery and Method of Manufacture," the disclosures of which are incorporated herein by reference in their entireties.

[0052]

[1094] In some embodiments, separator 130 can be a thin, microporous membrane that electrically separates cathode 120 from anode 110 but allows ions to pass through its pores between the two electrodes during discharge and charge. In some embodiments, separator 130 comprises a thermoplastic polymer, such as polyolefin, polyvinyl chloride, nylon, fluorocarbon, and polystyrene, among others. In some embodiments, separator 130 comprises a polyolefin material, including, for example, polyethylene, ultra-high molecular weight polyethylene, polypropylene, polybutene, polymethylpentene, polyisoprene, copolymers thereof, and combinations thereof. Exemplary combinations can include, but are not limited to, blends comprising two or more of polyethylene, ultra-high molecular weight polyethylene, and polypropylene, as well as blends of the above with copolymers, such as ethylene butene copolymers and ethylene hexene copolymers.

[0053]

[1095] In some embodiments, battery 100 further includes an electrolyte (not shown in FIG. 1A) substantially contained within pouch 140. The electrolyte can include a non-aqueous electrolyte, such as a lithium salt (for lithium-ion batteries) or a sodium salt (for sodium-ion batteries) in a solvent. Exemplary lithium salts can include LiPF, LiBF, and LiClO, among others. Exemplary sodium salts include NaClO, NaPF, and sodium bis(trifluoromethanesulfonimide) (Na-TFSI). Exemplary The solvents are propylene carbonate (PC), ethylene carbonate (EC), dimethyl carbonate (DMC), and dimethicone. Dimethyl ether (DME), diethyl carbonate (DEC), tetrahydrofuran (THF), and triethylene Contains ethylene glycol dimethyl ether (Triglyme).

[0054]

[1096] 1A , the pouch 140 of the battery cell 100 substantially contains the anode 110, the cathode 120, the separator 130, and the electrolyte (not shown). The pouch 140 can physically separate the battery cell 100 from adjacent cells to reduce or eliminate defect propagation and facilitate handling of the battery cell 100 during battery manufacturing. The pouch 140 can also reduce the possibility of ignition of the flammable electrolyte during welding processes that may occur in battery manufacturing, which can create sparks.

[0055]

[1097] In some embodiments, the anode 110, cathode 120, separator 130, and electrolyte (not shown) are completely sealed (e.g., by vacuum sealing) within the pouch 140. In some embodiments, the pouch 140 may be only partially sealed or not sealed at all. In some embodiments, the perimeter of the pouch 140 may be sealed to enclose the anode 110, cathode 120, separator 130, and electrolyte. In some embodiments, the seal of the pouch 140 may substantially enclose the anode 110, cathode 120, separator 130, and electrolyte. In some embodiments, the seal of pouch 140 has a sealing area that is approximately 10 μm to approximately 10 mm in width, approximately 10 μm to approximately 9 mm in width, approximately 10 μm to approximately 8 mm in width, approximately 10 μm to approximately 7 mm in width, approximately 10 μm to approximately 6 mm in width, approximately 10 μm to approximately 5 mm in width, approximately 10 μm to approximately 4 mm in width, approximately 10 μm to approximately 3 mm in width, approximately 10 μm to approximately 2 mm in width, including all widths and width ranges between the following values: The width ranges are about 10 μm to about 1 mm, about 10 μm to about 900 μm, about 10 μm to about 800 μm, about 10 μm to about 700 μm, about 10 μm to about 600 μm, about 10 μm to about 500 μm, about 10 μm to about 400 μm, about 10 μm to about 300 μm, about 10 μm to about 200 μm, about 10 μm to about 100 μm, and about 10 μm to about 50 μm.

[0056]

[1098] In some embodiments, the sealed area of ​​the pouch 140 is a particular distance from the outer edge of the pouch 140 . In some embodiments, the distance between the sealed area and the outer edge can be about 10 μm to about 20 mm, about 10 μm to about 15 mm, about 10 μm to about 10 mm, about 10 μm to about 5 mm, about 10 μm to about 4 mm, about 10 μm to about 3 mm, about 10 μm to about 2 mm, about 10 μm to about 1 mm, about 10 μm to about 900 μm, about 10 μm to about 800 μm, about 10 μm to about 700 μm, about 10 μm to about 600 μm, about 10 μm to about 500 μm, about 10 μm to about 400 μm, about 10 μm to about 300 μm, about 10 μm to about 200 μm, about 10 μm to about 100 μm, and about 10 μm to about 50 μm, including all distances and distance ranges between the following values.

[0057]

[1099] In some embodiments, the sealed area of ​​pouch 140 is a particular distance from the outermost edge of at least one of anode 110 and cathode 120. In some embodiments, the distance between the sealed area and the outermost edge of at least one of anode 110 and cathode 120 is between about 1 μm and about 10 mm, between about 1 μm and about 9 mm, between about 1 μm and about 8 mm, between about 1 μm and about 7 mm, between about 1 μm and about 6 mm, between about 1 μm and about 5 mm, between about 1 μm and about 4 mm, between about 1 μm and about 5 mm, between about 1 μm and about 6 mm, between about 1 μm and about 7 mm, between about 1 μm and about 8 mm, between about 1 μm and about 9 mm, between about 1 μm and about 9 mm, between about 1 μm and about 9 mm, between about 1 μm and about 10 ... to about 3 mm, about 1 μm to about 2 mm, about 1 μm to about 1 mm, about 1 μm to about 900 μm, about 1 μm to about 800 μm, about 1 μm to about 700 μm, about 1 μm to about 600 μm, about 1 μm to about 500 μm, about 1 μm to about 400 μm, about 1 μm to about 300 μm, about 1 μm to about 200 μm, about 1 μm to about 100 μm, and about 1 μm to about 50 μm.

[0058]

[1100] In some embodiments, separator 130 is larger than at least one of anode 110 and cathode 120. In some embodiments, separator 130 is larger than at least one of anode current collector 150 and cathode current collector 160. In some embodiments, separator 130 is larger than at least one of anode material 111 and cathode material 121. In some embodiments, separator 130 extends beyond at least one of anode 110, cathode 120, anode material 111, cathode material 121, ACC 150, and CCC 160, and thus can be sealed inside the sealed area of ​​pouch 140. In other words, separator 130 extends into the sealed area of ​​pouch 140, effectively separating anode 110 and cathode 120. In some embodiments, separator 130 extends into the sealed area of ​​pouch 140, completely separating anode 110 and cathode 120. In some embodiments, separator 130 extends partially into the sealed area of ​​pouch 140, partially separating anode 110 and cathode 120. In some embodiments, separator 130 extends into multiple locations within the sealed region of pouch 140, effectively separating anode 110 and cathode 120 at those locations. For example, if at least one of anode 110 and cathode 120 has a tab connection for making an external electrical connection, separator 130 may not extend into locations and areas around the tab connection of pouch 140. In some embodiments, one or more of the locations and areas reached by separator 130 extending into the sealed region of pouch 140 can be used to form one or more structures for functional purposes in single-pouch battery cell 100. For example, the functional purpose may be in the form of pressure relief or pressure relief in the event of pressure buildup due to overcharging, gas generation, or some form of electrochemical malfunction. Similarly, in some embodiments, one or more of the locations or areas within the sealed area of ​​pouch 140 that are not reached by separator 130 may be used to form one or more structures for functional purposes within single-pouch battery cell 100.

[0059]

[1101] In these embodiments, pouch 140 can still reduce or eliminate exposure to sparks (e.g., from the welding process) that could ignite the electrolyte. After the welding process, a final sealing step can be performed to seal one or more single-pouch battery cells within an outer pouch or package, which can then serve the function of moisture control. In some embodiments, pouch 140 is mechanically attached to cathode 120 and / or anode 110. In some embodiments, pouch 140 is attached to the current collector of cathode 120 and / or anode 110, for example, by heat sealing, gluing, or any other method known to those skilled in the art.

[0060]

[1102] In some embodiments, the pouch 140 includes a three-layer structure, i.e., a middle layer sandwiched between an outer layer and an inner layer, with the inner layer in contact with the electrodes and electrolyte. For example, the outer layer can include a nylon-based polymer film. The inner layer can include a polypropylene (PP) polymer film, which can be made corrosion-resistant to acids or other electrolytes and insoluble in electrolyte solvents. The middle layer can include aluminum (Al) foil. This structure allows the pouch to have both high mechanical flexibility and strength.

[0061]

[1103] In some embodiments, the outer layer of the pouch 140 is made of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), nylon, high density polyethylene (HDP E), oriented polypropylene (o-PP), polyvinyl chloride (PVC), polyimide (PI), poly Polymeric materials such as sulfones (PSU) and any combination thereof.

[0062]

[1104] In some embodiments, the middle layer of the pouch 140 is made of aluminum (Al), copper (Cu), stainless steel (SUS), and alloys thereof, or any combination thereof. This includes metal layers (foils, substrates, films, etc.) on which the metal is formed.

[0063]

[1105] In some embodiments, the inner layer of the pouch 140 comprises a material such as cast polypropylene (c-PP), polyethylene (PE), ethylene vinyl acetate (EVA), PET, polyvinyl acetate (PVA), polyamide (PA), acrylic adhesive, ultraviolet (UV) / electron beam (EB) / infrared (IR) curable resin, and any combination thereof.

[0064]

[1106] In some embodiments, pouch 140 can include a non-flammable material such as, for example, polyetheretherketone (PEEK), polyethylene naphthalate (PEN), polyethersulfone (PES), PI, polyphenylene sulfide (PPS), polyphenylene oxide (PPO), and any combination thereof. In some embodiments, pouch 140 can include a coating or film of a flame-retardant additive material, such as flame-retardant PET.

[0065]

[1107] In some embodiments, pouch 140 comprises a two-layer structure, i.e., an outer layer and an inner layer. In some embodiments, the outer layer can comprise PET, PBT, or other materials as described above. In some embodiments, the inner layer can comprise PP, PE, or other materials as described above.

[0066]

[1108] In some embodiments, pouch 140 can include a water barrier layer and / or a gas barrier layer. In some embodiments, the barrier layer can include a metal layer and / or an oxide layer. In some embodiments, including an oxide layer can be advantageous because oxide layers tend to be insulating and can prevent short circuits within the battery.

[0067]

[1109] In some embodiments, there may be only one (or two) unit cell assemblies within pouch 140, and pouch 140 may be substantially thinner than pouches typically used in multi-stack battery cells. For example, pouch 140 may have a thickness of less than 200 μm, less than 150 μm, less than 100 μm, less than 50 μm, less than 45 μm, less than 40 μm, less than 35 μm, less than 30 μm, less than 25 μm, less than 20 μm, less than 18 μm, less than 16 μm, less than 14 μm, less than 12 μm, less than 10 μm, less than 9 μm, less than 8 μm, less than 7 μm, less than 6 μm, less than 5 μm, less than 4 μm, less than 3 μm, less than 2 μm, or less than 1 μm. In some embodiments, the thickness of pouch 140 may be determined by at least two aspects. In one aspect, it may be desirable to achieve a high energy density in the resulting cell, in which case a thinner pouch may be useful because it may reserve a larger portion of the space within the battery cell for the electrode material. In another aspect, it may be desirable to maintain or enhance the safety benefits of pouch 140, in which case a thicker pouch and / or a non-flammable pouch may be useful, for example, to reduce fire hazards. In some embodiments, pouch thickness may be quantified as the ratio of the volume occupied by the pouch material to the total volume of the battery cell.

[0068]

[1110] In some embodiments, the ratio of electrode material (e.g., anode material 111 and / or cathode material 121) to non-electrode material, such as current collector and / or pouch 140, can be defined by their thickness ratio. In some embodiments, the ratio of electrode material to current collector is about 12:1, about 14:1, about 16:1, about 18:1, about 20:1, about 22:1, about 24:1, about 26:1, about 28:1, about 30:1, about 32:1, about 34:1, about 36:1, about 38:1, about 40:1, about 42:1, about 44:1, about 46:1, about 48:1, about 50:1, about 52:1, including all thickness ratios between the following values: , about 54:1, about 56:1, about 58:1, about 60:1, about 62:1, about 64:1, about 66:1, about 68:1, about 70:1, about 72:1, about 74:1, about 76:1, about 78:1, about 80:1, about 82:1, about 84:1, about 86:1, about 88:1, about 90:1, about 92:1, about 94:1, about 96:1, about 98:1, about 100:1, about 110:1, about 112:1, about 114:1, about 116 :1, about 118:1, about 120:1, about 122:1, about 124:1, about 126:1, about 128:1, about 130:1, about 132:1, about 134:1, about 136:1, about 138:1, about 140:1, about 142:1, about 144:1, about 146:1, about 148:1, about 150:1, about 152:1, about 154:1, about 156:1, about 158:1, about 160:1, about 162:1, about 164:1, about 166:1, about 168:1, about 17 It can be greater than 0:1, about 172:1, about 174:1, about 176:1, about 178:1, about 180:1, about 182:1, about 184:1, about 186:1, about 188:1, about 190:1, about 192:1, about 194:1, about 196:1, about 198:1, about 200:1, about 300:1, about 400:1, about 500:1, about 600:1, about 700:1, about 800:1, about 900:1, about 1000:1, and about 2000:1.

[0069]

[1111] In some embodiments, the current collector can be coated onto the pouch 140 to form a combined thickness. In these embodiments, the ratio between the electrode material and the combined thickness of the current collector and pouch 140 can be about 12:1, about 14:1, about 16:1, about 18:1, about 20:1, about 22:1, about 24:1, about 26:1, about 28:1, about 30:1, about 32:1, about 34:1, about 36:1, about 38:1, about 40:1, about 42:1, about 44:1, about 46:1, about 48:1, about 50:1, about 52:1, about 56:1, about 58:1, about 59:1, about 60:1, about 61:1, about 62:1, about 63:1, about 64:1, about 65:1, about 66:1, about 67:1, about 68:1, about 69:1, about 70:1, about 72:1, about 73:1, about 74:1, about 75:1, about 76:1, about 77:1, about 78:1, about 79:1, about 80:1, about 81:1, about 82:1, about 83:1, about 84:1, about 85:1, about 86:1, about 87:1, about 88:1, about 89:1, about 90:1, about 91:1, about 92:1, about 93:1, about 94:1, about 95:1, about 96:1, about 97:1, about 98:1, about 99:1, about 100:1, about 101:1, about 102 :1, about 54:1, about 56:1, about 58:1, about 60:1, about 62:1, about 64:1, about 66:1, about 68:1, about 70:1, about 72:1, about 74:1, about 76:1, about 78:1, about 80:1, about 82:1, about 84:1, about 86:1, about 88:1, about 90:1, about 92:1, about 94:1, about 96:1, about 98:1, about 100:1, about 110:1, about 112:1, about 114:1, about 116:1, about 118:1 , about 120:1, about 122:1, about 124:1, about 126:1, about 128:1, about 130:1, about 132:1, about 134:1, about 136:1, about 138:1, about 140:1, about 142:1, about 144:1, about 146:1, about 148:1, about 150:1, about 152:1, about 154:1, about 156:1, about 158:1, about 160:1, about 162:1, about 164:1, about 166:1, about 168:1, about 170:1 , about 172:1, about 174:1, about 176:1, about 178:1, about 180:1, about 182:1, about 184:1, about 186:1, about 188:1, about 190:1, about 192:1, about 194:1, about 196:1, about 198:1, about 200:1, about 300:1, about 400:1, about 500:1, about 600:1, about 700:1, about 800:1, about 900:1, about 1000:1, and about 2000:1.

[0070]

[1112] In some embodiments, pouch 140 includes a layer of thinner, lower cost material, such as polypropylene or a combination of polyolefins that can be sealed together using heat or pressure (e.g., hot fusion or vacuum sealing).

[0071]

[1113] In some embodiments, pouch 140 includes a layer of flame-retardant material to prevent the propagation of fire hazards from one single pouch battery cell to another. In some embodiments, pouch 140 includes an airtight material that prevents the propagation of gas released from one single pouch battery cell to another single pouch battery cell, thereby reducing defect propagation.

[0072]

[1114] In practice, battery 100 can have several advantages. For example, this single-pouch battery cell approach (also referred to as the individually packaged cell approach) can be advantageously integrated into the manufacture of batteries that include semi-solid electrodes. The use of individually packaged cells facilitates handling and processing of the individual stacks. It also provides a way to protect the individual stacks from deformation that can occur when packaging the electrode stacks.

[0073]

[1115] Another advantage of using one pouch per stack is that it avoids metallic contamination of the electrode materials or electrolyte. The pouch in each single-pouch battery cell can prevent metallic contaminants (or other types of contaminants) from getting into the electrode materials and electrolyte.

[0074]

[1116] In some embodiments, a single pouch can have an energy capacity, also referred to herein as a "package size." In some embodiments, the package size comprises an energy capacity of about 0.1 Ah to about 40 Ah. In some embodiments, the package size comprises an energy capacity of about 0.5 Ah to about 35 Ah. In some embodiments, the package size comprises an energy capacity of about 1 Ah to about 30 Ah. In some embodiments, the package size comprises an energy capacity of about 1.5 Ah to about 25 Ah. In some embodiments, the package size comprises an energy capacity of about 2 Ah to about 20 Ah. In some embodiments, the package size comprises an energy capacity of about 2.5 Ah to about 15 Ah. In some embodiments, the package size comprises an energy capacity of about 3 Ah to about 10 Ah. In some embodiments, the package size comprises an energy capacity of about 3 Ah to about 8 Ah. In some embodiments, the package size comprises an energy capacity of about 3 Ah to about 6 Ah. In some embodiments, the package size comprises an energy capacity of about 3 Ah to about 5 Ah. In some embodiments, the package size comprises an energy capacity of about 0.1 Ah to about 5 Ah. In some embodiments, the package size comprises an energy capacity of about 0.1 Ah to about 4 Ah. In some embodiments, the package size comprises an energy capacity of about 0.1 Ah to about 3 Ah. In some embodiments, the package size comprises an energy capacity of about 0.1 Ah to about 2 Ah. In some embodiments, the package size comprises an energy capacity of about 0.1 Ah to about 1 Ah.In some embodiments, the package sizes are about 0.1 Ah, about 0.2 Ah, about 0.3 Ah, about 0.4 Ah, about 0.5 Ah, about 0.6 Ah, about 0.7 Ah, about 0.8 Ah, about 0.9 Ah, about 1 Ah, about 1.2 Ah, about 1.4 Ah, about 1.6 Ah, about 1.8 Ah, about 2 Ah, about 2.2 Ah, about 2.4 Ah, about 2.6 Ah, about 2.8 Ah, about 3 Ah, about 3.2 Ah, about 3.4 Ah, about 3.6 Ah, about 3.8 Ah, about 4 Ah, about 4.2 Ah, inclusive of all energy capacities and capacity ranges between the following values: h, about 4.4 Ah, about 4.6 Ah, about 4.8 Ah, about 5 Ah, about 5.5 Ah, about 6 Ah, about 6.5 Ah, about 7 Ah, about 7.5 Ah, about 8 Ah, about 8.5 Ah, about 9 Ah, about 9.5 Ah, about 10 Ah, about 11 Ah, about 12 Ah, about 13 Ah, about 14 Ah, about 15 Ah, about 16 Ah, about 17 Ah, about 18 Ah, about 19 Ah, about 20 Ah, about 22 Ah, about 24 Ah, about 26 Ah, about 28 Ah, about 30 Ah, about 32 Ah, about 34 Ah, about 36 Ah, about 38 Ah, and about 40 Ah.

[0075]

[1117] Furthermore, the use of a simple single pouch material to seal a stack can also relax the stringent requirements for pouch materials and sealing methods in traditional battery manufacturing. Because each pouch typically contains only one or two unit cell assemblies and therefore fewer electrode materials and electrolytes than traditional multi-stack battery cells, pouch materials can have more options, such as a single polymer layer rather than a multi-layer structure. Pouch thickness can also be made smaller (e.g., <100 μm), and sealing methods can be more flexible (e.g., pressure sealing, heat sealing, and / or UV sealing).

[0076]

[1118] In some embodiments, separator 130 can be sized so that it can be placed and sealed with pouch 140. In some embodiments, pouch 140 can include a laminate sheet that includes a perimeter that extends beyond the perimeter of separator 130 so that the pouch can be joined to form a seal. In some embodiments, the inner layers of the pouch are each formed of a material that can be heat-sealed to itself. This allows the two inner layers to be bonded around their peripheries and heat-sealed together to form an airtight seal when the two laminated sheets are joined. Further examples are found in "Electrochemical This is described in International Patent Publication WO2013 / 173689 entitled "Cells and Methods of Manufacturing the Same."

[0077]

[1119] In some embodiments, the tabs (electrical leads) can be long enough that when the pouch is sealed, the tabs are exposed outside the pouch and can be used to electrically connect the battery cells. For example, a first tab on ACC 150 and a second tab on CCC 160 can be used to connect to at least one of the negative and positive terminals of an external circuit. In some embodiments, the tabs can be sealed within the pouch, in which case the pouch can be pierced to allow electrical connection between at least one of ACC 150 and CCC 160 and an external contact or electrical circuit. The hole or holes can be located anywhere in the pouch, but are preferably located adjacent to ACC 150 and CCC 160, respectively.

[0078]

[1120] 1B is a schematic diagram illustrating a battery cell 101 according to various other embodiments of the present invention, sometimes referred to as a "bi-cell." In the battery cell 101, the anode current collector 151 is made up of two anode materials 111a and 111b (collectively referred to as "anode materials 111"). Separators 131a and 131b (collectively referred to as "separators 131") are disposed on each of the anode materials 111a and 111b, respectively. Cathode materials 121a and 121b (collectively referred to as "cathode materials 121") are On each of the cathode materials 121a and 121b, a corresponding cathode current collector 161a and 161b (collectively referred to as "cathode current collector 161a" and "cathode current collector 161b") is disposed. 1A ) are disposed. The anode material 111, anode current collector 151, cathode material 121, cathode current collector 161, and separator 131 can be substantially the same as those described above in connection with FIG. 1A . In one example, the anode current collector 151 and the cathode current collector 161 comprise substantially the same material. In another example, the anode current collector 151 comprises a first metallic material (e.g., copper) and the cathode current collector 161 comprises a second metallic material (e.g., aluminum). The battery cell 101 is substantially sealed in a pouch (not shown) to form a single-pouch battery cell.

[0079]

[1121] 1B is a cross-sectional view of an exemplary embodiment of a bi-cell including a double-sided anode (including anode current collector 151 and a pair of anode materials 111a and 111b) and two single-sided cathodes (including a first cathode material 121a disposed on first cathode current collector 161a and a second cathode material 121b disposed on second cathode current collector 161b) disposed on either side of the double-sided anode. In some other embodiments, battery 101 can also include a double-sided cathode and two single-sided anodes disposed on either side of the cathode. As described herein, battery cell 101 can be packaged alone in a pouch or with multiple "bi-cells" in a pouch.

[0080]

[1122] 1C is a top view of the battery cell 101 shown in FIG. 1B. From this top view, it can be seen that the cathode current collectors 161a and 161b are offset or staggered within the bi-cell. In some embodiments, the anode current collector 151 and the cathode current collector 161 are located on different sides of the battery cell 101. In some embodiments, the anode current collector 151 and the cathode current collector 161 are located on opposite sides of the battery cell 101. In some embodiments, the anode current collector 151 and the cathode current collector 161 are located on the same side of the battery cell 101.

[0081]

[1123] FIG. 1D illustrates another embodiment of a battery cell 102. In this embodiment, the battery cell 102 includes two bi-cells each including two double-sided anodes. In some embodiments, the battery cell 102 can also include two bi-cells each including two double-sided cathodes. As shown in this figure, cathode current collectors 161c, 161d, 161e, and 161f (collectively referred to herein as “cathode current collectors 161x”) are seen to be offset or staggered within the battery cell 102. Similarly, anode current collectors 151a and 151b (collectively referred to herein as “anode current collectors 151x”) are seen to be offset or staggered within the battery cell 102. In some embodiments, anode current collector 151x and cathode current collector 161x are located on different sides of the battery cell 102. In some embodiments, the anode current collector 151x and the cathode current collector 161x are located on opposite sides of the battery cell 102. In some embodiments, the anode current collector 151x and the cathode current collector 161x are located on the same side of the battery cell 102.

[0082]

[1124] In some embodiments, offset or staggered current collectors allow for various interconnections of the current collectors within the single pouch cell. In some embodiments, a single extension tab can be used to extend into the sealed area of ​​the single pouch cell for external electrical connection, for example, by connecting desired current collectors together using the extension tab. This prevents contamination of the electrodes or battery by welding electrical contacts outside the single pouch cell.

[0083]

[1125] FIG. 1E is a schematic diagram showing a single-pouch battery cell using the self-welding concept. Only one electrode (anode or cathode) is shown in FIG. 1E; separators and other electrodes within the battery cell can be added according to any of the embodiments shown in FIG. 1A, FIG. 1B, FIG. 1C, or FIG. 1D. Battery cell 103 includes tab 112 for coupling battery cell 103 to other battery cells or external electrical contacts, foil 122 containing multiple slurry pockets 142 for containing electrode material, multiple foil bridges 152 electrically coupling multiple slurry pockets 142 to each other, and epoxy portion 132 filling the portions of the foil not covered by the slurry pockets 142 and foil bridges 152. FIG. 1F is a photograph of a portion of battery cell 103.

[0084]

[1126] 2 illustrates a battery module 200 including multiple single-pouch battery cells, according to some embodiments. As shown, the battery module 200 includes multiple single-pouch battery cells 201, 202, and 203 enclosed in a module case 260. The battery module also includes tab connections 250 that couple the tabs of each single-pouch battery cell 201-203 to external tabs 252, which then electrically connect the battery module 200 to an external circuit.

[0085]

[1127] In some embodiments, the tabs of each single-pouch battery module 201-203 can be part of the respective current collector. For example, each current collector of the single-pouch battery cells 201-203 can have a lead portion that extends outside the electrode portion (i.e., the portion disposed with the electrode material) as a tab. In some embodiments, the tabs of each single-pouch battery cell 201-203 can be an additional, separate component electrically coupled to the respective current collector or electrode material. For example, each tab can be a metal strip attached to the current collector by soldering, welding, glue, or other means known in the art.

[0086]

[1128] In some embodiments, the bond between the tab connection 250 and the outer tab 252 can be achieved by, for example, a weld, a rivet, a screw, or other means known in the art. In some cases, welding can be performed after sealing each single-pouch battery cell 201-203 within a respective pouch that can prevent metal particles from reaching the electrode material, so that metal contamination of the electrode material can still be substantially avoided.

[0087]

[1129] In some embodiments, the module case 260 can apply force to the stack of single-pouch battery cells 201-203 to apply stacking pressure to the battery module 200. In some embodiments, the module case 260 comprises a metal material, such as stainless steel. In some embodiments, the module case 260 comprises a plastic or polymer material. In some embodiments, the module case 260 comprises substantially the same material as that comprising the pouches within each of the single-pouch battery cells 201-203. In these embodiments, the module case 260 can be considered an additional pouch that can further mitigate defect propagation, fire hazards, and metal contamination.

[0088]

[1130] In some embodiments, the single pouch battery cells 201-203 can be stacked and bonded by gluing, applying an adhesive, or heat staking. For example, the application of heat or adhesive can be performed by sequentially applying glue to each cell or by simultaneously applying glue to all of the single pouch battery cells. In some embodiments, the stacking process can include non-contact heating techniques. For example, each single pouch battery cell can be coated with a layer or portion of material that, when activated, can act as an adhesive when subjected to heat, light such as UV or IR, or mechanical or electrical agitation such as ultrasound or sound waves, radio frequency or microwaves, or any combination thereof.

[0089]

[1131] 2 includes three single-pouch battery cells 201-203. However, in practice, the number of single-pouch battery cells in the module may be more or less than three depending on the desired output capacity, thickness requirements, or other specifications.

[0090]

[1132] 3 is a schematic diagram illustrating a battery pack including multiple battery modules, according to some embodiments. Battery pack 300 includes a first battery module 310, a second battery module 320, and a third battery module 330. Each battery module of the multiple battery modules 310-330 can be substantially similar to battery module 200 shown in FIG. 2. Each battery module of the multiple battery modules 310-330 includes an external tab 312, 322, and 332, respectively, which is coupled to an external bus bar 352. The coupling between the external tabs 312-332 and the external bus bar 352 can be achieved by, for example, welding, soldering, riveting, screwing, or other means known in the art.

[0091]

[1133] The modular design of each battery module in the plurality of battery modules 310-330 allows for convenient construction of a battery that can meet the actual demands of the application. In some embodiments, the plurality of battery modules 310-330 can be connected in series, as shown in FIG. 3, to achieve a higher output voltage. In some embodiments, the plurality of battery modules 310-330 can be connected in parallel to achieve a higher output current. In some embodiments, the plurality of battery modules 310-330 can be stacked vertically, as shown in FIG. 3, to meet specific thickness or shape requirements. In some embodiments, the plurality of battery modules 310-330 can be distributed horizontally to achieve a specific form factor (e.g., when a battery pack sheet having a custom thickness is desired).

[0092]

[1134] The battery pack 300 shown in FIG. 3 includes three battery modules 310 to 330. However, in practice, the number of battery modules in a battery pack may be more or less than three depending on the desired output capacity, thickness requirements, or other specifications.

[0093] Tab connections for single pouch battery cells and modules

[1135] 4A-4B are perspective views illustrating a single-pouch battery including conductive tabs for coupling the battery cell to an external circuit, adjacent battery cells, or other electrical components in an application. The single-pouch battery cell 400 shown in FIG. 4A includes an anode 410, a separator 430, and a cathode 420 (shown in FIG. 4B behind the separator 430), which are stacked together as described above. A pouch 440 substantially houses the stack of the anode 410, the cathode 420, and the separator 430. The anode 410 has an anode lead portion 412 that extends as a tab outside the electrode portion (i.e., the portion covered with the anode material) of the current collector (not shown). Similarly, the cathode has a cathode lead portion 422 that extends as a tab outside the electrode portion (i.e., the portion covered with the cathode material) of the current collector. In some embodiments, the lead portions 412 and 422 shown in FIG. 4A are metal strips. In some embodiments, the current collectors used in the anode 410 and cathode 420 can be mesh current collectors, and the corresponding lead portions 412 and 422 can be, for example, a metal wire, a bundle of metal wires, a braid of metal wires, or an array of metal wires. In some embodiments, the metal wire can be substantially the same as the wires that make up the mesh current collector. In some embodiments, the metal wire can comprise a different conductive material than the metallic material used in the mesh current collector.

[0094]

[1136] 4A also shows an example of the relative dimensions of each component of a single-pouch battery cell. As shown in FIG. 4A, both the anode 410 and the cathode 420 are smaller than the separator 430, preventing electrical contact between the anode 410 and the cathode 420. The pouch 440 is larger than the electrode portions of the anode 410 and the cathode 420 and the separator 430, sealing the battery cell and / or preventing leakage of the electrode material and electrolyte. Two tabs 412 and 422 extend outside the pouch 440 and are adapted to electrically couple the battery cell 400 to an external element, such as another battery cell.

[0095]

[1137] 4B is a close-up view of a corner of single-pouch battery cell 400, more clearly showing the relative dimensions of each of the elements described above. In FIG. 4B, cathode 420 is slightly smaller than anode 410, and thus cathode 420 is "hidden" in this view by anode 410. In some embodiments, at least a portion of separator 430 is heat-sealed within pouch 440 to prevent any contact between anode 410 and cathode 420. In some embodiments, cathode 420 can be substantially the same size as anode 410.

[0096]

[1138] The relatively large size of pouch 440 provides a means for supporting electrode materials, particularly semi-solid electrode materials, during battery fabrication. That is, pouch 440 can hold anode and cathode materials. Pouch 440 can also prevent the electrodes from deforming, particularly at the edges of the electrodes, which can occur when packaging an electrode stack.

[0097]

[1139] Exemplary dimensions for each element of single pouch battery cell 400 may be as follows: anode 410 and cathode 420 may have dimensions of 202 mm x 150 mm, separator 430 may be 3 mm larger in each direction, or 205 mm x 153 mm, and pouch 440 may be 3 mm larger in each direction than the anode 410 and cathode 420, or 205 mm x 153 mm. The single-pouch battery may have dimensions of 214 mm by 162 mm, which is 12 mm larger than the anode 410 and cathode 420. The thickness of each electrode (anode 410 and cathode 420) may be, for example, greater than 150 μm, greater than 200 μm, or greater than 300 μm. The overall thickness of the single-pouch battery may be, for example, greater than 600 μm, greater than 800 μm, or greater than 1 mm.

[0098]

[1140] FIG. 5 is a top view illustrating a battery module including multiple single-pouch battery cells enclosed in a metal case. The battery module 500 includes a metal case 560 that substantially encloses multiple single-pouch battery cells (only one single-pouch battery cell is shown in FIG. 5). Each single-pouch battery cell includes an anode 510, a separator 530, and a cathode (located behind the separator 530 and not shown in FIG. 5), all of which are housed and sealed within a pouch 540. The anode 510 has a current collector with a lead portion 512 that extends outside the electrode portion as an anode tab. Similarly, the cathode has a current collector with a lead portion 522 that extends outside the electrode portion as a cathode tab. The multiple anode tabs 512 and cathode tabs 522 are bonded to each other, and the bonded tabs 521 and 522 are further bonded to external electrical connectors 514 and 524. More specifically, the anode tab 512 is coupled to an anode connector 514 of the battery module 500 , and the cathode tab 522 is coupled to a cathode connector 524 of the battery module 500 .

[0099]

[1141] The anode connector 514 includes a conductive element 515 coupled at one end to the anode tab 512 and at the other end to an external element, such as another battery or utility. The conductive element 515 is disposed through the wall of the metal case 560 and electrically isolated from the wall of the metal case 560 by an anode connector coupler 516, which also substantially holds the conductive element 515 and prevents it from sliding. Similarly, the cathode connector 524 includes a conductive element 525 coupled at one end to the cathode tab 522 and at the other end to an external element. The cathode connector coupler 526 is configured to electrically insulate the conductive element 525 from the wall of the metal case 560 and substantially hold the conductive element 525. In some embodiments, one of the conductive elements 515 or 525 can be directly connected to the metal case 560 without insulation. In these embodiments, the metal case 560 can have the same polarity as the polarity of the conductive element (ie, 515 or 525) directly connected to the metal case 560.

[0100]

[1142] In some embodiments, the anode connector coupler 516 and / or the cathode connector coupler 526 can be a pair of fasteners (e.g., screws or bolts) and nuts that are constructed of or coated with a non-conductive material and are mechanically coupled to each other and to the wall of the metal casing 560. In some embodiments, the anode connector coupler 516 and / or the cathode connector coupler 526 can be a pair of magnetic couplers that are coupled to each other by magnetic forces. In some embodiments, the anode connector coupler 516 and / or the cathode connector coupler 526 can be glued together to and positioned through the wall of the metal casing 560.

[0101]

[1143] In some embodiments, metal case 560 is substantially rigid to protect the battery cells within metal case 560. In some embodiments, metal case 560 has a certain mechanical flexibility to provide higher impact resistance. In some embodiments, metal case 560 comprises a material such as stainless steel, copper, aluminum, or a combination or alloy thereof. In some embodiments, metal case 560 has a thickness of approximately 0.2 mm to 2 mm, or 0.5 mm to 1.5 mm, or 0.8 mm to 1 mm. In some embodiments, metal case 560 can be slightly larger than pouch 540. In one example, pouch 540 has dimensions of 214 mm by 162 mm, and metal case 560 is approximately 0.2 mm to 2 mm thick. The case 560 has dimensions of 232 mm x 165 mm, so the single pouch battery cell is expected to be substantially fixed within the metal case without being free to move.

[0102]

[1144] In some embodiments, battery module 500 functions as an independent battery providing power via anode connector 514 and cathode connector 524. In some embodiments, battery module 500 can be coupled to other battery modules of the same or different type to form a battery pack having particular specifications (e.g., capacity, voltage, current, size, shape, etc.).

[0103]

[1145] 6A-6B are side views illustrating a battery module including a single-pouch battery cell enclosed within a metal case. FIG. 6 illustrates a battery module 600 including a metal can 660 and a lid 662 that cooperate to form a metal case and house a plurality of single-pouch battery cells 601. The battery module also includes an electrode connector 614, which can be either an anode or cathode connector. While only one electrode connector is shown in FIG. 6A, other electrode connectors may be behind the illustrated connector and therefore not visible.

[0104]

[1146] In practice, multiple single-pouch battery cells can be placed within a metal can 660, after which a lid 662 can be placed on top of the metal can 660 and sealed to form the battery module 600. The completed battery module 600 is shown in Figure 6B.

[0105]

[1147] In some embodiments, the lid 662 and the metal can 660 can comprise substantially the same material, such as stainless steel, copper, and aluminum, among others. In some embodiments, the lid 662 comprises a material that is different from the material of the metal can 660. For example, the metal can 660 is constructed of stainless steel, and the lid 662 comprises aluminum foil or tin foil that can be more easily welded to the metal can 660. In some embodiments, the lid 662 can be attached to the metal can 660 by mechanical methods such as laser welding, seam welding, crimping, or any other method known in the art.

[0106]

[1148] FIG. 7A is a top view illustrating a battery module including multiple single-pouch battery cells enclosed in a plastic frame. The battery module 700 includes a plastic frame 760 that substantially encases the periphery (sides) of multiple single-pouch battery cells (only one single-pouch battery cell is shown in FIG. 7A). Each single-pouch battery cell includes an anode 710, a separator 730, and a cathode (located behind the separator 730 and not shown in FIG. 7), all of which are housed and sealed within a pouch 740. The anode 710 has a current collector including a lead portion 712 that extends outside the electrode portion as an anode tab. Similarly, the cathode has a current collector including a lead portion 722 that extends outside the electrode portion as a cathode tab. The multiple anode tabs 712 and cathode tabs 722 are bonded to one another, and these bonded tabs are further bonded to an external electrical connector. More specifically, the anode tab 712 is coupled to an anode connector 714 of the battery module 700 , and the cathode tab 722 is coupled to a cathode connector 724 of the battery module 700 .

[0107]

[1149] In some embodiments, the anode connector 714 and the cathode connector 724 are in direct contact with the walls of the plastic frame 760 because the plastic frame 760 is insulating. In some embodiments, additional couplers, such as couplers 516 and 526 shown in FIG. 5, may be utilized to mechanically hold the anode connector 714 and the cathode connector 724 together.

[0108]

[1150] In some embodiments, the plastic frame 760 can have a thickness of about 2 mm to about 10 mm to provide sufficient rigidity and protection for the single pouch battery within the plastic frame 760. In some embodiments, the thickness of the plastic frame 760 can be about 3 mm to about 7 mm, or about 4 mm to about 6 mm. In some embodiments, the plastic frame 760 can be made of nylon, acrylic, polyvinyl chloride (PVC), uPVC, polythene, polypropylene, polycarbonate, among others. Materials suitable for use in the plastic frame 760 include materials such as PET, Bakelite, epoxy resin, and melamine. In some embodiments, the plastic frame 760 can include a thin metal plate or foil on the outer surface, on the inner top surface, or within the plastic frame 760 to prevent gas or water penetration. In some embodiments, the plastic frame 760 can include a surface coating. In some embodiments, the surface coating can reduce water and gas penetration.

[0109]

[1151] FIG. 7B is a side view of the battery module 700 shown in FIG. 7A. As can be seen in FIG. 7B, the battery module 700 also includes a pair of lids 762a and 762b disposed on each side (top and bottom) of the plastic frame 760, forming an overall container that substantially houses the single-pouch battery cell. In some embodiments, the lids 762a and 762b include a polymer foil that can be heat-sealed to the plastic frame 760. In some embodiments, the lids 762a and 762b include a polymer or other plastic foil that can be vacuum-sealed to the plastic frame 760. In some embodiments, the lids 762a and 762b include a foil that can be glued to the plastic frame 760. In some embodiments, one or both of the lids 762a and 762b include a plate that can be plastic or metal. In some embodiments, the plastic plate can include a metal foil disposed on an outer surface or an inner surface. In some embodiments, the plate can have a surface coating.

[0110]

[1152] 8A-8C illustrate tab designs and corresponding tab connection areas for a battery module including multiple single-pouch battery cells enclosed in a metal case. FIG. 8A is a side view of a battery module 800 including a metal case 860 (only a portion of the entire case is shown in FIG. 8A ) that substantially houses multiple single-pouch battery cells 801, each having a tab 812 that couples the single-pouch battery cell to the remaining battery cells in the battery module 800 via multiple spacers 871. A spacer coupler 872 electrically couples the spacer 871 and tab 812 to an end piece 876, which is electrically coupled to an electrode connector 814 (either an anode connector or a cathode connector). The electrode connector 814 further includes a conductive piece 815 that penetrates the wall of the metal case 860 and a connector coupler 816 that electrically insulates the conductive piece 815 from the wall of the metal case 860. The battery module 800 can provide power to a utility through electrode connector 814. In some embodiments, conductive piece 815 is a coaxial connector. In some embodiments, conductive piece 815 is a snap connector. In some embodiments, conductive piece 815 is a pin connector or any other electrical connector known in the art.

[0111]

[1153] 8B is a side view of one of the spacers 871 shown in FIG. 8A. The spacer 871 includes a bridge portion 874 and an end portion 875. The bridge portion 874 of each spacer 871 presses against the tab 812 of the single-pouch battery cell 801. Thus, the tabs can be electrically coupled to the spacers, which mechanically hold the tabs in place. The end portion 875 has a hole that can receive the spacer coupler 872. In some embodiments, the spacer The coupler 872 may be a rivet, screw, bolt, or any other conductive piece.

[0112]

[1154] 8C illustrates a connector portion 870 of the battery module 800 near the tabs 812 and electrode connectors 814 to illustrate the tab design. When the spacer couplers 872 (e.g., rivets) are secured, each tab 812 can be in physical and electrical contact with a bridge portion 874 of the spacer 871. The bridge portion 874 is further electrically coupled to an end portion 875, which is electrically coupled to an end piece 876 via the spacer coupler 872. The electrode connector 814 connects to the end piece 876 to provide power to an external utility or receive power from an external power source (e.g., to charge the battery). In some embodiments, both the bridge portion 874 and the end portion 875 of the spacer 871 can be conductive to form a conductive path from the single-pouch battery cell 801 to the electrode connector 814. In some embodiments, only a portion of the bridge portion 874 (e.g., the portion that contacts the tab 812) is conductive.

[0113]

[1155] In some embodiments, the spacer 871 comprises a metallic material (e.g., stainless steel, copper, aluminum, silver, etc.). In some embodiments, the spacer 871 comprises a non-conductive substrate (e.g., plastic) coated with a conductive material (e.g., metal, carbon, conductive metal oxide, etc.) to reduce the weight or cost of the battery module 800. In some embodiments, several tabs 812 can be connected together to extension tabs rather than to the spacer 871, in which case several extension tabs are connected to the end piece 876. In some embodiments, all of the tabs are connected together to the end piece 876 at once.

[0114]

[1156] In some embodiments, the metal casing 860 and / or the battery module 800 may include silicone oil or any liquid that promotes battery safety. Such liquid, silicone oil, or the like may help maintain pressure (e.g., stack pressure) within the metal casing 860. In some embodiments, the use of such liquid may also help prevent water from penetrating into the metal casing 860 and / or the battery module 800.

[0115] Method for manufacturing single pouch battery cells and modules

[1157] 9 is a flow diagram illustrating a method for manufacturing single-pouch battery cells and modules, according to some embodiments. The method 900 begins with electrode slurry preparation in step 910, where anode and cathode slurries can be prepared separately.

[0116]

[1158] In some embodiments, the electrode slurry comprises a mixture of an electrochemically active ion storage compound, a conductive additive, and a polymer binder.

[0117]

[1159] In some embodiments, at least one of the anode slurry and the cathode slurry comprises a semi-solid electrode material comprising a suspension of an active material and a conductive material in a non-aqueous liquid electrolyte. Examples of semi-solid electrode materials are described in U.S. Patent Publication No. US 2013 / 0065122 A1, entitled "Semi-solid Electrode Cell Having A Porous Current Collector and Methods of Manufacture," the disclosure of which is incorporated herein by reference in its entirety.

[0118]

[1160] The prepared electrode slurry is then placed (e.g., painted or coated) onto a current collector (e.g., foil, mesh, porous conductive foam) to form an electrode in step 920. An additional compression step is performed to compress the electrode slurry-coated current collector under high pressure to increase density and thickness. The thickness can be controlled.

[0119]

[1161] In some embodiments, the slurry preparation step 910 and the electrode formation step 920 can be combined into a single step called mixing and forming the slurry electrode, which generally includes (i) conveying and / or feeding raw materials, (ii) mixing, (iii) conveying the mixed slurry, (iv) compounding and / or extruding, and (v) forming. In some embodiments, multiple steps in this process can be performed simultaneously and / or using the same equipment. For example, mixing and conveying the slurry can be performed simultaneously using an extruder. Each step in this process can include one or more possible embodiments. For example, each step in this process can be performed manually or by various process equipment. Each step can include one or more sub-processes and can optionally include an inspection step to monitor the quality of the process.

[0120]

[1162] Conveying and / or feeding of raw materials may be accomplished by a variety of methods, including: batch hand metering of materials with natural feeding (e.g., allowing the mixer to receive and mix the materials without external force); batch hand metering of materials with forced feeding by a piston mechanism or screw type "side stuffer"; gravimetric screw solid feeders with natural feeding (e.g., feeding at a rate at which the mixer can naturally receive the materials); and gravimetric screw solid feeders with forced feeding (e.g., a Brabender device combined with a piston mechanism or screw type "side stuffer"). and / or any other suitable transport and / or delivery method, and / or any suitable combination thereof.

[0121]

[1163] In some embodiments, the slurry can be mixed using a Banburry® type batch mixer, the mixing section of a twin screw extruder, a centrifugal planetary mixer, and / or a planetary mixer. In some embodiments, the slurry can be sampled and / or monitored after mixing to measure and / or evaluate homogeneity, rheology, conductivity, viscosity, and / or density.

[0122]

[1164] In some embodiments, for example, after mixing, the slurry can be conveyed and / or pressurized using, for example, a piston pump, a peristaltic pump, a gear / lobe pump, a single screw pump, a single screw extruder, a mixing section of a twin screw extruder, and / or any other suitable conveying device. In some embodiments, the torque and / or power of the conveying device, the pressure at the outlet of the conveying device, the flow rate, and / or the temperature can be measured, monitored, and / or controlled during conveying and / or pressurization.

[0123]

[1165] In some embodiments, for example, after conveying and / or applying pressure, the slurry can be dispensed and / or extruded using, for example, a "hanger die" sheet extrusion die, a "winter manifold" sheet extrusion die, a profile-style sheet extrusion die, any nozzle operable to apply a continuous stream of material to a substrate, pouring into a mold of the correct size and shape (e.g., filling the material into pockets), and / or any other suitable dispensing device.

[0124]

[1166] In some embodiments, after compounding, the slurry can be formed into a final electrode. For example, the slurry can be calendered, stamped and / or pressed, vibratory settled, and / or cut into individual portions. Additionally, in some embodiments, unwanted portions of the material can be removed (e.g., masked and washed) and optionally recycled into the slurry manufacturing process.

[0125]

[1167] After forming the electrodes (anode and cathode), the unit cells can be assembled in step 930. In some embodiments, each unit cell assembly can be assembled, e.g., 1A and described above, each unit cell assembly can include an anode, a cathode, and a separator disposed between the anode and cathode to electrically insulate them. In some embodiments, each unit cell assembly can include a double-sided anode, two single-sided cathodes, and two separators, as shown in FIG. 1B and described above.

[0126]

[1168] At step 940, each assembled unit cell is sealed in a pouch. In some embodiments, the pouch comprises a three-layer structure, e.g., an outer layer comprising a nylon-based polymer film, an inner layer comprising a polypropylene (PP) polymer film, and a middle layer comprising aluminum (Al) foil. This type of pouch can be sealed by heat sealing, e.g., using an MTI MSK-140 Compact Heat Sealer. The sealing temperature can be, e.g., 50°C to 200°C, and the sealing pressure can be, e.g., 0 to 0.7 MPa. In some embodiments, the pouch can comprise a single layer of a thinner, lower-cost material. For example, these materials can be polypropylene, resin, or a combination of multiple polyolefins that can be sealed together using heat or pressure. In some embodiments, a pre-charging process can be performed on the unit cells before sealing each individual pouch. The pre-charging process can generate gas before the pouch is sealed, eliminating the need for a degassing process traditionally performed after battery formation.

[0127]

[1169] In some embodiments, the electrode slurry is a semi-solid electrode material and the prepared electrodes and subsequent unit cell assembly already contain the electrolyte in the electrode material, in which case the pouch can be sealed immediately after preparing the unit cell assembly, hi some embodiments, a separate electrolyte (i.e., a liquid electrolyte) is introduced into the pouch before sealing.

[0128]

[1170] After the pouch is sealed, in step 950, a tab is provided for each unit cell assembly to facilitate construction of a battery module, battery pack, or other application. In some embodiments, the tab can be part of the current collector. For example, the current collector can have a lead portion that extends outside of the electrode portion (e.g., 412 and 422 shown in FIG. 4A ). In some embodiments, the tab can be a separate element (e.g., a metal strip or wire) electrically coupled to the electrode. This coupling can be to the current collector or to the electrode material (i.e., the electrode slurry) and can be achieved by welding, gluing, stapling, or other means known in the art.

[0129]

[1171] Following preparation of each unit cell assembly, in step 960, multiple unit cell assemblies are bonded together to form a basic battery module. In this step, the multiple unit cell assemblies may be stacked vertically on top of one another, aligned horizontally, or both, depending on the actual application. Also, in this step, all of the cathode tabs are typically bonded together into a single connection point that can be further bonded to a cathode connector. Similarly, all of the anode tabs are typically bonded together into a single connection point that can be further bonded to an anode connector. In some embodiments, the tabs (anode tabs, cathode tabs, or both) are bonded together by welding, soldering, or glue. In some embodiments, the tabs are bonded together using spacers and rivets (e.g., as shown in FIGS. 8A-8C ). In some embodiments, the tabs are bonded together by screws.

[0130]

[1172] At step 970, the base battery modules are enclosed within a case. In some embodiments, the case is metal (e.g., as shown in FIG. 5). In these embodiments, the base battery modules are first placed within a metal can, and then each single pouch is sealed. The tabs of the battery cells can be bonded to the anode and cathode connectors. A metal lid can then be placed over the metal can to form the completed housing of the basic battery module. The metal lid can be bonded to the metal can by, for example, welding, soldering, or mechanical means. In some embodiments, the case includes a plastic frame on the sides and two foils on the top and bottom (e.g., as shown in Figures 7A-7B). In these embodiments, the basic module can be bonded to the plastic frame by first connecting the tabs to the anode and cathode connectors, and then the two foils can be bonded to the plastic frame by, for example, heat fusing or pressure sealing.

[0131]

[1173] The encapsulated battery module can then be subjected to a formation process and an initial charging operation performed to create a stable solid electrolyte interface (SEI) that can passivate the electrode / electrolyte interface and prevent side reactions, in step 980. Several charge and discharge cycles are also performed to ensure the battery capacity meets the required specifications.

[0132]

[1174] 10A and 10B are top and side views, respectively, illustrating an anode assembly layout including multiple anodes according to some embodiments. FIG. 10A shows an anode assembly 1000 including a pouch film 1040 (e.g., a PE / PP film) onto which anodes 1001a, 1001b, 1001c, and 1001d are disposed, which can form a pouch that houses the resulting battery cell. For example, a first anode 1001a includes an anode material 1010a disposed on an anode current collector 1020a disposed on the pouch film 1040. The first anode 1001a further includes an anode tab 1022a electrically coupled to the anode current collector 1020a, such that the first anode 1001a can be coupled to an external circuit. Similarly, the second anode 1001b includes a tab 1022b and an anode material 1010b disposed on an anode current collector 1020b. Each anode (1001a-1001d) is electrically isolated (e.g., by physical separation) from the other anodes in the anode assembly 1000.

[0133]

[1175] The tabs (1022a, 1022b, etc.) are arranged in alternating positions relative to their respective current collectors. More specifically, if one tab (e.g., 1022a) is located to the right of its associated current collector (1020a), the adjacent tab (e.g., 1022b) is located to the left of its associated current collector (1020b), and vice versa. This alternating tab configuration allows for convenient assembly of unit cells in subsequent steps in the manufacture of single-pouch cells.

[0134]

[1176] 10A includes four anodes 1001a-1001d, but this is for illustrative purposes only. In practice, the number of anodes disposed on the pouch film 1040 may be more or less than four.

[0135]

[1177] FIG. 10B is a cross-sectional view (taken along 10B-10B shown in FIG. 10A) illustrating, from top to bottom, an anode assembly 1000 including an anode material 1010, an anode current collector 1020, and a pouch film 1040. As can be seen from FIGS. 10A-10B, the anode material 1010 is small in size compared to the anode current collector 1020, which is even smaller in size compared to the pouch film 1040. This pyramidal structure actually allows for convenient handling of the anode during manufacturing. More specifically, the relatively large size of the pouch film 1040 provides a means for supporting the electrode materials, particularly semi-solid electrode materials, during battery manufacturing. That is, the pouch film can hold the electrode materials. The pouch film 1040 prevents any potential sagging, particularly at the edges of the electrodes, that may occur during packaging of the electrode stack. Furthermore, the pouch film 1040 can prevent leakage of the electrode material and contamination of other components that may occur during battery manufacturing by containing the electrode material within the space defined by the pouch film 1040.

[0136]

[1178] The method for preparing the anode assembly 1000 shown in FIGS. 10A-10B can begin with a pouch film. Then, multiple anode current collectors can be laminated (e.g., with an adhesive) onto the pouch film in an alternating tab configuration as described above. The multiple anode current collectors can be arranged in a periodic structure to facilitate subsequent assembly of unit battery cells. In some embodiments, the anode current collectors are arranged in a one-dimensional array (e.g., as shown in FIG. 10A). In some embodiments, the anode current collectors can be arranged in a two-dimensional array. After the pouch film and anode current collectors are adhered to each other, anode material can be disposed on each anode current collector to form the anode assembly 1000.

[0137]

[1179] In some embodiments, the multiple anode current collectors are deposited by deposition processes such as, but not limited to, chemical vapor deposition (CVD) (such as initiated CVD, hot wire CVD, plasma enhanced CVD, and other forms of CVD), physical vapor deposition, sputter deposition, magnetron sputtering, It can be deposited on the pouch by any of the coating or deposition techniques such as radio frequency sputtering, atomic layer deposition, pulsed laser deposition, plating, electroplating, dip coating, brushing, spray coating, sol-gel processes (by dip coating, brushing or spray coating), electrostatic spray coating, 3D printing, spin coating, electrodeposition, powder coating, sintering, self-assembly, and any combination of these techniques.

[0138]

[1180] In some embodiments, the properties of the deposited anode current collector can be optimized by varying the deposition parameters during deposition. Physical properties such as surface morphology, including coating texture, coating thickness, thickness uniformity, surface roughness, porosity, and general mechanical properties such as fracture toughness, ductility, and tensile strength, can be optimized by fine-tuning the deposition parameters. Similarly, chemical properties such as chemical and corrosion resistance to electrolytes and salts, as well as other chemical properties such as specific reactivity, adhesion, and affinity, can be optimized by varying the deposition parameters to create a functional current collector. In some embodiments, various physical and chemical properties of the current collector formed by deposition or coating can be further improved or modified after deposition by subsequent surface or temperature treatments, such as annealing or rapid thermal (flash) annealing, or electrochemical polishing, or using any combination of these techniques.

[0139]

[1181] FIG. 11A is a top view of a cathode assembly layout including multiple anodes according to some embodiments, and FIG. 11B is a cross-sectional view (taken along 11B-11B in FIG. 11A ) of the cathode assembly layout. The cathode assembly 1100 includes multiple cathodes 1101a, 1101b, 1101c, and 1101d disposed on a pouch film 1140. Each cathode (1101a-1101d) includes a cathode material 1110a (in the case of the first cathode) disposed on a cathode current collector 1120a laminated on the pouch film 1140. Each cathode further includes a tab 1122a for electrical coupling. FIG. 11B is a cross-sectional view of the cathode assembly 1100, including the cathode material 1110, the cathode current collector 1120, and the pouch film 1140, from top to bottom.

[0140]

[1182] The method for preparing the cathode assembly 1100 can be substantially the same as the method for preparing the anode assembly 1000 described above. The current collectors can be stacked in an array on a pouch film, and then cathode material can be placed on each cathode current collector to form the cathode assembly.

[0141]

[1183] In some embodiments, the anode assembly 1000 shown in Figures 10A-10B and the cathode assembly shown in Figures 11A-11B can be provided on the same pouch film (1040 or 1140). In some embodiments, the anode assembly 1000 and the cathode assembly 1100 can be provided on separate pouch films.

[0142]

[1184] Similarly, multiple cathode current collectors can be deposited on the pouch film by some of the deposition or coating techniques described above in connection with Figures 10A-10B, and the properties of the deposited cathode current collectors can be optimized by the optimization techniques described above.

[0143]

[1185] 12 is a top view illustrating an electrode assembly layout 1200 including both an anode assembly 1201 and a cathode assembly 1202 disposed on a common pouch film 1240. The anode assembly 1201 and the cathode assembly 1202 can be substantially similar to the anode assembly 1000 of FIG. 10A and the cathode assembly 1100 of FIG. 10B, respectively, and therefore will not be described in detail here. The anode assembly 1201 and the cathode assembly 1202 are aligned such that each anode of the anode assembly 1201 overlaps a corresponding cathode of the cathode assembly 1202 when the electrode assembly 1200 is folded along the central dashed line 10. Furthermore, the tabs 1221 of the anode assembly and the tabs 1222 of the cathode assembly are arranged in a complementary manner. More specifically, when folded along dashed line 10, each anode tab 1221 is on one side of a respective current collector, and each cathode tab 1222 is on the opposite side of a respective current collector. In other words, when electrode assembly 1200 is folded along dashed line 10, the anode tabs 1221 do not contact the cathode tabs 1222.

[0144]

[1186] In some embodiments, the pouch film can be maintained in a folded state for an extended period of time by application of heat or any other suitable method to prevent loss of the folded state. In some embodiments, application of heat or any other suitable method to maintain the folded state can be performed before laminating the current collector to the pouch film. In some embodiments, application of heat or any other suitable method to maintain the folded state can be performed after laminating the current collector to the pouch film. Similarly, in some embodiments, application of heat or any other suitable method to maintain the folded state can be performed before depositing the current collector on the pouch film or covering the pouch film with the current collector. In some embodiments, application of heat or any other suitable method to maintain the folded state can be performed after depositing the current collector on the pouch film or covering the pouch film with the current collector. The electrode assembly 1200 can be prepared in a manner similar to that described in connection with FIGS. 10A-10B and 11A-11B. However, the above method steps (e.g., lamination of current collectors, deposition of electrode materials, etc.) can be arranged in various orders to prepare the electrode assembly 1200. In some embodiments, the method for preparing the electrode assembly 1200 begins with a pouch film, followed by lamination of the anode and cathode current collectors separately. Anode material can then be disposed on each anode current collector, and cathode material can be disposed on each cathode current collector.

[0145]

[1187] In some embodiments, the method of preparing the electrode assembly 1200 begins with laminating the anode current collectors onto a pouch film, followed by laminating a film onto each anode current collector. The anode material is deposited, and the method then proceeds with laminating cathode current collectors and depositing a cathode material onto each cathode current collector.

[0146]

[1188] In some embodiments, the anode current collector and / or cathode current collector can be deposited onto the pouch film in turn by some of the deposition or coating techniques described herein. The properties of the deposited anode current collector and / or cathode current collector can also be optimized as described above by the aforementioned optimization techniques or approaches.

[0147]

[1189] In some embodiments, the current collectors can be stacked on the pouch film in an alternating order. More specifically, every time a current collector of one type (anode or cathode) is stacked on the pouch film, a current collector of the other type (cathode or anode) is stacked in registration with a current collector of the opposite type. These embodiments described herein are for illustrative purposes only. One skilled in the art will appreciate that various other sequences can be implemented to prepare the electrode assembly 1200.

[0148]

[1190] A separator can be disposed on each electrode (anode or cathode) of the electrode assembly during or after preparation of the electrode assembly 1200. In some embodiments, a separator is disposed on each anode material. In some embodiments, a separator is disposed on each cathode material. In some embodiments, a separator is disposed on the electrode material after preparation of the electrode assembly 1200. In some embodiments, a separator is disposed on the electrode material during preparation of the electrode assembly. For example, a separator can be disposed on the anode material after preparation of the anode assembly 1201 and before preparation of the cathode assembly 1202. One skilled in the art will appreciate that various other process sequences can be performed to dispose the separator on the electrode material.

[0149]

[1191] After the separator (or one large sheet of separator) is placed on the electrode assembly 1200 (anode assembly 1201 or cathode assembly 1202), the electrode assembly 1200 is folded along the center line 10 to form a unit cell assembly 1300, as shown in FIGS. 13A-13B. The unit cell assembly 1300 includes a plurality of unit cells 1301a, 1301b, 1301c, and 1301d. A pouch film 1340 substantially houses the plurality of unit cells 1301a-1301d, except for tabs 1321 and 1322 that protrude from the pouch film 1340 to enable electrical coupling to external components. While four unit cells are shown in FIG. 13A, this is for illustrative purposes only. In practice, the number of unit cells in a unit cell assembly may be more or less than four, depending on manufacturing specifications.

[0150]

[1192] Each unit cell of the unit cell assembly (e.g., first unit cell 1301a) includes a cathode tab 1321 on one side of the unit cell and an anode tab 1322 on the other side of the unit cell. Adjacent unit cells in the unit cell assembly 1300 have opposite configurations of the tabs 1321 and 1322. Take first unit cell 1301a and second unit cell 1301b as examples. In first unit cell 1301a, the cathode tab 1321 is on the left side of the unit cell and the anode tab 1322 is on the right side. In contrast, in second unit cell 1301b, the cathode tab 1321 is on the right side of the unit cell and the anode tab 1322 is on the left side. This alternating tab configuration allows for convenient cell assembly and battery fabrication in subsequent processes, as described in detail below.

[0151]

[1193] FIG. 13B shows a unit cell assembly including, from top to bottom, a first pouch film 1340a, a cathode current collector 1310, a cathode material 1320, a separator 1330, an anode material 1330, an anode current collector 1350, and a second pouch film 1340b. 13B is a cross-sectional view (taken along 13B-13B in FIG. 13A) of a pouch film 1300. In some embodiments, the first pouch film 1340a and the second pouch film 1340b can be different portions of the same film, as shown, for example, in FIG. 12. In some embodiments, the first pouch film 1340a and the second pouch film 1340b can be different pouch films onto which the anode assembly and cathode assembly are disposed, respectively.

[0152]

[1194] The unit cell assembly 1300 shown in Figures 13A-13B can be subjected to a sealing process to form individual unit cells, each housed in a pouch, i.e., a single-pouch unit cell. Figure 14 illustrates a sealing scheme for a unit cell assembly 1400, which can be substantially similar to the unit cell assembly 1300. The unit cell assembly 1400 includes a plurality of unit cells 1401a-1401d that are substantially housed in a pouch film 1440. The dashed line 20 indicates the location of the seal, which can be, for example, a vacuum seal or a heat seal.

[0153]

[1195] In some embodiments, the sealing process can be performed first along two horizontal lines (one at the top and one at the bottom of the unit cell assembly 1400), followed by each vertical line. Some embodiments can reverse the above order, i.e., perform the vertical sealing first, followed by the horizontal sealing. In some embodiments, both vertical and horizontal sealing can be performed simultaneously along a given sealing line 20.

[0154]

[1196] 15A-15B illustrate a stacking procedure for unit cells after sealing each unit cell within a pouch, according to some embodiments. FIG. 15A shows a unit cell assembly 1500 substantially similar to the sealed unit cell assembly 1400 shown in FIG. 14. The unit cell assembly 1500 includes a plurality of unit cells 1501a-1501d. Sealing occurs along dashed line 20. Vertical dash-dotted line 30 indicates the location along which the unit cell assembly 1500 is folded to form a unit cell stack. After folding, the anode tab is at one edge of the resulting stack and the cathode tab is at the other edge of the resulting stack, such that the anode tab is electrically isolated from the cathode tab.

[0155]

[1197] In some embodiments, multiple unit cells 1501a-1501d are folded in a rolling manner. For example, unit cell 1501d can be folded counterclockwise onto unit cell 1501c, and then the resulting stack of 1501c and 1501d can be folded counterclockwise onto unit cell 1501b. This rolling process can continue until the last unit cell in the assembly (or the first unit cell, depending on which unit cell was started).

[0156]

[1198] In some embodiments, as shown in FIG. 15B, multiple unit cells 1501a-1501d are folded in a zigzag pattern. For example, unit cells 1501a and 1501b can be folded in a counterclockwise direction, while unit cells 1501c and 1501d can be folded in a clockwise direction. The stack of 1501a and 1501b can be folded in either a counterclockwise or clockwise direction, along with the stack of 1501c and 1501d. In other words, the folding direction can be different for each unit cell in unit cell assembly 1500.

[0157]

[1199] In some embodiments, folding of multiple unit cells 1501a-1501d can be performed simultaneously, for example by applying force from both the left and right sides of the unit cell assembly to push the unit cells against each other, similar to the side panels of a window air conditioner. They can also be stacked on top of each other.

[0158]

[1200] In some embodiments, the folded state of the plurality of unit cells 1501a-1501d can be maintained for an extended period of time by application of heat or any other suitable method to prevent loss of the folded state. In some embodiments, application of heat or any other suitable method to maintain the folded state can be performed after folding in a counterclockwise folding direction, after folding in a clockwise folding direction, after folding in a zigzag folding direction, or any combination of these folding directions. In some embodiments, the folded state of the plurality of unit cells 1501a-1501d can be maintained for an extended period of time by application of heat or any other suitable method before folding the plurality of cells. In some embodiments, the folded state of the plurality of unit cells 1501a-1501d can be maintained for an extended period of time by application of heat or any other suitable method after each folding of the plurality of cells. In some embodiments, the folded state of the plurality of unit cells 1501a-1501d can be maintained for an extended period of time after the plurality of cells are all folded by application of heat or any other suitable method.

[0159]

[1201] FIG. 16A is a top view of a unit cell stack prepared using the method shown in FIGS. 15A-15B, and FIG. 16B is a cross-sectional view (taken along line 16B-16B shown in FIG. 16A) of the unit cell stack. The unit cell stack 1600 includes a plurality of unit cells 1601a-1601d (collectively referred to as unit cells 1601). Each unit cell is sealed within a pouch 1640. A cathode tab 1621 is aligned with the left edge of the unit cell stack 1600, and an anode tab 1622 is aligned with the right edge of the unit cell stack 1600. Both the cathode tab 1621 and the anode tab 1622 protrude from the pouch 1640 to allow electrical connection to other components in the system, such as other cell stacks, utilities, or connectors.

[0160]

[1202] 17A-17B illustrate pouch cells with additional portions for gas generation and resealing, illustrating an exemplary method for performing venting during the manufacture of single-pouch battery cells, according to some embodiments. FIG. 17A is a top view illustrating a unit cell assembly 1700 including unit cells 1701a, 1701b, 1701c, and 1701d sealed into respective pouches along seal line 20. Each unit cell 1701a-1701d further includes a portion, also referred to herein as a venting portion 1761a-1761d, for containing gas generated during cell formation. The venting portions 1761a-1761d extend from the electrode portions of the unit cells and include empty pouch space. Gas generated during the venting process can be contained in these venting portions 1761a-1761d. After the degassing process is complete, the degassed portions 1761a-1761d can be cut along the white dotted lines shown in FIG. 17B to release the contained gas and removed from the unit cell assembly 1700. The degassed unit cell assembly 1700 can then be resealed along a new seal line 25 to form a resealed unit cell assembly (e.g., the unit cell stack shown in FIGS. 15A-15B) for further processing. In some embodiments, the degassing process can be performed after stacking the unit cells by sealing several stacked pouch materials at once. This approach can make fabrication more efficient.

[0161]

[1203] In some embodiments, a unit cell assembly 1700 including a venting portion in each unit cell can be prepared in a manner substantially similar to that described above in connection with Figure 12, except that a larger size pouch film is used. More particularly, the areas on either side of the central line 10 in Figure 12 can be enlarged to form the venting portion when the electrode assembly is folded along the central line 10.

[0162]

[1204] In some embodiments, the cathode and anode assemblies can be prepared on separate pouch films, with an additional film located at the bottom of each assembly, and the two assemblies can then be stacked together and sealed along dashed line 20 to form unit cell assembly 1700, as shown in FIG.

[0163]

[1205] 10A-17B illustrate a method for preparing a unit cell assembly having both the anode tab and the cathode tab on the same side of the resulting unit cell assembly. In some embodiments, as shown in FIG. 18, the anode tab 1821 and the cathode tab 1822 are on opposite sides of the unit cell assembly 1800. In this example, the anode tab 1821 and the cathode tab 1822 of unit cells 1801a-1801d can utilize a larger available width of the current collector; that is, the tabs can be wider. Increasing the tab width can reduce the electrical resistance of the tab, thereby improving the performance of the resulting battery. Increasing the width can also improve the mechanical and electrical stability of the resulting battery, because tabs with wider widths are less likely to corrode, break, or otherwise be compromised for physical and / or chemical reasons.

[0164]

[1206] A unit cell assembly 1800 can be prepared by stacking an anode assembly (e.g., 1000 shown in FIG. 10A with a wider tab) onto an inverted cathode assembly (e.g., 1100 shown in FIG. 11A with a wider tab) so that the cathode and anode tabs are on opposite sides of the resulting unit cell assembly. The resulting unit cell assembly 1800 can then be sealed along seal line 20 to form an individually packaged single-pouch battery cell.

[0165]

[1207] 19A-19B illustrate an exemplary manufacturing method for preparing a single-pouch battery cell in which the electrode assembly includes both an anode and a cathode in the same row. For illustrative purposes only, FIG. 19A shows an electrode assembly 1900 including two anodes (1901a and 1901c) and two cathodes (1901b and 1901d) disposed on the same pouch film 1940 and arranged in the same alternating order. The first anode 1901a and the first cathode 1901b form a first unit cell 1901 when folded along a first dash-dotted line 50. The second anode 1901c and the second cathode 1901d form a second unit cell 1902 when folded along a second dash-dotted line 55. In some embodiments, the two unit cells 1901 and 1902 are further folded along solid line 40 to form a simple unit cell stack. In some embodiments, the folded state of the unit cells 1901 and 1902 along solid line 40 can be maintained in the folded state for extended periods of time by application of heat or any other suitable method to prevent loss of the folded state. In some embodiments, the two unit cells 1901 and 1902 are cut along the solid line to form two separate, independent unit cells for further processing (e.g., stacking, sealing, etc.).

[0166]

[1208] 19B is a cross-sectional view showing a folded region of a first unit cell 1901, including a pouch film 1904 that substantially encloses, from three directions (bottom, top, and right side), a cathode material 1920 disposed on a cathode current collector 1910, an anode material 1950 disposed on an anode current collector 1960, and a separator 1930 disposed between the anode material 1950 and the cathode material 1920. In some embodiments, a longer pouch film can be used at a connecting portion 1942 of the pouch film 1940 to form a venting portion.

[0167]

[1209] 19C-19D illustrate an exemplary manufacturing method for preparing a cylindrically configured battery cell, according to some embodiments. FIG. 19C is a top view illustrating a cylindrical battery cell 1903 including multiple electrode stacks. Each electrode stack further includes a cathode 1913, an anode 1923, and a separator 1933 disposed between the cathode 1913 and the anode 1923. Adjacent electrode stacks are separated by a pouch layer 1943. FIG. 19D is a schematic diagram illustrating the cylindrical battery cell 1903.

[0168]

[1210] 19E-19G illustrate an exemplary manufacturing method for preparing a battery cell in a prismatic configuration, according to some embodiments. FIG. 19E is a partial top view of a prismatic battery cell 1905, illustrating the detailed structure of the circled portion of FIG. 19F, which is the overall top view of the prismatic battery cell 1905. The prismatic battery cell 1905 includes multiple electrode stacks, each of which further includes a cathode 1915, an anode 1925, and a separator 1935 disposed between the cathode 1915 and the anode 1925. Adjacent electrode stacks are separated by a pouch layer 1945. FIG. 19G is a schematic diagram illustrating the prismatic battery cell 1905.

[0169]

[1211] Both the cylindrical battery cell 1903 and the prismatic battery cell 1905 can be prepared by the methods described below. In some embodiments, the cathode (1913 or 1915) and the anode (1923 or 1925) can be prepared separately. For example, the cathode can be prepared by disposing the cathode material on a cathode current collector, and the anode can be prepared by disposing the anode material on an anode current collector. A separator can then be disposed on the anode material or the cathode material. The prepared cathode and anode can then be stacked together to form an electrode stack, after which a pouch layer is disposed on one side (the anode side or the cathode side) of the electrode stack. The electrode stack, along with the pouch layer, can then be rolled into a cylindrical or prismatic battery cell. In some embodiments, the pouch layer can also be disposed on one of the electrodes before stacking them together to facilitate electrode preparation.

[0170]

[1212] In some embodiments, the electrode stack (including the pouch layer) can be prepared layer by layer. For example, the fabrication can begin with placing an anode current collector on the pouch layer, followed by placing an anode material on the anode current collector. A separator can then be placed on the anode material, followed by placing a cathode material thereon, followed by placing a cathode current collector. After this layer-by-layer procedure, the resulting electrode stack can be rolled into a battery cell in a cylindrical or prismatic configuration. In some embodiments, the pouch layer can be placed after the electrode stack is formed.

[0171]

[1213] In some embodiments, before the electrode stack is rolled into a battery cell, a cutting process can be performed to achieve a desired shape factor for the resulting battery cell after rolling.

[0172]

[1214] In some embodiments, the battery cells shown in Figures 19C-19F can be further sealed in an outer pouch or package, which can be used to mitigate corrosion caused by, for example, moisture or chemicals in the surrounding environment.

[0173]

[1215] 19C-19F show only one pouch layer in each battery cell 1903 or 1905, in practice multiple pouch layers may be used. In some embodiments, two pouch layers may be used, with one pouch layer placed over the anode current collector and the other pouch layer placed over the cathode current collector to facilitate electrode preparation. This allows for the electrode material to be easily removed (e.g., avoiding leakage or deformation of the electrode material).

[0174]

[1216] Figure 20 illustrates a single-pouch battery cell manufactured according to the above-described method. Battery cell 2000 includes a pouch 2040 that houses an anode 2010, a cathode, and a separator. The cathode and separator are recessed within anode 2010 and are not numbered. The battery cell also includes an anode tab 2012 constructed of copper and a cathode tab 2014 constructed of aluminum. As can be seen in Figure 20, pouch 2040 substantially houses the electrode portions, with tabs 2012 and 2014 extending outside the pouch for external connection.

[0175]

[1217] FIG. 21 shows capacity retention curves for three groups of single-pouch battery cells. The first group, also referred to as the control group, includes single-pouch battery cells that were subjected to a degassing process before testing for capacity retention. The second group, also referred to as the "non-degassing" group, includes single-pouch battery cells that were not subjected to any degassing process before testing. The third group of single-pouch battery cells, also referred to as the "pre-charged" group, was subjected to a pre-charging process before sealing the pouch. The pre-charging was performed at a C / 10 rate for approximately one hour. The batteries in the third group were not subjected to a degassing process.

[0176]

[1218] The battery cells in all groups had a cathode slurry containing 50% by volume lithium iron phosphate and 0.936% by volume carbon additive, mixed in a speed mixer. In some embodiments, the procedure for mixing the cathode slurry included two cycles of mixing at 650 RPM for 3 minutes, followed by mixing at 1250 RPM for 1 minute. The anodes used in the battery cells included 50% by volume graphite powder and 2% by volume carbon additive, also mixed in a mixer. In some embodiments, the procedure for mixing the anode slurry included mixing at 650 RPM for 6 minutes. The anodes had a thickness of approximately 265 μm. The electrolyte used in these battery cells included a 50 / 50 ethylene carbonate / γ-butyrolactone (GBL) solvent and 1 M LiTFSI dissolved in the solvent. The electrolyte further contains additives such as 2% vinylene carbonate (VC). The total thickness of the battery cell is approximately 900 μm.

[0177]

[1219] As shown in Figure 21, the battery cells in the pre-charged group exhibit substantially the same capacity retention as the battery cells in the control group. Furthermore, the battery cells in the non-vented group exhibit an increase in capacity over the first 15 to 20 cycles, indicating that the full capacity of the battery cells in the non-vented group is not attained during those cycles. The comparison of capacity retention demonstrates that performing the pre-charging process on single-pouch cells can eliminate the need for a venting step and further eliminate the resealing step in conventional battery manufacturing.

[0178] Exemplary Battery Modules and Battery Packs Including Single-Pouch Battery Cells

[1220] FIG. 22 is a top view illustrating a battery module 2200 including an array of single-pouch battery cells 2210(1) through 2210(8) (collectively referred to as battery cells 2210) enclosed within a case 2220. Each battery cell 2210 includes an anode tab 2212 and a cathode tab 2214 that can be used to couple the battery cell to other battery cells. While the battery module 2200 illustrated in FIG. 22 includes eight single-pouch battery cells, this is for illustrative purposes only. In practice, the number of single-pouch battery cells in a battery module may be more or less than eight, depending, for example, on the desired battery specifications.

[0179]

[1221] Furthermore, the plurality of battery cells 2210 are arranged in a two-dimensional array. , which is also for purposes of example only. In some embodiments, the plurality of battery cells 2210 are arranged in a line (i.e., in a one-dimensional array). In some embodiments, the plurality of battery cells 2210 are arranged radially toward a common center point such that the battery module 2200 can have a cylindrical configuration.

[0180]

[1222] 22 shows only one layer of battery modules, again for illustrative purposes only. In practice, one or more battery modules similar to battery module 2200 can be coupled together to achieve a desired output specification, such as capacity, voltage, or current.

[0181]

[1223] 23A and 23B are an exploded view and a completed view, respectively, showing a battery module including multiple single-pouch battery modules enclosed in a metal case. As shown in Fig. 23A, battery module 2300 includes upper cover 2310, upper foam 2320, cell stack 2330, and integrated case 2340 that houses the cell stack.

[0182]

[1224] The cell stack 2330 further includes an anode tab 2334 and a cathode tab 2332. The anode tab 2334 is in electrical communication with each anode of the battery cells in the cell stack 2330, and the cathode tab 2332 is in electrical communication with each cathode of the battery cells in the cell stack 2330. The unitary case 2340 further includes an anode connector 2344 and a cathode connector 2342. When the cell stack 2330 is properly positioned within the unitary case 2340, the anode tab 2334 is electrically coupled to the anode connector 2344 and the cathode tab 2332 is electrically coupled to the cathode connector 2342, allowing the battery module 2300 to provide (during discharging) or receive (during charging) power via the anode connector 2344 and the cathode connector 2342.

[0183]

[1225] In some embodiments, top cover 2310 comprises the same metal material (e.g., stainless steel, aluminum, copper, etc.) used for unitary case 2340. In some embodiments, top cover 2310 comprises a lightweight material (e.g., polymer, plastic, light metal, etc.) to facilitate removal and reinstallation of top cover 2310.

[0184]

[1226] In some embodiments, the top foam 2320 is soft (e.g., cushion foam) to reduce the likelihood of damage to the cell stack 2330 upon impact. In some embodiments, the top foam 2320 comprises a flame-retardant foam, such as synthetic foam, aqueous film-forming foam, alcohol-resistant foam, and protein foam, among others.

[0185]

[1227] 24A-24B are exploded and assembled views, respectively, of a battery module including multiple single-pouch battery modules enclosed in a plastic case. As shown in FIG. 24A, battery module 2400 includes a top cover 2410, top foam 2420, a cell stack 2430, an inner liner 2450, and a one-piece case 2440 that houses the cell stack. Top cover 2410, top foam 2420, and cell stack 2430 can be substantially the same as top cover 2310, top foam 2320, and cell stack 2330 shown in FIG. 23A and described above. One-piece case 2440 includes a plastic material, for example, to reduce the weight of battery module 2400.

[0186]

[1228] In some embodiments, the inner liner 2450 comprises a soft material (e.g., plastic, polymer, rubber, etc.) to reduce the likelihood of damage to the cell stack 2430 upon impact. In some embodiments, the inner liner 2450 comprises a soft material (e.g., plastic, polymer, rubber, etc.) to reduce the risk of fire. In some embodiments, the inner liner 2450 comprises an antistatic material, such as long-chain aliphatic amines (optionally ethoxylated) and amides, quaternary ammonium salts (e.g., behentrimonium chloride or cocamidopropyl betaine), phosphate esters, polyethylene glycol esters, or polyol-based materials. In some embodiments, the inner line 2450 comprises a moisture-resistant material to prevent short circuits in the cell stack 2430 caused by moisture. In some embodiments, the inner liner 2450 comprises a composite material. For example, the inner line 2450 can include a cushioning, soft material coated with a flame-retardant material to reduce fire hazard.

[0187]

[1229] Battery module 2300 shown in Figures 23A-23B and battery module 2400 shown in Figures 24A-24B, commonly referred to as battery modules, can have several features that can facilitate practical applications. In some embodiments, the battery modules can allow for interlocking between modules so that battery packs having particular desired specifications (e.g., voltage, current, capacity, etc.) can be conveniently constructed. In some embodiments, the battery modules include a modular design so that each battery module can function independently as a power source or cooperate with other components in a particular application.

[0188]

[1230] In some embodiments, the battery module may have the following specifications: output voltage 3.2V, cell capacity 280Ah, cell weight 4.5kg, total energy 0.896kWh, cell volume 4.14L, volumetric energy density 216Wh / L, and specific energy density 200Wh / kg. These specifications are for illustrative purposes only. In practice, different specifications may be utilized to meet different practical requirements in different application fields.

[0189]

[1231] FIG. 25 is a schematic diagram illustrating a battery pack 2500 including multiple battery modules 2510(1) through 2510(4), collectively referred to as battery module 2510. Battery module 2510 can be substantially similar to battery module 2300 shown in FIGS. 23A-23B or battery module 2400 shown in FIGS. 24A-24B. While battery pack 2500 shown in FIG. 25 includes four battery modules 2510 arranged in a two-dimensional array, this is for illustrative purposes only. In practice, the number of battery modules in a battery pack may vary depending, for example, on desired specifications. This array configuration can also be varied. For example, FIG. 26 illustrates a battery module 2600 including an array of four battery modules 2610(1) through 2610(4) arranged in a one-dimensional array, for example, to fit particular space requirements.

[0190]

[1232] 27A-27C are schematic diagrams showing a battery pack including vertically stacked battery modules and an enlarged portion of the stacked modules to illustrate the battery pack's interlocking mechanism. The battery pack 2700 shown in FIG. 27A includes a first battery module 2710a and a second battery module 2710b stacked vertically on top of each other. The weight of the first battery module 2710a can apply a stack pressure to the second battery module 2710b. In some embodiments, when 28 modules are stacked in order, the pressure differential between the top and bottom battery modules can be approximately 5 PSI.

[0191]

[1233] The battery pack 2700 includes a left contact portion 2712a and a right contact portion 2712b between the two battery modules. The two contact portions 2712a and 2712b are shown in Figures 27B and 27C, respectively. Figures 27B and 27C show the top of the lower battery module 2710b positioned to receive the bottom of the upper battery module 2710a. This configuration allows a plurality of battery modules to be conveniently coupled together to form a battery pack having desired specifications.

[0192]

[1234] 28A-28B are assembled and exploded views illustrating a battery rack 2800 including multiple battery modules 2850 (e.g., battery modules 2300 and / or 2400) arranged in a rack configuration (i.e., a two-dimensional vertical array). A plurality of support frames 2840 are disposed on the four edges of the multiple battery modules 2850 to hold the battery modules 2850 together. The support frames 2840 are mechanically coupled to the battery modules 2850 by a plurality of bolts 2870. A top end plate 2810 and a bottom end plate 2880 surround the multiple battery modules 2850 from above and below, respectively. A plurality of compression plates 2830 with a plurality of compression springs 2820 disposed thereon can be disposed between the top end plate 2810 and the multiple battery modules 2850 for shock absorption. Each battery module includes a battery cable 2860 to facilitate electrical coupling between that battery module and other battery modules. The resulting completed battery rack 2800 is shown in Figure 28A.

[0193]

[1235] One exemplary specification of the battery rack 2800 may be as follows: output voltage 716V, cell capacity 280Ah, cell weight 1150kg, total energy 200kWh, rack dimensions 600mm x 760mm x 2100mm, volumetric energy density 210Wh / L, and specific energy density 175Wh / kg. This specification is for illustrative purposes only. In practice, various specifications may be utilized to meet various practical requirements in the application fields.

[0194]

[1236] While various embodiments have been described above, it should be understood that they are presented by way of example only and not by way of limitation. For example, while the embodiments herein describe electrochemical devices, such as lithium-ion batteries, the systems, methods, and principles described herein can be applied to any device that includes an electrochemically active medium. In other words, any electrode and device that includes at least an active material (a source or sink of charge carriers), a conductive additive, and an ionically conductive medium (an electrolyte), such as a battery, capacitor, electric double-layer capacitor (e.g., ultracapacitor), lithium-ion capacitor (hybrid capacitor), pseudocapacitor, etc., is within the scope of the present disclosure. Furthermore, the above-described embodiments can be used with non-aqueous and / or aqueous electrolyte battery chemistries.

[0195]

[1237] While the methods and steps described above depict certain events occurring in a particular order, one of ordinary skill in the art having the benefit of this disclosure will recognize that the order of certain steps can be modified and that such modifications are in accordance with variations of the present invention. Furthermore, certain of these steps can be performed simultaneously in a parallel process where possible, or can be performed sequentially as described above. Furthermore, certain steps can be partially completed before proceeding to a subsequent step and / or can be skipped before proceeding to a subsequent step.

[0196]

[1238] While various embodiments have been specifically illustrated and described, various changes may be made in form and detail. For example, while various embodiments have been described as having particular features and / or combinations of components, other embodiments are possible having any combination or subcombination of any of the features and / or components of any of the embodiments described herein. The specific configurations of these various components may also vary.

Claims

1. 1. An electrochemical cell comprising: a cathode material disposed on the first conductive layer; an anode material disposed on the second conductive layer; a separator between the cathode material and the anode material; a first insulating material disposed on at least a portion of the first conductive layer; a second insulating material disposed on at least a portion of the second conductive layer; and Equipped with an edge of the first insulating material is bonded to an edge of the second insulating material to form a sealed perimeter, and the separator extends at least partially into the sealed perimeter to electrically insulate the cathode material from the anode material.

2. 2. The electrochemical cell of claim 1 , wherein the first conductive layer, the second conductive layer, and a separator each have a first side and a second side opposite the first side, the cathode material is disposed on the first side of the first conductive layer adjacent the first side of the separator, and the first insulating material is bonded to at least a portion of the second side of the first conductive layer.

3. 3. The electrochemical cell of claim 2, wherein the anode material is disposed on the first side of the second conductive layer adjacent the second side of the separator, and the second insulating material is bonded to at least a portion of the second side of the second conductive layer such that the bonded edges of the first insulating material and the second insulating material at least partially encapsulate the cathode material, the first conductive layer, the anode material, the second conductive layer, and the separator.

4. 10. The electrochemical cell of claim 1, wherein the separator has a cross-sectional area greater than a cross-sectional area of ​​at least one of the cathode material or the anode material.

5. 10. The electrochemical cell of claim 1, wherein a peripheral edge of the separator is sealed to the sealing periphery between edges of the first insulating material and the second insulating material, and a portion of the sealing periphery extends beyond the peripheral edge of the separator.

6. 10. The electrochemical cell of claim 1, wherein at least one of the cathode material or the anode material is a semi-solid electrode material.

7. 10. The electrochemical cell of claim 1, further comprising a housing defining an interior volume, wherein the cathode material, the anode material, the first conductive layer, the second conductive layer, the first insulating material, and the second insulating material are disposed within the interior volume.

8. 8. The electrochemical cell of claim 7, further comprising a conductive element electrically coupled to at least one of the first conductive layer or the second conductive layer, at least a portion of the conductive element extending outside the sealed periphery.

9. 9. The electrochemical cell of claim 8, wherein the housing includes a conductive portion, and the conductive element is electrically coupled to the conductive portion of the housing.

10. 1. An electrochemical cell assembly comprising: a first electrochemical cell and a second electrochemical cell, each of the first electrochemical cell and the second electrochemical cell comprising: a cathode material electrically coupled to the first conductive layer; an anode material electrically coupled to the second conductive layer; a separator interposed between the cathode material and the anode material; a first insulating material disposed on at least a portion of the first conductive layer; a second insulating material disposed on at least a portion of the second conductive layer; and Including, an edge of the first insulating material is joined to an edge of the second insulating material to form a sealed perimeter, the separator extending into the sealed perimeter; An electrochemical cell assembly, wherein the second electrochemical cell is electrically coupled in series or parallel to the first electrochemical cell.

11. 11. The electrochemical cell assembly of claim 10, further comprising a conductive element electrically coupled to at least one of the first conductive layer or the second conductive layer, at least a portion of the conductive element extending outside the sealed periphery.

12. 12. The electrochemical cell assembly of claim 11, further comprising a casing defining an interior volume, the first electrochemical cell and the second electrochemical cell being disposed within the interior volume.

13. 13. The electrochemical cell assembly of claim 12, further comprising an opening defined in a wall of the casing, the conductive element extending at least partially through the opening to an area exterior to the casing.

14. the casing is formed from an electrically conductive material, and the first electrochemical cell and the second electrochemical cell are 14. The electrochemical cell assembly of claim 13, further comprising a third insulating material interposed between the conductive material and the casing to electrically insulate the conductive material from the casing.

15. 13. The electrochemical cell assembly of claim 12, wherein the casing is formed from a conductive material, and the conductive material is electrically coupled to the casing such that the casing has the same polarity as the first conductive layer or the second conductive layer.

16. the conductive element is a first conductive element electrically coupled to the first conductive layer, and the electrochemical cell assembly comprises: a second conductive element electrically coupled to the second conductive layer; a first terminal coupled to the casing, the first terminal configured to be electrically coupled to the first conductive element; a second terminal coupled to the casing, the second terminal configured to be electrically coupled to the second conductive element; an insulating portion disposed within the casing between the first terminal and the second terminal, the insulating portion configured to electrically insulate the first terminal from the second terminal; 13. The electrochemical cell assembly of claim 12, further comprising:

17. 13. The electrochemical cell assembly of claim 12, further comprising a lid hinged to the casing, the lid configured to transition between an open configuration allowing access to the first and second electrochemical cells disposed therein and a closed configuration in which the lid encloses the first and second electrochemical cells within the casing.

18. 18. The electrochemical cell assembly of claim 17, wherein a portion of the lid includes a safety material configured to at least one of provide a cushion for the first electrochemical cell and the second electrochemical cell within the casing or suppress a fire within the casing.

19. 1. A method comprising: disposing a first electrode material on the first conductive layer; disposing a second electrode material on the second conductive layer; interposing a separator between the first electrode material and the second electrode material; bonding an edge of a first portion of insulating material to an edge of a second portion of insulating material to form a sealed perimeter, an outer edge of the separator extending at least partially into the sealed perimeter to electrically insulate a first electrode material from a second electrode material, and forming an electrochemical cell with the first electrode material, the first conductive layer, the second electrode material, the second conductive layer, and the separator; A method comprising:

20. the electrochemical cell is a first electrochemical cell, and the method comprises:

20. The method of claim 19, further comprising electrically coupling a second electrochemical cell in series or parallel to the first electrochemical cell.

21. 21. The method of claim 20, further comprising enclosing the first electrochemical cell and the second electrochemical cell in a casing.

22. 22. The method of claim 21, further comprising electrically coupling at least one of the first electrochemical cell or the second electrochemical cell to the casing.

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