Anode assembly for battery cells

Abstract

The present disclosure provides an anode assembly for a battery cell. The anode assembly includes a separator layer, an anode layer, a deposition layer, and an anode current collector. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer and a second surface facing away from the separator layer. The anode layer includes a solid-state electrolyte (SSE) having micropores. The deposition layer is at least partially disposed on the second surface of the anode layer. The deposition layer includes at least one of a conductive material and a nucleation material. The anode current collector is bonded to the deposition layer. The present disclosure also provides a method for forming an anode assembly for a battery cell.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Application No. 63 / 383,040, filed November 9, 2022, the entire contents of which are incorporated herein by reference.

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

[0003] Lithium (Li) metal is considered an ideal electrode (e.g., anode) material for next-generation energy storage systems (e.g., batteries) due to its low reduction potential (-3.04 V vs. the standard hydrogen electrode) and high specific capacity (3860 mAh / g). However, lithium electrodes (e.g., anodes) tend to form dendrites, which can penetrate between the anode and cathode and cause short circuits. Furthermore, organic liquid electrolytes are highly flammable, raising safety concerns. As an alternative, solid-state electrolytes (SSEs) have been proposed, which offer the advantages of suppressing lithium dendrites through their high mechanical strength and being non-flammable.

[0004] Furthermore, anodes of solid-state battery cells (e.g., lithium-ion battery cell anodes) may be fabricated using metallic materials (e.g., lithium metal) disposed on a layer. The metallic materials often disposed on the anode layer are sensitive to environmental conditions (e.g., moisture and oxygen). This sensitivity of the metallic materials and the costs associated with purifying battery-grade metallic materials contribute to the manufacturing costs of battery cells, as the manufacturing process of the battery cell must consider the procurement, storage, and handling of the metallic materials. Preferably, the anode is formed without lithium, and the lithium metal that forms the anode active material is generated from the lithium initially disposed in the cathode upon the first charge of the cell.

[0005] Therefore, there remains a need to provide improved anode assemblies for battery cells. Summary of the Invention [Means for solving the problem]

[0006] In one aspect, the present invention provides an anode assembly for a battery cell. The anode assembly includes a separator layer, an anode layer, a deposition layer, and an anode current collector. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer and a second surface facing away from the separator layer. The anode layer includes a solid-state electrolyte (SSE) material having micropores. The deposition layer is at least partially disposed on the second surface of the anode layer. The deposition layer includes at least one of a conductive material and a nucleation material. The anode current collector is bonded to the deposition layer.

[0007] In some embodiments, the deposition layer includes at least one of a conductive layer and a nucleation layer. The conductive layer is at least partially disposed on the second surface of the anode layer and includes a conductive material. The nucleation layer is at least partially disposed on the second surface of the anode layer and includes a nucleation material. The anode current collector is coupled to at least one of the conductive layer and the nucleation layer.

[0008] In some embodiments, the deposition layer comprises a conductive layer, hi other embodiments, the deposition layer comprises a nucleation layer.

[0009] In some embodiments, the deposition layer includes at least one of a conductive layer and a nucleation layer. In some embodiments, the nucleation layer is disposed between the anode layer and the conductive layer. In other embodiments, the conductive layer is disposed between the anode layer and the nucleation layer.

[0010] In some embodiments, the conductive layer is substantially impermeable to liquids, hi other embodiments, the nucleation layer is substantially impermeable to liquids.

[0011] In some embodiments, the anode assembly further includes a sealing layer at least partially disposed on at least one of the conductive layer and the nucleation layer. The sealing layer is substantially impermeable to liquids. In some embodiments, the sealing layer includes a polymer. In some embodiments, the polymer includes polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene-vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof.

[0012] In some embodiments, the sealing layer has a thickness of about 1 μm to about 50 μm. In other embodiments, the sealing layer has a thickness of about 1 μm to about 20 μm. In some embodiments, the sealing layer has a thickness of about 1 μm to about 10 μm. In some embodiments, the sealing layer has a thickness of about 1 μm to about 5 μm.

[0013] In some embodiments, the sealing layer bonds the anode current collector to at least one of the conductive layer and the nucleation layer (e.g., by contacting and bonding the anode current collector to at least one of the conductive layer and the nucleation layer).

[0014] In some embodiments, a conductive tape bonds the anode current collector to at least one of the conductive layer and the nucleation layer.

[0015] In some embodiments, the conductive layer is further defined as a first conductive layer, and the anode assembly further includes a second conductive layer disposed at least partially on the first conductive layer and comprising a conductive material.

[0016] In some embodiments, the conductive material of the conductive layer comprises a metal, a metal oxide, a metal alloy, carbon black, carbon nanotubes, graphite, graphene, amorphous carbon, or any combination thereof. In other embodiments, the conductive layer is substantially free of metals or metal alloys that react with or form alloys with lithium metal at room temperature. Also, in some embodiments, the conductive material of the conductive layer comprises copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof.

[0017] In some embodiments, the conductive layer has a thickness of about 1 nm to about 15 μm. In other embodiments, the conductive layer has a thickness of about 1 nm to about 1 μm. In some embodiments, the conductive layer has a thickness of about 1 nm to about 500 nm. In some embodiments, the conductive layer has a thickness of about 1 nm to about 100 nm.

[0018] In some embodiments, the nucleation material of the nucleation layer comprises silver, gold, aluminum, bismuth, antimony, indium, zinc, gallium, nickel oxide, titanium oxide, copper oxide, zinc oxide, graphene, graphite, carbon black, or any combination thereof.

[0019] In some embodiments, the nucleation layer has a thickness of about 1 nm to about 1 μm. In other embodiments, the nucleation layer has a thickness of about 1 nm to about 500 nm. In some embodiments, the nucleation layer has a thickness of about 1 nm to about 100 nm. In some embodiments, the nucleation layer has a thickness of about 1 nm to about 50 nm.

[0020] In some embodiments, the separator layer is substantially pore-free. In some embodiments, the separator layer comprises an SSE material. In some embodiments, the SSE material of the separator layer comprises a polymer, a sulfide, an oxide, a chalcogenide, or any combination thereof.

[0021] In some embodiments, the separator layer has a thickness of about 1 μm to about 300 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 200 μm. In other embodiments, the separator layer has a thickness of about 1 μm to about 100 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 50 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 20 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 10 μm.

[0022] In some embodiments, the pores of the anode layer are substantially free of lithium material (eg, lithium metal).

[0023] In some embodiments, the anode layer defines a first porous region and a second porous region, the first porous region being defined between a first surface and a second surface of the anode layer, and the second porous region being defined between the first porous region and the second surface of the anode layer.

[0024] In some embodiments, the pores of the first porous region are substantially free of metallic materials, while in other embodiments, the pores of the first porous region are substantially free of lithium materials (e.g., lithium metal).

[0025] In some embodiments, at least some of the pores of the second porous region comprise a conductive material, a nucleation material, or any combination thereof. In some embodiments, the conductive material of the second porous region comprises a metal, a metal oxide, a metal alloy, carbon black, carbon nanotubes, graphite, graphene, amorphous carbon, or any combination thereof. Also, in some embodiments, the nucleation material of the second porous region comprises silver, gold, aluminum, bismuth, antimony, indium, zinc, gallium, nickel oxide, titanium oxide, copper oxide, zinc oxide, graphene, graphite, carbon black, or any combination thereof.

[0026] In some embodiments, the anode layer has a thickness of about 1 μm to about 500 μm. In some embodiments, the anode layer has a thickness of about 1 μm to about 200 μm. In other embodiments, the anode layer has a thickness of about 1 μm to about 100 μm. In some embodiments, the anode layer has a thickness of about 1 μm to about 50 μm. In some embodiments, the anode layer has a thickness of about 1 μm to about 20 μm.

[0027] In some embodiments, the anode current collector comprises a metal foil. In other embodiments, the metal foil comprises copper, nickel, titanium, alloys thereof, or any combination thereof. Also, in some embodiments, the metal foil has a tab configured for connection to an external circuit.

[0028] In some embodiments, the anode current collector has a tab configured for connection to an external circuit.

[0029] In some embodiments, the deposition layer comprises a conductive material. In other embodiments, the deposition layer comprises a nucleation material. Furthermore, in some embodiments, the deposition layer comprises a conductive material and a nucleation material.

[0030] In some embodiments, the conductive material of the deposited layer comprises a metal, a metal oxide, a metal alloy, carbon black, carbon nanotubes, graphite, graphene, amorphous carbon, or any combination thereof. In other embodiments, the deposited layer is substantially free of metals or metal alloys that react with or form alloys with lithium metal at room temperature. Also, in some embodiments, the conductive material of the deposited layer comprises copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof.

[0031] In some embodiments, the nucleation material of the deposition layer comprises silver, gold, aluminum, bismuth, antimony, indium, zinc, gallium, nickel oxide, titanium oxide, copper oxide, zinc oxide, graphene, graphite, carbon black, or any combination thereof.

[0032] In some embodiments, the deposition layer has a thickness of about 1 nm to about 20 μm. In other embodiments, the deposition layer has a thickness of about 1 nm to about 5 μm. In some embodiments, the deposition layer has a thickness of about 1 nm to about 1 μm. In some embodiments, the deposition layer has a thickness of about 1 nm to about 100 nm.

[0033] In some embodiments, the deposited layer is substantially impermeable to liquids.

[0034] In some embodiments, the anode assembly further includes a sealing layer disposed at least partially on the deposition layer. The sealing layer is substantially impermeable to liquids. In some embodiments, the sealing layer includes a polymer. In other embodiments, the polymer includes polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof.

[0035] In some embodiments, the sealing layer has a thickness of about 1 μm to about 50 μm. In other embodiments, the sealing layer has a thickness of about 1 μm to about 20 μm. In some embodiments, the sealing layer has a thickness of about 1 μm to about 10 μm. In some embodiments, the sealing layer has a thickness of about 1 μm to about 5 μm.

[0036] In some embodiments, the seal layer bonds the anode current collector to the deposition layer (eg, by contacting and bonding the anode current collector to the deposition layer).

[0037] In some embodiments, a conductive tape bonds the anode current collector to the deposited layer.

[0038] In another aspect, the present invention provides a battery cell. The battery cell includes an anode assembly described herein and a cathode assembly. The cathode assembly includes a cathode layer and a cathode current collector. The cathode layer is at least partially disposed on a separator layer of the anode assembly. The cathode current collector is bonded to the cathode layer.

[0039] In some embodiments, the battery cell further comprises a liquid comprising an electrolyte, an anolyte, a catholyte, or any combination thereof, while in other embodiments, the liquid comprises a lithium salt, a linear carbonate, a cyclic carbonate, an ionic liquid, or any combination thereof.

[0040] In another aspect, the present invention provides a method of forming the anode assembly described herein.

[0041] The following figures are illustrative and do not limit the scope of the claimed invention. [Brief explanation of the drawings]

[0042] [Figure 1A] FIG. 1 is a cross-sectional view illustrating a first exemplary embodiment of an anode assembly for a battery cell.

[0043] [Figure 1B] 1B is a cross-sectional view illustrating an exemplary embodiment of a multi-layer anode assembly including two anode assemblies shown in FIG. 1A, the anode assemblies sharing a common anode current collector.

[0044] [Figure 1C] FIG. 1B is a front view of the anode assembly shown in FIG. 1A.

[0045] [Figure 2]FIG. 2 is a cross-sectional view illustrating a second exemplary embodiment of an anode assembly for a battery cell.

[0046] [Figure 3A] FIG. 10 is a cross-sectional view illustrating a third exemplary embodiment of an anode assembly for a battery cell.

[0047] [Figure 3B] 3B is a cross-sectional view of an exemplary embodiment of a multi-layer anode assembly including two anode assemblies shown in FIG. 3A, the anode assemblies sharing a common seal layer.

[0048] [Figure 3C] FIG. 3B is a front view of the anode assembly shown in FIG. 3A.

[0049] [Figure 4A] FIG. 10 is a cross-sectional view illustrating a fourth exemplary embodiment of an anode assembly for a battery cell.

[0050] [Figure 4B] 4B is a cross-sectional view of an exemplary embodiment of a multi-layer anode assembly including two anode assemblies shown in FIG. 4A, the anode assemblies sharing a common anode current collector.

[0051] [Figure 4C] FIG. 4B is a front view of the anode assembly shown in FIG. 4A.

[0052] [Figure 5A] FIG. 10 is a cross-sectional view illustrating a fifth exemplary embodiment of an anode assembly for a battery cell.

[0053] [Figure 5B] 5B is a cross-sectional view illustrating an exemplary embodiment of a multi-layer anode assembly that includes two anode assemblies shown in FIG. 5A, the anode assemblies sharing a common barrier film.

[0054] [Figure 5C] FIG. 5B is a front view of the anode assembly of FIG. 5A.

[0055] [Figure 6A] FIG. 10 is a cross-sectional view illustrating a sixth exemplary embodiment of an anode assembly for a battery cell.

[0056] [Figure 6B] 6B is a cross-sectional view of an exemplary embodiment of a multi-layer anode assembly including two anode assemblies shown in FIG. 6A, which share a common sealing layer.

[0057] [Figure 6C] FIG. 6B is a front view of the node assembly shown in FIG. 6A.

[0058] [Figure 7A] FIG. 10 is a cross-sectional view illustrating a seventh exemplary embodiment of an anode assembly for a battery cell.

[0059] [Figure 7B] 7B is a cross-sectional view of an exemplary embodiment of a multi-layer anode assembly including two anode assemblies shown in FIG. 7A, the anode assemblies sharing a common deposition layer.

[0060] [Figure 7C] FIG. 7B is a front view of the anode assembly shown in FIG. 7A.

[0061] [Figure 8A] FIG. 10 is a cross-sectional view illustrating an eighth exemplary embodiment of an anode assembly for a battery cell.

[0062] [Figure 8B] 8B is a cross-sectional view illustrating an exemplary embodiment of a multi-layer anode assembly comprising two anode assemblies shown in FIG. 8A, which share a common conductive layer and anode current collector.

[0063] [Figure 8C] FIG. 8B is a front view of the anode assembly of FIG. 8A.

[0064] [Figure 9A] FIG. 13 is a cross-sectional view illustrating a ninth exemplary embodiment of an anode assembly for a battery cell.

[0065] [Figure 9B] 9B is a cross-sectional view illustrating an exemplary embodiment of a multi-layer anode assembly including two anode assemblies shown in FIG. 9A, the anode assemblies sharing a common anode current collector.

[0066] [Figure 9C] FIG. 9B is a front view of the anode assembly shown in FIG. 9A.

[0067] [Figure 10A] FIG. 19 is a cross-sectional view illustrating a tenth exemplary embodiment of an anode assembly for a battery cell.

[0068] [Figure 10B] 10B is a cross-sectional view of an exemplary embodiment of a multi-layer anode assembly including two anode assemblies shown in FIG. 10A, the anode assemblies sharing a common anode current collector.

[0069] [Figure 10C] FIG. 10B is a front view of the anode assembly shown in FIG. 10A.

[0070] [Figure 11A] FIG. 19 is a cross-sectional view illustrating a tenth exemplary embodiment of an anode assembly for a battery cell.

[0071] [Figure 11B] 11B is a cross-sectional view of an exemplary embodiment of a multi-layer anode assembly comprising two anode assemblies shown in FIG. 11A, which share a common barrier film.

[0072] [Figure 11C] FIG. 11B is a front view of the anode assembly shown in FIG. 11A.

[0073] [Figure 12] 3 is a flowchart of a method of forming an anode assembly according to one embodiment of the present invention.

[0074] [Figure 13A] 1 is a scanning electron microscope (SEM) image showing a cross section of an anode assembly according to Example 1, illustrating the anode layer of the anode assembly.

[0075] [Figure 13B] 13B is a black and white corrected energy dispersive X-ray (EDX)-SEM image showing a cross section of the anode assembly shown in FIG. 13A, showing the nickel layer disposed on the anode layer.

[0076] [Figure 13C] 13B is a black and white corrected EDX-SEM image showing a cross section of the anode assembly shown in FIG. 13A, showing the silver layer disposed on the anode layer.

[0077] [Figure 13D] 13B is another SEM image showing a cross section of the anode assembly shown in FIG. 13A, illustrating the anode layer and separator layer of the anode assembly.

[0078] [Figure 13E] FIG. 13E is a black and white corrected EDX-SEM image showing a cross section of the anode assembly shown in FIG. 13D, showing the nickel layer.

[0079] [Figure 13F] FIG. 13E is a black and white corrected EDX-SEM image showing a cross section of the anode assembly shown in FIG. 13D, with the silver layer shown.

[0080] [Figure 14A]1 is another SEM image showing a cross section of an anode assembly according to Example 1, showing the anode layer of the anode assembly.

[0081] [Figure 14B] FIG. 14B is a black and white corrected EDX-SEM image showing a cross section of the anode assembly shown in FIG. 14A, showing the nickel layer.

[0082] [Figure 14C] FIG. 14B is a black and white corrected EDX-SEM image showing a cross section of the anode assembly shown in FIG. 14A, with the silver layer shown.

[0083] [Figure 15A] 1 is a graph of voltage (V) versus capacity (mAh / cm2) for the half-cell of Example 1.

[0084] [Figure 15B] FIG. 15B is an enlarged view of the graph shown in FIG. 15A.

[0085] [Figure 15C] 1 is a plot showing electrochemical impedance spectroscopy (EIS) profiles in the frequency range of 2 MHz to 1 Hz for the half-cell of Example 1 after 8 hours under a cathodic current density of 20 μA / cm 2 .

[0086] [Figure 16A] 1 is a graph of voltage (V) versus capacity (mAh / cm2) for the battery cell of Example 2 during the first charge-discharge cycle at 180 μA / cm2.

[0087] [Figure 16B] FIG. 16B is an enlarged view of the graph shown in FIG. 16A.

[0088] [Figure 16C]10 is a plot showing EIS profiles in the frequency range of 10 kHz to 0.1 Hz for the battery cell of Example 2 after a first cycle charge at 180 μA / cm for 12 hours.

[0089] [Figure 17A] 1 is a scanning electron microscope (SEM) image showing a cross section of an anode assembly according to Example 3, illustrating the anode layer and separator layer of the anode assembly.

[0090] [Figure 17B] 17B is a black and white corrected EDX-SEM image showing a cross section of the anode assembly shown in FIG. 17A, showing an indium layer disposed on the anode layer.

[0091] [Figure 17C] 17B is a black and white corrected EDX-SEM image showing a cross section of the anode assembly shown in FIG. 17A, showing a copper layer disposed on the anode layer.

[0092] [Figure 18A] 1 is another SEM image showing a cross section of an anode assembly according to Example 1, showing the anode layer of the anode assembly.

[0093] [Figure 18B] 18B is a black and white corrected EDX-SEM image showing a cross section of the anode assembly shown in FIG. 18A, with the indium layer shown.

[0094] [Figure 18C] FIG. 18B is a black and white corrected EDX-SEM image showing a cross section of the anode assembly shown in FIG. 18A, with the copper layer shown.

[0095] [Figure 19] 1 is a plot of voltage versus time for the test cell of Example 4.

[0096] [Figure 20] 1 is a plot of voltage versus time for the test cell of Example 5. DETAILED DESCRIPTION OF THE INVENTION

[0097] Like reference numbers refer to like elements in each figure, for example, a separator layer may be designated as 102 in Figures 1A-1C and 202 in Figure 2.

[0098] The present invention provides an anode assembly for a battery cell, a battery cell including the anode assembly, a method for forming the anode assembly, and a multi-layer anode assembly.

[0099] As used herein, the following definitions shall apply unless otherwise stated.

[0100] I. Definition

[0101] The terminology used herein is used only for the purpose of describing particular exemplary configurations and is not intended to be limiting. As used herein, the singular articles "a," "an," and "the" may be intended to include the plural unless the context clearly dictates otherwise. The terms "comprises," "comprising," "including," and "having" are inclusive and thus specify the presence of features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein should not be construed as necessarily requiring their performance in the particular order described or illustrated, unless specifically stated as an order of performance. Additional or alternative steps may be employed.

[0102] Terms such as "first," "second," and "third" may be used herein to describe various elements, components, regions, layers, and / or sections. These elements, components, regions, layers, and / or sections should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or section from another region, layer, or section. Terms such as "first," "second," and other numerical terms do not imply an order or sequence unless clearly indicated by context. Thus, a first element, component, region, layer, or section described below could be referred to as a second element, component, region, layer, or section without departing from the teachings of the illustrated configuration.

[0103] As used herein, when an element is described as being "on," "engaged to," "connected," "attached," or "coupled" to another element, the element may be directly on, engaged with, connected to, attached to, or coupled to the other element, or there may be intervening elements. Conversely, when an element is described as being "directly abutting," "directly engaged," "directly connected," "directly attached," or "directly coupled" to another element, this means that there are no intervening elements or layers present. Other terms used to describe relationships between elements should be interpreted similarly (e.g., "between" and "directly between," "adjacent" and "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0104] As used herein, the term "battery cell" refers to a rechargeable secondary battery. In some embodiments, the battery cell may be a solid-state lithium-ion battery cell.

[0105] As used herein, the term "anode assembly" refers to an assembly comprising a separator layer, an anode layer, a stack layer, and an anode current collector.

[0106] As used herein, the term "separator layer" refers to a layer disposed between an anode layer and a cathode layer in a battery cell, allowing cations (e.g., lithium cations) to flow between the anode layer and the cathode layer. In some embodiments, the separator layer is substantially free of pores (e.g., having an apparent porosity of less than 50%, less than 40%, less than 30%, less than 20%, less than 15%, less than 10%, less than 5%, or less than 1%). In some embodiments, the separator layer is completely free of pores.

[0107] As used herein, the term "anode layer" refers to a negative electrode layer through which electrons flow during the discharge phase of a battery cell. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer and a second surface facing away from the separator layer. The anode layer includes a porous solid electrolyte (SSE) material.

[0108] As used herein, the term "bilayer" refers to an anode layer disposed on a separator layer.

[0109] As used herein, the term "deposition layer" refers to a layer at least partially disposed on the second surface of the anode layer. The deposition layer includes at least one of a conductive material and a nucleation material. In some embodiments, the deposition layer facilitates electronic conduction. In some embodiments, the deposition layer electrochemically alloys and / or reacts with a metallic material (e.g., lithium metal) at room temperature. Also, in some embodiments, the deposition layer includes at least one of a conductive layer and a nucleation layer.

[0110] As used herein, the term "conductive layer" refers to a layer that facilitates electronic conduction. The conductive layer is at least partially disposed on the second surface of the anode layer. The conductive layer comprises a conductive material. In some embodiments, the conductive layer serves as a substrate for metal plating during operation (e.g., charging) of the battery cell.

[0111] As used herein, the term "conductive material" refers to a material that facilitates electronic conduction. The conductive material may be any material suitable for facilitating electronic conduction. In some embodiments, the conductive material comprises a metal, a metal oxide, a metal alloy, carbon black, carbon nanotubes, graphite, graphene, amorphous carbon, or any combination thereof. Also, in some embodiments, the conductive material comprises copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof.

[0112] As used herein, the term "nucleation layer" refers to a layer that electrochemically alloys and / or reacts with a metallic material (e.g., lithium metal) at room temperature. The nucleation layer is at least partially disposed on the second surface of the anode layer. The nucleation layer comprises a nucleation material.

[0113] As used herein, the term "nucleating material" refers to a material that electrochemically alloys and / or reacts with a metallic material (e.g., lithium metal) at room temperature. The nucleating material may be any material suitable for alloying and / or reacting with a metallic material. In some embodiments, the nucleating material comprises silver, gold, aluminum, bismuth, antimony, indium, zinc, gallium, nickel oxide, titanium oxide, copper oxide, zinc oxide, graphene, graphite, carbon black, or any combination thereof.

[0114] As used herein, the term "anode current collector" refers to a current collector coupled to a deposition layer (e.g., a conductive layer and / or a nucleation layer). The anode current collector is configured to electrically couple to the deposition layer during operation of the battery cell (e.g., during charging and / or discharging of the battery cell). In some embodiments, the anode current collector comprises a metal foil. In other embodiments, the anode current collector comprises a tab configured to connect to an external circuit.

[0115] As used herein, the term "cathode assembly" refers to an assembly consisting of a cathode layer and a cathode current collector.

[0116] As used herein, the term "cathode layer" refers to the positive electrode layer into which electrons flow during the discharge phase of a battery cell.

[0117] As used herein, the term "cathode current collector" refers to a current collector coupled to a cathode layer. The cathode current collector is configured to be electrically coupled to the cathode layer during operation of the battery cell (e.g., during charging and / or discharging of the battery cell). In some embodiments, the cathode current collector comprises a metal foil. In other embodiments, the cathode current collector has a tab configured to connect to an external circuit.

[0118] As used herein, the term "apparent porosity" refers to open (or accessible) porosity (i.e., porosity excluding the volume of closed or enclosed pores, cells, or voids). Apparent porosity can be expressed as the fraction or percentage of the total volume that is accounted for by the volume of open pores, cells, or voids.

[0119] II. Anode Assembly

[0120] In one aspect, the present invention provides an anode assembly for a battery cell.

[0121] As shown in FIGS. 1A and 1C, the anode assembly 100 includes a separator layer 102, an anode layer 104, a stack layer 106, and an anode current collector 108.

[0122] A. Separator layer

[0123] The separator layer may include any suitable material that allows cations (e.g., lithium cations) to flow between the anode layer and the cathode layer during operation (e.g., charging and / or discharging) of the battery cell. In some embodiments, the separator layer includes a solid-state electrolyte (SSE) material. For example, the SSE material of the separator layer may include a polymer, a sulfide, an oxide, a chalcogenide, or any combination thereof. For example, the SSE material may include a sulfide. In some embodiments, the SSE material includes LSS, LTS, LXPS, LXPSO, LATS, lithium garnet, or any combination thereof, where X is Si, Ge, Sn, As, Al, or any combination thereof; S is S, Si, or any combination thereof; and T is Sn.

[0124] As used herein, "LSS" refers to lithium silicon sulfide, which can be described as Li2S-SiS2, Li-SiS2, Li-S-Si, or an SSE material containing Li, S, and Si. In some embodiments, LSS is Li x Si y S z where 0.33≦x≦0.5, 0.1≦y≦0.2, and 0.4≦z≦0.55. In some embodiments, the LSS may include up to 10 atomic % oxygen. In other embodiments, the LSS may include an SSE material including Li, Si, and S. In some embodiments, the LSS includes a mixture of Li2S and SiS2. In some embodiments, the molar ratio of Li2S:SiS2 is 90:10, 85:15, 80:20, 75:25, 70:30, 2:1, 65:35, 60:40, 55:45, or 50:50. In some embodiments, the LSS includes a mixture of Li x POy , Li x BO y , Li4SiO4, Li3MO4, Li3MO3, PS, and / or lithium halides, including but not limited to LiI, LiCl, LiF, or LiBr, where 0 <x≦5かつ0<y≦5である。

[0125] As used herein, "LTS" refers to a lithium tin sulfide compound, which can be described as Li2S-SnS2, Li2S-SnS, Li-S-Sn, or an SSE material containing Li, S, and Sn. In some embodiments, LTS is Li x Sn y S z (0.25≦x≦0.65, 0.05≦y≦0.2, and 0.25≦z≦0.65). In some embodiments, the LTS may comprise a mixture of LiS and SnS in a molar ratio of 80:20, 75:25, 70:30, 2:1, or 1:1 (i.e., LiS:SnS). In some embodiments, the LTS may comprise up to 10 atomic % oxygen. In other embodiments, the LTS may be doped with Bi, Sb, As, P, B, Al, Ge, Ga, In, or any combination thereof. As used herein, "LATS" refers to LTS as used above, further including arsenic (As).

[0126] As used herein, "LXPS" refers to a compound of formula Li a MP b S c "LSPS" refers to a material characterized by the formula L a SiP b S c (2≦a≦8, 0.5≦b≦2.5, 4≦c≦12)

[0127] When M is Sn and Si (i.e., when both Sn and Si are present), the LXPS material is referred to as an "LSTPS." As used herein, "LSTPSO" refers to an LSTPS that is doped with, has O, or has O present. In some embodiments, "LSTPSO" refers to an LSTPS material having an oxygen content of 0.01 to 10 atomic %. As used herein, "LSPS" refers to an electrolyte material having chemical components of Li, Si, P, and S. As used herein, "LSTPS" refers to an electrolyte material having chemical components of Li, Si, P, Sn, and S. As used herein, "LSPSO" refers to an LSPS that is doped with, has O, or has O present. In some embodiments, "LSPSO" refers to an LSPS material having an oxygen content of 0.01 to 10 atomic %. As used herein, "LATP" refers to an electrolyte material having chemical components of Li, As, Sn, and P. As used herein, "LAGP" refers to an electrolyte material having a chemical composition of Li, As, Ge, and P. As used herein, "LXPSO" refers to an electrolyte material having a chemical composition of Li, As, Ge, and P. a MP b S c O d where M is Si, Ge, Sn, Al, or any combination thereof, and 2≦a≦8, 0.5≦b≦2.5, 4≦c≦12, and d<3. LXPSO refers to LXPS as defined above, having 0.1 to about 10 atomic % oxygen doping. As used herein, "LPS" refers to an electrolyte material comprising Li2S-P2S5. As used herein, "LPSO" refers to LPS as defined herein, further including 0.1 to about 10 atomic % oxygen doping.

[0128] In some embodiments, the SSE material of the separator layer comprises a polymer. For example, the polymer may include polyolefin, natural rubber, synthetic rubber, polybutadiene, polyisoprene, epoxidized natural rubber, polyisobutylene, polypropylene oxide, polyacrylate, polymethacrylate, polyester, polyvinyl ester, polyurethane, styrenic polymer, epoxy resin, epoxy polymer, poly(bisphenol A-co-epichlorohydrin), vinyl polymer, polyvinyl halide, polyvinyl alcohol, polyethyleneimine, poly(maleic anhydride), silicone polymer, siloxane polymer, polyacrylonitrile, polyacrylamide, polychloroprene, polyvinylidene fluoride, polyvinylpyrrolidone, polyepichlorohydrin, mixtures thereof, or copolymers thereof. In some embodiments, the polymer is a polyolefin. In some embodiments, the polymer is natural rubber. In some embodiments, the polymer is synthetic rubber. In some embodiments, the polymer is polybutadiene. In some embodiments, the polymer is polyisoprene. In some embodiments, the polymer is epoxidized natural rubber. In other embodiments, the polymer is polyisobutylene. In some embodiments, the polymer is polypropylene oxide. In some embodiments, the polymer is polyacrylate. In some embodiments, the polymer is polymethacrylate. In some embodiments, the polymer is polyester. In other embodiments, the polymer is polyvinyl ester. In some embodiments, the polymer is polyurethane. In some embodiments, the polymer is a styrene-based polymer. In some embodiments, the polymer is an epoxy resin. In some embodiments, the polymer is an epoxy polymer. In some embodiments, the polymer is poly(bisphenol A-co-epichlorohydrin). In some embodiments, the polymer is a vinyl polymer. In some embodiments, the polymer is polyvinyl halide. In some embodiments, the polymer is polyvinyl alcohol. In some embodiments, the polymer is polyethyleneimine. In other embodiments, the polymer is poly(maleic anhydride). In some embodiments, the polymer is a silicone polymer.In some embodiments, the polymer is a siloxane polymer. In some embodiments, the polymer is polyacrylonitrile. In some embodiments, the polymer is polyacrylamide. In some embodiments, the polymer is polychloroprene. In some embodiments, the polymer is polyvinylidene fluoride. In some embodiments, the polymer is polyvinylpyrrolidone. In some embodiments, the polymer is polyepichlorohydrin. In some embodiments, the molecular weight of the polymer is greater than about 50,000 g / mol.

[0129] In some embodiments, the polymer is preformed and is selected from the group consisting of polypropylene, polyethylene, polybutadiene, polyisoprene, epoxidized natural rubber, poly(butadiene-co-acrylonitrile), polyethyleneimine, polydimethylsiloxane, and poly(ethylene-co-vinyl acetate). In other embodiments, the molecular weight of the polymer is greater than about 50,000 g / mol.

[0130] When the SSE material includes a polymer, the SSE material may further include a metal salt (eg, a lithium salt (eg, LiPF6)).

[0131] In some embodiments, the SSE material of the separator layer is a lithium perovskite material, LiN, Li-β-alumina, lithium superionic conductor (LISICON), Li 2.88 PO 3.86 N 0.14 (LiPON), Li9AlSiO8, Li 10 GeP2S 12 , a lithium garnet SSE material, a doped lithium garnet SSE material, a lithium garnet composite material, or any combination thereof. In various embodiments, the lithium garnet SSE material is a cation-doped Li5La3M 1 2O 12 (M 1 is Nb, Zr, Ta, or any combination thereof), cation-doped Li6La2BaTa2O 12 , cation-doped Li7La3Zr2O12 , and cation-doped Li6BaY2M 1 2O 12 where the cation dopant is barium, yttrium, zinc, or any combination thereof. In various other embodiments, the lithium garnet SSE material is Li5La3Nb2O 12 , Li5La3Ta2O 12 , Li7La3Zr2O 12 , Li6La2SrNb2O 12 , Li6La2BaNb2O 12 , Li6La2SrTa2O 12 , Li6La2BaTa2O 12 , Li7Y3Zr2O 12 , Li 6.4 Y3Zr 1.4 Ta 0.6 O 12 , Li 6.5 La 2.5 Ba 0.5 TaZrO 12 , Li6BaY2M 1 2O 12 , Li7Y3Zr2O 12 , Li 6.75 BaLa2Nb 1.75 Zn 0.25 O 12 , Li 6.75 BaLa2Ta 1.75 Zn 0.25 O 12 , or any combination thereof.

[0132] In some embodiments, the SSE material of the separator layer and the SSE material of the anode layer are the same (e.g., the SSE material of the separator layer can be any SSE material described herein for the anode layer), while in other embodiments, the SSE material of the separator layer and the SSE material of the separator layer are different.

[0133] In some embodiments, the separator layer is substantially free of pores (e.g., having an apparent porosity of less than 50%, having an apparent porosity of less than 40%, having an apparent porosity of less than 30%, having an apparent porosity of less than 20%, having an apparent porosity of less than 15%, having an apparent porosity of less than 10%, having an apparent porosity of less than 5%, or having an apparent porosity of less than 1%). Also, in some embodiments, the separator layer is free of pores.

[0134] In some embodiments, the separator layer has a thickness of about 1 μm to about 300 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 200 μm. In other embodiments, the separator layer has a thickness of about 1 μm to about 100 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 50 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 20 μm. In some embodiments, the separator layer has a thickness of about 1 μm to about 10 μm.

[0135] B. Anode layer

[0136] Referring again to FIG. 1A , the anode layer is at least partially disposed on the separator layer. The anode layer has a first surface 110 and a second surface 112. The first surface faces the separator layer, and the second surface faces away from the separator layer. The anode layer comprises a porous SSE material. In some embodiments, the anode layer is disposed on the entire surface of the separator layer. In other embodiments, the anode layer is disposed on only a portion of the surface of the separator layer. The anode layer has an outer surface 114 extending from the first surface to the second surface.

[0137] In some embodiments, the anode layer has an apparent porosity of about 20% to about 80%. In other embodiments, the anode layer has an apparent porosity of about 35% to about 75%. In some embodiments, the anode layer has an apparent porosity of about 45% to about 65%. In some embodiments, the anode layer has an apparent porosity of about 50% to about 60%. In some embodiments, the anode layer has an apparent porosity of about 60% to about 80%. In some embodiments, the anode layer has an apparent porosity of about 20% to about 95%. In some embodiments, the anode layer has an apparent porosity of about 50% to about 90%.

[0138] In some embodiments, the SSE material of the anode layer and the SSE material of the separator layer are the same. In other embodiments, the SSE material of the anode layer and the SSE material of the separator layer are different. In some embodiments, the SSE material comprises a lithium conductor, a sodium conductor, or a magnesium conductor. In some embodiments, the SSE material comprises a lithium conductor. In other embodiments, the SSE material comprises a sodium conductor. In some embodiments, the SSE material comprises a magnesium conductor.

[0139] In some embodiments, the SSE material of the anode layer can include a garnet material. Non-limiting examples of garnet materials include lithium garnet materials, doped lithium garnet materials, lithium garnet composite materials, and combinations thereof. Non-limiting examples of lithium garnet materials include Li3-phase lithium garnet SSE materials (e.g., Li3M 1 Te2O 12 , where M 1 is a lanthanide such as Y, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Zr, Ta, or a combination thereof, and Li 3+x Nd3Te 2-x O 12 , where x is 0.05 to 1.5, Li5 phase lithium garnet SSE materials (e.g., Li5La3M 2 2O 12 , where M 2is Nb, Zr, Ta, Sb, or a combination thereof, cation-substituted Li5La3M 2 2O 12 , e.g. Li6M 1 La3M 2 2O 12 , where M 1 is Mg, Ca, Sr, Ba, or a combination thereof, and Li7La3M 2 2O 12 , where M 2 Zr, Sn, or a combination thereof), Li6 phase lithium garnet SSE materials (e.g., Li6M 1 La2M 2 2O 12 , where M 1 is Mg, Ca, Sr, Ba, or a combination thereof, and M 2 is Nb, Ta, or a combination thereof), cation-doped Li6La2BaTa2O 12 , cation-doped Li6BaY2M 2 2O 12 , where M 2 is Nb, Ta, or a combination thereof, and the cation dopant is barium, yttrium, zinc, or a combination thereof, Li7 phase lithium garnet SSE materials (e.g., cubic Li7La3Zr2O 12 and Li7Y3Zr2O 12 ), cation-doped Li7La3Zr2O 12 , Li 5+2x La3, Ta 2-x O2, where x is 0.1 to 1, Li 6.8 (La 2.95 , Ca 0.5 )(Zr 1.75 , Nb 0.25 )O 12 (LLCZN), Li 6.4 Y3Zr 1.4 Ta 0.6 O 12 , Li 6.5 La 2.5 Ba 0.5 TaZrO 12 , Li6BaY2M 1 2O 12 , Li7Y3Zr2O 12, Li 6.75 BaLa2Nb 1.75 Zn 0.25 O 12 , or Li 6.75 BaLa2Ta 1.75 Zn 0.25 O 12 ), lithium garnet composites (e.g., lithium garnet composites with a conductive carbon matrix or other materials). Other examples of lithium ion conducting SSE materials include 3 mol% YSZ doped Li 7.6 La3Zr 1.94 Y 0.06 O 12 and 8mol% YSZ-doped Li 7.16 La3Zr 1.94 Y 0.06 O 12 Further examples of suitable lithium garnet SSE materials include cubic garnet-type materials such as Li5La3Nb2O 12 , Li5La3Ta2O 12 , Li7La3Zr2O 12 , Li6La2SrNb2O 12 , Li6La2BaNb2O 12 , Li6La2SrTa2O 12 , Li6La2BaTa2O 12 , Li7Y3Zr2O 12 , Li 6.4 Y3Zr 1.4 Ta 0.6 O 12 , Li 6.5 La 2.5 Ba 0.5 TaZrO 12 , Li7Y3Zr2O 12 , Li 6.75 BaLa2Nb 1.75 Zn 0.25 O 12 , or Li 6.75 BaLa2Ta 1.75 Zn 0.25 O 12 In some embodiments, the garnet material may be, for example, Li 7-x La 3-y M 1 y Zr 2-zM 2 z O 12 where x is greater than 0 and less than 2, and M 1 is selected from Ba, Ca, Y, and combinations thereof; M 2 is selected from Nb, Ta, and combinations thereof. In some embodiments, the garnet material is 6.75 La3Zr 1.75 Ta 0.25 O 12 (LLZT), Li 6.75 La 2.75 Zr 1.75 Ca 0.25 Nb 0.25 O 12 (LLZCN), Li5La3Nb2O 12 (LLZNO), Li7La3Zr2O 12 (LLZ), Li5La3Ta2O 12 , Li6La2SrNb2O 12 , Li6La2BaNb2O 12 , Li6La2SrTa2O 12 , Li6La2BaTa2O 12 , Li7Y3Zr2O 12 , Li 6.4 Y3Zr 1.4 Ta 0.6 O 12 , Li 6.5 La 2.5 Ba 0.5 TaZrO 12 , Li6BaY2M 1 2O 12 , Li 6.75 BaLa2Nb 1.75 Zn 0.25 O 12 , Li 6.75 BaLa2Ta 1.75 Zn 0.25 O 12 , or any combination thereof.

[0140] In some embodiments, the garnet material comprises a composition of formula (I): M1 7-x D1 a M2 3-y D2 bM3 2-z D3 c O 12-w D4 d (I) During the ceremony, M1 is Li, M2 is La, M3 is Zr, D1 is H, Be, B, Al, Fe, Zn, Ga, Ge, or any combination thereof; D2 is Na, K, Ca, Rb, Sr, Y, Ag, Ba, Bi, Pr, Nd, Pm, Sm, Gd, Tb, Dy, Ho, Er, Tm, Zn, Ce, or any combination thereof; D3 is Mg, Si, Sc, Ti, V, Cr, Mn, Co, Ni, Cu, Ge, As, Se, Nb, Mo, Tc, Ru, Rh, Pd, Cd, In, Sn, Sb, Hf, Ta, W, Ir, Pt, Au, Hg, Tl, Pb, Ce, Eu, Te, Y, Sr, Ca, Ba, Gd, Ge, or any combination thereof; and D4 is F, Cl, Br, I, S, Se, Te, N, P, or any combination thereof; however, 0≦w≦2, -0.5 <x≦3、 0≦y≦3, 0≦z≦2, 0≦a≦2, 0≦b≦3, 0≦c≦2, and 0≦d≦2, where at least one of a, b, c, and d is greater than 0.

[0141] In some embodiments, the pores of the anode layer are substantially free of metallic material (e.g., the pores contain less than 1%, less than 0.5%, less than 0.25%, less than 0.1%, less than 0.01%, or less than 0.001% metallic material by volume of the pores). In some embodiments, the pores of the anode layer are free of metallic material. In the context of the present disclosure, when the pores of the anode layer are referred to as being "substantially free of" or "free of" metallic material, it will be understood that the pores of the anode layer are substantially free of or free of metallic material prior to operation of the battery cell, i.e., immediately after fabrication of the battery cell and prior to operation of the battery cell (e.g., charging / discharging the battery cell).

[0142] In some embodiments, the metallic material comprises a lithium material, a sodium material, a magnesium material, or any combination thereof. When the metallic material comprises a lithium material, the lithium material comprises lithium metal. In other embodiments, the metallic material comprises lithium metal, sodium metal, magnesium metal, or any combination thereof.

[0143] In some embodiments, the anode layer defines a first porous region 216 and a second porous region 218, as shown in Figure 2. The first porous region is defined between the first and second surfaces 210, 212 of the anode layer. The second porous region is defined between the first porous region and the second surface of the anode layer.

[0144] In some embodiments, the pores of the first porous region are substantially free of metallic material (e.g., prior to operation of the battery cell), which may be any metallic material described herein (e.g., lithium metal).

[0145] In some embodiments, at least some of the pores of the second porous region comprise a conductive material, a nucleation material, or any combination thereof. In other embodiments, at least some of the pores of the second porous region comprise a conductive material. In some embodiments, at least some of the pores of the second porous region comprise a nucleation material. And, in some embodiments, at least some of the pores of the second porous region comprise a conductive material and a nucleation material.

[0146] The conductive material can be any conductive material described herein. For example, the conductive material can include a metal, a metal oxide, a metal alloy, carbon black, carbon nanotubes, graphite, graphene, amorphous carbon, or any combination thereof. In some embodiments, the conductive materials of the second porous region and the deposited layer are the same. In other embodiments, the conductive materials of the second porous region and the deposited layer are different.

[0147] The nucleation material can be any nucleation material described herein. For example, the nucleation material can include silver, gold, aluminum, bismuth, antimony, indium, zinc, gallium, nickel oxide, titanium oxide, copper oxide, zinc oxide, or any combination thereof. In some embodiments, the nucleation materials of the second porous region and the deposition layer are the same. In other embodiments, the nucleation materials of the second porous region and the deposition layer are different.

[0148] In some embodiments, the anode layer has a thickness of about 1 μm to about 500 μm. In some embodiments, the anode layer has a thickness of about 1 μm to about 200 μm. In other embodiments, the anode layer has a thickness of about 1 μm to about 100 μm. In some embodiments, the anode layer has a thickness of about 1 μm to about 50 μm. In some embodiments, the anode layer has a thickness of about 1 μm to about 20 μm.

[0149] C. Sedimentary layer

[0150] A deposition layer is at least partially disposed on the second surface of the anode layer. The deposition layer comprises at least one of a conductive material and a nucleation material. In some embodiments, the deposition layer is disposed over the entire second surface of the anode layer. In some embodiments, the deposition layer is disposed over substantially the entire second surface (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%) of the second surface of the anode layer. In other embodiments, the deposition layer is disposed over only a portion of the anode layer.

[0151] In some embodiments, the deposition layer facilitates electronic conduction. In some embodiments, the deposition layer electrochemically alloys and / or reacts with a metallic material (e.g., lithium metal) at room temperature. In some embodiments, the conductive layer also serves as a substrate for metal plating (e.g., lithium plating) during operation (e.g., charging) of the battery cell.

[0152] In some embodiments, the deposition layer comprises a conductive material. In other embodiments, the deposition layer comprises a nucleation material. In some embodiments, the deposition layer comprises a conductive material and a nucleation material.

[0153] The conductive material facilitates electronic conduction. In some embodiments, the conductive material includes a metal, a metal oxide, a metal alloy, carbon black, carbon nanotubes, graphite, graphene, amorphous carbon, or any combination thereof. Non-limiting examples of metals suitable for the conductive material include copper, nickel, titanium, iron, and combinations thereof. Non-limiting examples of metal oxides suitable for the conductive material include copper oxide, nickel oxide, titanium oxide, iron oxide, and combinations thereof. Non-limiting examples of alloys suitable for the conductive material include copper alloys, nickel alloys, titanium alloys, iron alloys, and combinations thereof.

[0154] In some embodiments, the conductive material comprises carbon black, carbon nanotubes, graphite, graphene, amorphous carbon, or any combination thereof. In some embodiments, the conductive material comprises carbon black. In other embodiments, the conductive material comprises carbon nanotubes. In some embodiments, the conductive material comprises graphite. In some embodiments, the conductive material comprises graphene. In some embodiments, the conductive material comprises amorphous carbon.

[0155] In some embodiments, the conductive material comprises a metal, a metal alloy, or any combination thereof. In some embodiments, the conductive material comprises copper, nickel, titanium, stainless steel, an alloy thereof, or any combination thereof. In some embodiments, the conductive material comprises copper. In some embodiments, the conductive material comprises nickel. In other embodiments, the conductive material comprises titanium. In some embodiments, the conductive material comprises steel. In some embodiments, the conductive material comprises a copper alloy. In some embodiments, the conductive material comprises a nickel alloy. In other embodiments, the conductive material comprises a titanium alloy. In some embodiments, the conductive material comprises a steel alloy.

[0156] In some embodiments, the conductive material is substantially free of, or free of, metals or metal alloys that react with or form alloys with metallic lithium, sodium, or magnesium at room temperature (e.g., the deposited layer contains less than 5%, less than 2.5%, less than 1%, less than 0.5%, less than 0.1%, less than 0.01%, or 0% of such metals or metal alloys by weight of the deposited layer). In other embodiments, the conductive material is substantially free of, metals or metal alloys that react with or form alloys with lithium metal at room temperature. In some embodiments, the conductive material is free of, metals or metal alloys that react with or form alloys with lithium metal at room temperature. In such embodiments, the deposited layer can serve as a substrate for metal plating (e.g., lithium plating) during operation (e.g., charging) of the battery cell.

[0157] The nucleation material is capable of electrochemically alloying and / or reacting with a metallic material (e.g., lithium metal) at room temperature. The nucleation material can be any material suitable for electrochemically alloying and / or reacting with a metallic material (e.g., lithium metal) at room temperature.

[0158] In some embodiments, the nucleation material and the conductive material are the same. In other embodiments, the nucleation material and the conductive material are different.

[0159] In some embodiments, the nucleation material comprises a metal, a metalloid, an oxide thereof, or any combination thereof. In some embodiments, the nucleation material comprises silver, gold, aluminum, bismuth, antimony, indium, zinc, gallium, nickel oxide, titanium oxide, copper oxide, zinc oxide, graphene, graphite, carbon black, or any combination thereof. In some embodiments, the nucleation material comprises gold. In some embodiments, the nucleation material comprises silver. In other embodiments, the nucleation material comprises aluminum. In some embodiments, the nucleation material comprises bismuth. In some embodiments, the nucleation material comprises antimony. In some embodiments, the nucleation material comprises indium. In some embodiments, the nucleation material comprises zinc. In some embodiments, the nucleation material comprises gallium. In some embodiments, the nucleation material comprises nickel oxide. In some embodiments, the nucleation material comprises titanium oxide. In some embodiments, the nucleation material comprises copper oxide. In some embodiments, the nucleation material comprises graphene. In some embodiments, the nucleation material comprises zinc oxide.

[0160] In some embodiments, the deposition layer consists essentially of the conductive material. In other embodiments, the deposition layer consists essentially of the nucleation material. In some embodiments, the deposition layer consists essentially of the conductive material and the nucleation material.

[0161] In some embodiments, the deposition layer comprises a conductive material, in other embodiments, the deposition layer comprises a nucleation material, and in some embodiments, the deposition layer comprises a conductive material and a nucleation material.

[0162] The deposition layer has a first surface 220 facing the anode layer and a second surface 222 facing away from the anode layer, as shown in Figure 2. In some embodiments, the deposition layer defines a first deposition region 224 and a second deposition region 226. The first deposition region is defined between the first and second surfaces of the deposition layer. The second deposition region is defined between the first porous region and the second surface of the deposition layer. In some embodiments, the volume of the first deposition region is the same as the volume of the second deposition region.

[0163] In some embodiments, the amount (e.g., w / w %) of nucleation material present in the first deposition zone is greater than the amount (e.g., w / w %) of nucleation material present in the second deposition zone. In other embodiments, the amount (e.g., w / w %) of nucleation material present in the first deposition zone is less than the amount (e.g., w / w %) of nucleation material present in the second deposition zone.

[0164] In some embodiments, the amount (e.g., w / w %) of conductive material present in the first deposition region is greater than the amount (e.g., w / w %) of conductive material present in the second deposition region. In other embodiments, the amount (e.g., w / w %) of conductive material present in the first deposition region is less than the amount (e.g., w / w %) of conductive material present in the second deposition region.

[0165] In some embodiments, the amount of nucleation material present in the first deposition region (e.g., w / w %) is greater than the amount of conductive material present in the first deposition region (e.g., w / w %). In other embodiments, the amount of nucleation material present in the first deposition region is less than the amount of conductive material present in the first deposition region.

[0166] In some embodiments, the amount (e.g., w / w %) of nucleation material present in the second deposition region is greater than the amount (e.g., w / w %) of conductive material present in the second deposition region. In other embodiments, the amount (e.g., w / w %) of nucleation material present in the second deposition region is less than the amount of conductive material present in the second deposition region.

[0167] In some embodiments, the amount (e.g., w / w %) of nucleation material present in the first deposition region is the same as the amount (e.g., w / w %) of nucleation material present in the second deposition region, while in other embodiments, the amount (e.g., w / w %) of conductive material present in the first deposition region is the same as the amount (e.g., w / w %) of conductive material present in the second deposition region.

[0168] In some embodiments, the amount (e.g., w / w %) of nucleation material present in the first deposition region is the same as the amount (e.g., w / w %) of conductive material present in the first deposition region. In other embodiments, the amount (e.g., w / w %) of nucleation material present in the second deposition region is the same as the amount of conductive material present in the second deposition region.

[0169] In some embodiments, the deposition layer has a thickness of about 1 nm to about 20 μm. In other embodiments, the deposition layer has a thickness of about 1 nm to about 5 μm. In some embodiments, the deposition layer has a thickness of about 1 nm to about 1 μm. In some embodiments, the deposition layer has a thickness of about 1 nm to about 100 nm.

[0170] In some embodiments, the deposition layer is substantially impermeable to liquids. In the context of the present disclosure, the term "substantially impermeable" means that the corresponding component (e.g., the deposition layer) is resistant to penetration by liquids. In other words, liquids cannot pass freely through the corresponding component (e.g., the deposition layer).

[0171] In some embodiments, the deposition layer is substantially liquid-impermeable but gas-permeable. In such embodiments, the deposition layer may function similarly to a seal, particularly in embodiments in which the deposition layer is disposed entirely on the second surface of the anode layer and entirely on the outer surface of the anode layer, as shown in FIG. 3A. When the deposition layer is substantially liquid-impermeable but gas-permeable, the deposition layer may restrict the flow of cathode electrolyte solution into the anode layer while allowing gas to escape from the anode layer.

[0172] In some embodiments, the deposition layer includes at least one of a conductive layer and a nucleation layer, hi such embodiments, the anode current collector is coupled to at least one of the conductive layer and the nucleation layer.

[0173] In some embodiments, the deposition layer comprises a conductive layer, hi other embodiments, the deposition layer comprises a nucleation layer.

[0174] 4A, the deposited layers include a conductive layer 428 and a nucleation layer 430. In some embodiments, and as shown, the nucleation layer is disposed between the anode layer and the conductive layer. In other embodiments, the conductive layer is disposed between the anode layer and the nucleation layer.

[0175] 1.Conductive layer

[0176] The conductive layer is at least partially disposed on the second surface of the anode layer and comprises a conductive material. The presence of the conductive layer facilitates electronic conduction. In some embodiments, the conductive layer serves as a substrate for metal plating (e.g., lithium plating) during operation (e.g., charging) of the battery cell.

[0177] The conductive material of the conductive layer may be any conductive material described herein. In some embodiments, the conductive material includes a metal, a metal oxide, a metal alloy, carbon black, carbon nanotubes, graphite, graphene, amorphous carbon, or any combination thereof. Non-limiting examples of metals suitable for the conductive material include copper, nickel, titanium, iron, and combinations thereof. Non-limiting examples of metal oxides suitable for the conductive material include copper oxide, nickel oxide, titanium oxide, iron oxide, and combinations thereof. Non-limiting examples of alloys suitable for the conductive material include copper alloys, nickel alloys, titanium alloys, iron alloys, and combinations thereof.

[0178] In some embodiments, the conductive material comprises carbon black, carbon nanotubes, graphite, graphene, amorphous carbon, or any combination thereof. In some embodiments, the conductive material comprises carbon black. In other embodiments, the conductive material comprises carbon nanotubes. In some embodiments, the conductive material comprises graphite. In some embodiments, the conductive material comprises graphene. In some embodiments, the conductive material comprises amorphous carbon.

[0179] In some embodiments, the conductive material comprises a metal, a metal alloy, or any combination thereof. In some embodiments, the conductive material comprises copper, nickel, titanium, stainless steel, an alloy thereof, or any combination thereof. In some embodiments, the conductive material comprises copper. In some embodiments, the conductive material comprises nickel. In other embodiments, the conductive material comprises titanium. In some embodiments, the conductive material comprises steel. In some embodiments, the conductive material comprises a copper alloy. In some embodiments, the conductive material comprises a nickel alloy. In other embodiments, the conductive material comprises a titanium alloy. In some embodiments, the conductive material comprises graphene. In some embodiments, the conductive material comprises graphite. In some embodiments, the conductive material comprises carbon black. In some embodiments, the conductive material comprises a steel alloy.

[0180] In some embodiments, the conductive layer is substantially free of metals or metal alloys that react with or form alloys with lithium metal at room temperature.

[0181] In some embodiments, the conductive layer consists essentially of the conductive material. In other embodiments, the conductive layer consists essentially of the conductive material.

[0182] In some embodiments, the conductive layer has a thickness of about 1 nm to about 15 μm. In other embodiments, the conductive layer has a thickness of about 1 nm to about 1 μm. In some embodiments, the conductive layer has a thickness of about 1 nm to about 500 nm. In some embodiments, the conductive layer has a thickness of about 1 nm to about 100 nm.

[0183] In some embodiments, the conductive layer is substantially liquid-impermeable. In some embodiments, the conductive layer is substantially liquid-impermeable and gas-permeable. In such embodiments, the conductive layer may function in a manner similar to a seal, particularly in embodiments in which the conductive layer is disposed entirely on the second surface of the anode layer and entirely on the outer surface of the anode layer. When the conductive layer is substantially liquid-impermeable and gas-permeable, the conductive layer may restrict the flow of cathode electrolyte to the anode layer while allowing gas to escape from the anode layer.

[0184] In some embodiments, the conductive layer is further defined as a first conductive layer, and the anode assembly further includes a second conductive layer. The second conductive layer is at least partially disposed on the first conductive layer. The second conductive layer includes a conductive material. The conductive material of the second conductive layer can be any conductive material described herein. In some embodiments, the conductive materials of the first and second conductive layers are the same. In other embodiments, the conductive materials of the first and second conductive layers are different.

[0185] 2. Nucleation layer

[0186] The nucleation layer is at least partially disposed on the second surface of the anode layer and includes a nucleation material, and when present, the nucleation layer electrochemically alloys and / or reacts with a metallic material (e.g., lithium metal) at room temperature.

[0187] The nucleation material of the nucleation layer can be any nucleation material described herein. In some embodiments, the nucleation material comprises a metal, a metalloid, an oxide thereof, or any combination thereof. In some embodiments, the nucleation material comprises silver, gold, aluminum, bismuth, antimony, indium, zinc, gallium, nickel oxide, titanium oxide, copper oxide, zinc oxide, graphene, graphite, carbon black, or any combination thereof. In some embodiments, the nucleation material comprises gold. In some embodiments, the nucleation material comprises silver. In other embodiments, the nucleation material comprises aluminum. In some embodiments, the nucleation material comprises bismuth. In some embodiments, the nucleation material comprises antimony. In some embodiments, the nucleation material comprises indium. In some embodiments, the nucleation material comprises zinc. In other embodiments, the nucleation material comprises gallium. In some embodiments, the nucleation material comprises nickel oxide. In some embodiments, the nucleation material comprises titanium oxide. In some embodiments, the nucleation material comprises copper oxide. In some embodiments, the nucleation material comprises graphene. And, in some embodiments, the nucleation material comprises zinc oxide.

[0188] In some embodiments, the nucleation layer consists essentially of the nucleation material. In other embodiments, the nucleation layer consists of the nucleation material.

[0189] In some embodiments, the nucleation layer has a thickness of about 1 nm to about 1 μm. In other embodiments, the nucleation layer has a thickness of about 1 nm to about 500 nm. In some embodiments, the nucleation layer has a thickness of about 1 nm to about 100 nm. And, in some embodiments, the nucleation layer has a thickness of about 1 nm to about 50 nm.

[0190] In some embodiments, the nucleation layer is substantially liquid-impermeable. In some embodiments, the nucleation layer is substantially liquid-impermeable and gas-permeable. In such embodiments, the nucleation layer may function in a manner similar to a seal, particularly in embodiments in which the nucleation layer is disposed entirely on the second surface of the anode layer and entirely on the outer surface of the anode layer. When the nucleation layer is substantially liquid-impermeable and gas-permeable, the nucleation layer can restrict the flow of cathode electrolyte into the anode layer while allowing gas to escape from the anode layer.

[0191] In some embodiments, the nucleation layer is further defined as a first nucleation layer, and the anode assembly further includes a second nucleation layer. The second nucleation layer is disposed at least partially on the first nucleation layer. The second nucleation layer includes a nucleation material. The nucleation material of the second nucleation layer can be any nucleation material described herein. In some embodiments, the nucleation materials of the first and second nucleation layers are the same. In other embodiments, the nucleation materials of the first and second nucleation layers are different.

[0192] D. Anode current collector

[0193] The anode current collector is bonded to the deposition layer. In some embodiments, when the deposition layer includes at least one of a conductive layer and a nucleation layer, the anode current collector is bonded to at least one of the conductive layer and the nucleation layer. For example, the anode current collector can be bonded to the conductive layer. In other embodiments, the anode current collector is bonded to the nucleation layer. And, in some embodiments, the anode current collector is bonded to the conductive layer and the nucleation layer.

[0194] 1A and 1C, in some embodiments, the anode current collector includes a metal foil 132. In such embodiments, the metal foil is at least partially disposed on the surface of the deposition layer. For example, the metal foil can be disposed on the entire surface of the deposition layer, as shown in FIGS. 1A and 1C. If the deposition layer includes at least one of a conductive layer and a nucleation layer, the metal foil can be disposed on the entire surface of the conductive layer and / or the nucleation layer. In other embodiments, the metal foil is disposed only partially on the deposition layer. And, in some embodiments, the metal foil is disposed only partially on the conductive layer and / or the nucleation layer.

[0195] In some embodiments, the metal foil has a tab 134 configured to connect to an external circuit, as shown in Figure 1C. In the illustrated embodiment, the tab is integral with the metal foil. In other embodiments, the tab is bonded (e.g., welded) to the metal foil.

[0196] As shown in Figures 3A, 3C, 5A, 5C, 6A, 6C, 7A, 7C, 8A, and 8C, the anode current collector may include a tab 334, 534, 634, 734, 834 configured to connect to an external circuit. The tab may be partially disposed within the deposition layer, as shown in Figures 3A, 5A, 6A, 7A, and 7C. In other embodiments, the tab is partially disposed within the conductive layer, as shown in Figure 8A. In some embodiments, the tab is partially disposed within the nucleation layer. Also, in some embodiments, the anode current collector is at least partially disposed on a surface of the deposition layer, the conductive layer, and / or the nucleation layer.

[0197] The anode current collector may be comprised of any suitable material. In some embodiments, the anode current collector (e.g., metal foil and / or tab) comprises copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof. In some embodiments, the anode current collector comprises copper. In other embodiments, the anode current collector comprises a copper alloy. In some embodiments, the anode current collector comprises nickel. In other embodiments, the anode current collector comprises a nickel alloy. In some embodiments, the anode current collector comprises titanium. In some embodiments, the anode current collector comprises a titanium alloy. In some embodiments, the anode current collector comprises stainless steel. In some embodiments, the anode current collector comprises a stainless steel alloy.

[0198] In some embodiments, the anode current collector comprises a film. For example, the film may comprise a polymeric material and a conductive material. The conductive material may be any conductive material described herein. In some embodiments, the conductive material comprises copper, nickel, titanium, stainless steel, an alloy thereof, or any combination thereof. In some embodiments, the polymer comprises polypropylene, polyethylene, polymethylpentene, polybutene-1, an ethylene-octene copolymer, a propylene-butane copolymer, polyisobutylene, a poly(α-olefin), an ethylene propylene rubber, an ethylene propylene diene monomer rubber, an ethylene vinyl acetate, an ethylene-acrylate copolymer, a polyamide, a polyester, a polyurethane, a styrene block copolymer, a polycaprolactone, a polyimide, a polyvinyl chloride, a polycarbonate, a polyacrylate, a polymethacrylate, a fluoropolymer, an epoxy resin, an epoxy polymer, a silicone rubber, or any combination thereof. When the anode current collector comprises a film, the anode current collector may be substantially impermeable to liquids.

[0199] Referring to FIG. 9A , conductive tape 936 can bond the anode current collector to the deposition layer. If the deposition layer includes at least one of a conductive layer and a nucleation layer, the conductive tape can bond the anode current collector to at least one of the conductive layer and the nucleation layer. For example, conductive tape 1036 can bond the anode current collector to the conductive layer, as shown in FIG. 10A . In other embodiments, conductive tape bonds the anode current collector to the nucleation layer. In some embodiments, conductive tape bonds the anode current collector to the conductive layer and the nucleation layer. During operation of the battery cell (e.g., during charging and / or discharging of the battery cell), the conductive tape can electrically bond the anode current collector to the deposition layer, the conductive layer, and / or the nucleation layer.

[0200] In some embodiments, the braze material bonds the anode current collector to the deposition layer. When the deposition layer includes at least one of a conductive layer and a nucleation layer, the braze material can bond the anode current collector to at least one of the conductive layer and the nucleation layer. For example, the braze material can bond the anode current collector to the conductive layer. In other embodiments, the braze material bonds the anode current collector to the nucleation layer. In some embodiments, the braze material bonds the anode current collector to the conductive layer and the nucleation layer.

[0201] The braze material may be any suitable material for electrically coupling the anode current collector to the deposition layer, the conductive layer, and / or the nucleation layer. For example, the braze material may include silver, gold, aluminum, bismuth, antimony, zinc, indium, copper, phosphorous, nickel, titanium, tungsten, chromium, silicon, vanadium, tantalum, zirconium, alloys thereof, or combinations thereof. In some embodiments, the braze material includes silver. In some embodiments, the braze material includes a silver alloy. In some embodiments, the braze material includes gold. In other embodiments, the braze material includes a gold alloy. In some embodiments, the braze material includes aluminum. In some embodiments, the braze material includes an aluminum alloy. In some embodiments, the braze material includes bismuth. In other embodiments, the braze material includes a bismuth alloy. In some embodiments, the braze material includes antimony. In some embodiments, the braze material includes an antimony alloy. In some embodiments, the braze material includes zinc. In other embodiments, the braze material includes a zinc alloy. In some embodiments, the braze material includes indium. In some embodiments, the braze material includes an indium alloy. In some embodiments, the braze material includes copper. In some embodiments, the brazing filler metal comprises a copper alloy. In some embodiments, the brazing filler metal comprises phosphorus. In other embodiments, the brazing filler metal comprises a phosphorus alloy. In some embodiments, the brazing filler metal comprises nickel. In some embodiments, the brazing filler metal comprises a nickel alloy. In some embodiments, the brazing filler metal comprises titanium. In other embodiments, the brazing filler metal comprises a titanium alloy. In some embodiments, the brazing filler metal comprises tungsten. In some embodiments, the brazing filler metal comprises a tungsten alloy. In some embodiments, the brazing filler metal comprises chromium. In some embodiments, the brazing filler metal comprises a chromium alloy. In some embodiments, the brazing filler metal comprises silicon. In other embodiments, the brazing filler metal comprises a silicon alloy. In some embodiments, the brazing filler metal comprises vanadium. In some embodiments, the brazing filler metal comprises a vanadium alloy. In some embodiments, the brazing filler metal comprises tantalum. In other embodiments, the brazing filler metal comprises a tantalum alloy. In some embodiments, the brazing filler metal comprises zirconium. In some embodiments, the brazing filler metal comprises a zirconium alloy.

[0202] In some embodiments, the deposition layer, the conductive layer, and / or the nucleation layer functions as a braze for the anode current collector.

[0203] E. Sealing layer

[0204] 6A and 6C, in some embodiments, the anode assembly further comprises a substantially liquid-impermeable sealing layer 638. In some embodiments, the sealing layer is substantially liquid-impermeable and gas-permeable.

[0205] In some embodiments, the sealing layer ensures that metal plating (e.g., lithium plating) is confined to the pores of the anode layer during charging. In other words, the sealing layer inhibits metal (e.g., lithium metal) from plating outside the pores of the anode layer during charging. The sealing layer may also restrict the flow of cathode electrolyte to the anode layer during operation of the battery cell. In some embodiments, the sealing layer also bonds or joins the anode current collector to the deposition layer (e.g., the conductive material, the nucleation material, or both).

[0206] In some embodiments, the sealing layer is at least partially disposed on the surface of the anode current collector facing away from the deposition layer. For example, the sealing layer can be disposed on the entire surface of the anode current collector facing away from the deposition layer. In other embodiments, the sealing layer is only partially disposed on the surface of the anode current collector facing away from the deposition layer.

[0207] In other embodiments, the sealing layer is at least partially disposed on the surface of the deposition layer facing away from the anode layer, as shown in FIG. 6A . In the illustrated embodiment, the sealing layer is disposed on the entire surface of the deposition layer facing away from the anode layer. With continued reference to FIG. 6A , the sealing layer may be at least partially disposed on the outer surface 640 of the deposition layer. In the illustrated embodiment, the sealing layer is disposed on the entire outer surface of the deposition layer. In other embodiments, the sealing layer is only partially disposed on the outer surface of the deposition layer.

[0208] In some embodiments, when the deposited layer includes at least one of a conductive layer and a nucleation layer, the sealing layer is at least partially disposed on at least one of the conductive layer and the nucleation layer. For example, the sealing layer can be at least partially disposed on the conductive layer. In other embodiments, the sealing layer is at least partially disposed on the nucleation layer. Also, in some embodiments, the sealing layer is at least partially disposed on the conductive layer and the nucleation layer.

[0209] If the sealing layer is at least partially disposed on the outer surface of the deposition layer, conductive layer, and / or nucleation layer, and the anode current collector includes a tab, the tab may be at least partially disposed within the sealing layer, as shown in FIG. 6A.

[0210] 6A, a sealing layer may be at least partially disposed on the outer surface 614 of the anode layer. In some embodiments, the sealing layer is disposed on the entire outer surface of the anode layer. In other embodiments, the sealing layer is only partially disposed on the outer surface of the anode layer.

[0211] The sealing layer can be composed of any suitable material that inhibits metal (e.g., lithium metal) from plating outside the pores of the anode layer during charging. For example, the sealing layer can include a polymer. In some embodiments, the polymer includes polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof. In some embodiments, the polymer includes polypropylene. In some embodiments, the polymer includes polyethylene. In other embodiments, the polymer includes polymethylpentene. In some embodiments, the polymer includes polybutene-1. In some embodiments, the polymer includes ethylene-octene copolymer. In some embodiments, the polymer includes propylene-butane copolymer. In some embodiments, the polymer comprises polyisobutylene. In some embodiments, the polymer comprises a poly(α-olefin). In some embodiments, the polymer comprises an ethylene propylene rubber. In other embodiments, the polymer comprises an ethylene propylene diene monomer rubber. In some embodiments, the polymer comprises ethylene vinyl acetate. In some embodiments, the polymer comprises an ethylene-acrylate copolymer. In other embodiments, the polymer comprises a polyamide. In some embodiments, the polymer comprises a polyester. In some embodiments, the polymer comprises a polyurethane. In some embodiments, the polymer comprises a styrene block copolymer. In some embodiments, the polymer comprises a polycaprolactone. In other embodiments, the polymer comprises a polyimide. In some embodiments, the polymer comprises polyvinyl chloride. In some embodiments, the polymer comprises a polycarbonate. In some embodiments, the polymer comprises a polyacrylate. In some embodiments, the polymer comprises a polymethacrylate.In some embodiments, the polymer comprises a fluoropolymer, in some embodiments, the polymer comprises an epoxy resin, in other embodiments, the polymer comprises an epoxy polymer, and in some embodiments, the polymer comprises a silicone rubber.

[0212] In some embodiments, the sealing layer comprises a conductive material. The conductive material of the sealing layer can be any conductive material described herein.

[0213] In some embodiments, the sealing layer has a thickness of about 1 μm to about 50 μm. In other embodiments, the sealing layer has a thickness of about 1 μm to about 20 μm. In some embodiments, the sealing layer has a thickness of about 1 μm to about 10 μm. In some embodiments, the sealing layer has a thickness of about 1 μm to about 5 μm.

[0214] F. Barrier Film

[0215] 5A and 11A, the anode assembly may include a barrier film 539, 1139. The barrier film electrically isolates two or more anode assemblies from each other. The barrier film may include any suitable material for electrically isolating one anode assembly from another. For example, the barrier film may include any polymer described herein for use in a sealing layer. In some embodiments, the barrier film includes polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof.

[0216] In some embodiments, the barrier film 539 is at least partially disposed on the deposition layer 506, as shown in Figure 5A. In the illustrated embodiment, the barrier film is disposed over the entire surface of the deposition layer. In other embodiments, the barrier film is disposed over only a portion of the deposition layer.

[0217] In some embodiments, the barrier film 1139 is at least partially disposed on the anode current collector 1108, as shown in Figure 11A. In the illustrated embodiment, the barrier film is disposed over the entire surface of the anode current collector. In other embodiments, the barrier film is disposed over only a portion of the anode current collector.

[0218] In some embodiments, the barrier film is substantially impermeable to liquids. In other embodiments, the barrier film is permeable to liquids.

[0219] G. Other Embodiments

[0220] In another aspect, the present invention provides an anode assembly for a battery cell. The anode assembly includes a separator layer, an anode layer, a deposition layer, and an anode current collector. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer and a second surface facing away from the separator layer. The anode layer includes a solid-state electrolyte (SSE) material having micropores. The deposition layer is at least partially disposed on the second surface of the anode layer. The deposition layer includes a conductive material and a nucleation material. The anode current collector is bonded to the deposition layer.

[0221] In yet another aspect, the present invention provides an anode assembly for a battery cell. The anode assembly includes a separator layer, an anode layer, a conductive layer, and an anode current collector. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer and a second surface facing away from the separator layer. The anode layer includes a solid-state electrolyte (SSE) material having micropores. The conductive layer is at least partially disposed on the second surface of the anode layer. The conductive layer includes a conductive material. The anode current collector is bonded to the conductive layer.

[0222] In another aspect, the present invention provides an anode assembly for a battery cell. The anode assembly includes a separator layer, an anode layer, a stack layer, and an anode current collector. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer and a second surface facing away from the separator layer. The anode layer includes a solid-state electrolyte (SSE) material having pores. A nucleation layer is at least partially disposed on the second surface of the anode layer. The nucleation layer includes a nucleation material. The anode current collector is bonded to the nucleation layer.

[0223] In a further aspect, the present invention provides an anode assembly for a battery cell. The anode assembly includes a separator layer, an anode layer, a conductive layer, a nucleation layer, and an anode current collector. The anode layer is at least partially disposed on the separator layer and has a first surface facing the separator layer and a second surface facing away from the separator layer. The anode layer includes a solid-state electrolyte (SSE) material having micropores. The nucleation layer is at least partially disposed on the second surface of the anode layer. The nucleation layer includes a nucleation material. The conductive layer is at least partially disposed on the surface of the nucleation layer facing away from the anode layer. The conductive layer includes a conductive material. The anode current collector is bonded to the conductive layer.

[0224] III. Multilayer Anode Assembly

[0225] Another aspect of the present invention provides a multilayer anode assembly. The multilayer anode assembly combines two anode assemblies described herein such that at least one component is common to each anode assembly. For example, with reference to FIGS. 1B, 4B, 9B, and 10B, the multilayer anode assemblies may have a common anode current collector. In other embodiments, the multilayer anode assemblies may have a common sealing layer, as shown in FIG. 6B. In other embodiments, the multilayer anode assemblies may have a common barrier film, as shown in FIGS. 3B, 5B, and 11B. In some embodiments, the multilayer anode assemblies have a common deposition layer and anode current collector, as shown in FIG. 7B. In some embodiments, the multilayer anode assemblies have a common conductive layer and anode current collector, as shown in FIG. 8B.

[0226] IV. Battery Cell

[0227] Another aspect of the present invention provides a battery cell. The battery cell includes an anode assembly and a cathode assembly. The anode assembly can be any anode assembly described herein. The cathode assembly includes a cathode layer and a cathode current collector.

[0228] A. Cathode layer

[0229] The cathode layer is at least partially disposed on the separator layer of the anode assembly. In some embodiments, the cathode layer is disposed entirely on the surface of the separator layer facing away from the anode layer. In other embodiments, the cathode layer is only partially disposed on the surface of the separator layer facing away from the anode layer.

[0230] The cathode layer may be composed of any suitable material. In some embodiments, the cathode layer comprises a lithium ion conducting material. For example, the lithium ion conducting material may be LiCoO, LiNi, or the like. 1 / 3 Co 1 / 3 Mn 1 / 3 O2, LiNi0.5 Co 0.2 Mn 0.3 Lithium Nickel Manganese Cobalt Oxide (NMC, LiNi x Mn y Co z O2, where x+y+z=1), LiMn2O4, LiNi 0.5 Mn 1.5 Lithium manganese oxides (LMOs) such as LiFePO, LiMnPO, LiCoPO, and Li2MMn3O8 (where M is selected from Fe, Co, or any combination thereof). In some embodiments, the ion-conducting cathode material is a high-energy ion-conducting cathode material such as Li2MMn3O8, where M is selected from Fe, Co, or any combination thereof.

[0231] In some embodiments, the cathode comprises a sodium ion conducting material. For example, the sodium ion conducting material may be Na2V2O5, P2-Na 2 / 3 Fe 1 / 2 Mn 1 / 2 O2, Na3V2(PO4)3, NaMn 1 / 3 Co 1 / 3 Ni 1 / 3 PO4, or any composite thereof (e.g., composite with carbon black) (e.g., Na 2 / 3 Fe 1 / 2 Mn 1 / 2 O2@graphene composite).

[0232] In some embodiments, the cathode layer comprises a magnesium ion conducting material. For example, the magnesium ion conducting material may be a doped manganese oxide (e.g., Mg x MnO 2·y HO).

[0233] In some embodiments, the cathode layer comprises an organic sulfide or polysulfide. For example, the organic sulfide or polysulfide can be carbyne polysulfide and copolymerized sulfur.

[0234] In some embodiments, the cathode layer comprises an air electrode, which may be, for example, a mesh of high surface area carbon particles (e.g., Super P (i.e., conductive carbon black)) and catalyst particles (e.g., α-MnO nanorods) bound together by a polymeric binder such as a PVDF binder.

[0235] In some embodiments, the cathode layer has a thickness of about 1 μm to about 500 μm. In some embodiments, the cathode layer has a thickness of about 1 μm to about 200 μm. In other embodiments, the cathode layer has a thickness of about 1 μm to about 100 μm. In some embodiments, the cathode layer has a thickness of about 1 μm to about 50 μm. In some embodiments, the cathode layer has a thickness of about 1 μm to about 20 μm. In some embodiments, the cathode layer has a thickness of about 10 μm to about 150 μm. In other embodiments, the cathode layer has a thickness of about 40 μm to about 100 μm. In some embodiments, the cathode layer has a thickness of about 60 μm to about 80 μm.

[0236] B. Cathode current collector

[0237] A cathode current collector is bonded to the cathode layer. In some embodiments, the cathode current collector comprises a metal foil. In such embodiments, the metal foil is at least partially disposed on the surface of the cathode layer facing away from the separator layer. For example, the metal foil can be disposed on the entire surface of the cathode layer facing away from the separator layer. In some embodiments, the metal foil is disposed only partially on the surface of the cathode layer facing away from the deposition layer.

[0238] In some embodiments, the metal foil has a tab configured to connect to an external circuit. In some embodiments, the tab is integral with the metal foil. In other embodiments, the tab is bonded (e.g., welded) to the metal foil. Also, in some embodiments, the cathode current collector includes a tab configured to connect to an external circuit.

[0239] The cathode current collector may be composed of any suitable material. In some embodiments, the cathode current collector (e.g., metal foil and / or tab) comprises aluminum, stainless steel, alloys thereof, or any combination thereof. In some embodiments, the cathode current collector comprises aluminum. In some embodiments, the cathode current collector comprises an aluminum alloy. In other embodiments, the cathode current collector comprises stainless steel. In some embodiments, the cathode current collector comprises a stainless steel alloy.

[0240] In some embodiments, the cathode current collector comprises a film. For example, the film may comprise a polymeric material and a conductive material. The conductive material may be any conductive material described herein. For example, the conductive material may be a metallic material. In some embodiments, the conductive material comprises aluminum, stainless steel, an alloy thereof, or any combination thereof. In some embodiments, the polymer comprises polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof. When the cathode current collector comprises a film, the cathode current collector may be substantially impermeable to liquids.

[0241] C.Liquid

[0242] In some embodiments, the battery cell includes a liquid. The liquid may include an electrolyte, an anolyte, a catholyte, or any combination thereof. In some embodiments, the liquid may include a lithium salt, a linear carbonate, a cyclic carbonate, an ionic liquid, or any combination thereof. For example, the liquid may include a mixture of lithium bis(fluorosulfonyl)imide and N-propyl-N-methylpyrrolidinium bis(fluorosulfonyl)imide. In other embodiments, the liquid may include lithium hexafluorophosphate, ethylene carbonate, and ethyl methyl carbonate, or a mixture thereof.

[0243] V. Method of Forming the Anode Assembly

[0244] Another aspect of the present invention provides a method of forming an anode assembly. Referring to Figure 12, a flow chart illustrating an exemplary embodiment of forming an anode assembly for a battery cell is provided. The method includes: (a) providing (1202) a separator layer and an anode layer at least partially disposed on the separator layer, the anode layer having a first surface facing the separator layer and a second surface facing away from the separator layer, the anode layer comprising an SSE having pores; (b) disposing (1204) a deposition layer at least partially on the second surface of the anode layer; (c) electrically coupling an anode current collector to the deposited layer to form an anode assembly (1206).

[0245] The separator layer may be any separator layer described herein. The anode layer may be any anode layer described herein. The stack layer may be any stack layer described herein.

[0246] In some embodiments, step (b) includes disposing a deposition layer at least partially on the second surface of the anode layer. For example, the deposition layer may be disposed over the entire second surface of the anode layer. In other embodiments, the deposition layer is disposed only partially on the second surface of the anode layer.

[0247] In some embodiments, step (b) includes disposing at least one of a conductive layer and a nucleation layer at least partially on the second surface of the anode layer. For example, the conductive layer and / or the nucleation layer may be disposed over the entire second surface of the anode layer. In other embodiments, the conductive layer and / or the nucleation layer is disposed only partially on the second surface of the anode layer.

[0248] The conductive layer may be any conductive layer described herein. The nucleation layer may be any nucleation layer described herein.

[0249] In some embodiments, step (b) includes at least partially disposing a conductive layer on the second surface of the anode layer. For example, the conductive layer may be disposed over the entire second surface of the anode layer. In other embodiments, the conductive layer is only partially disposed over the second surface of the anode layer.

[0250] In some embodiments, step (b) includes at least partially disposing a nucleation layer on the second surface of the anode layer. For example, the nucleation layer can be disposed over the entire second surface of the anode layer. In other embodiments, the nucleation layer is disposed only partially over the second surface of the anode layer.

[0251] In some embodiments, step (b) includes at least partially disposing a conductive layer and a nucleation layer on the second surface of the anode layer. For example, the conductive layer is disposed between the anode layer and the nucleation layer. In other embodiments, the nucleation layer is disposed between the anode layer and the conductive layer.

[0252] In some embodiments, step (b) comprises disposing the deposition layer, conductive layer, and / or nucleation layer by thermal evaporation, sputtering, electron beam evaporation, molecular beam epitaxy, pulsed laser deposition, plasma-enhanced physical vapor deposition, atomic layer deposition, screen printing, inkjet printing, casting, coating, or any combination thereof. In some embodiments, step (b) comprises disposing the deposition layer, conductive layer, and / or nucleation layer by thermal evaporation. In other embodiments, step (b) comprises disposing the deposition layer, conductive layer, and / or nucleation layer by sputtering. In some embodiments, step (b) comprises disposing the deposition layer, conductive layer, and / or nucleation layer by electron beam evaporation. In some embodiments, step (b) comprises disposing the deposition layer, conductive layer, and / or nucleation layer by molecular beam epitaxy. In other embodiments, step (b) comprises disposing the deposition layer, conductive layer, and / or nucleation layer by pulsed laser deposition. In some embodiments, step (b) comprises disposing the deposition layer, conductive layer, and / or nucleation layer by plasma-enhanced physical vapor deposition. In some embodiments, step (b) comprises disposing the deposition layer, conductive layer, and / or nucleation layer by atomic layer deposition. In some embodiments, step (b) comprises disposing the deposition layer, conductive layer, and / or nucleation layer by screen printing. In other embodiments, step (b) comprises disposing the deposition layer, conductive layer, and / or nucleation layer by inkjet printing. In some embodiments, step (b) comprises disposing the deposition layer, conductive layer, and / or nucleation layer by casting. Also, in some embodiments, step (b) comprises disposing the deposition layer, conductive layer, and / or nucleation layer by coating.

[0253] In some embodiments, step (b) further comprises: (b1) disposing at least one of a conductive layer and a nucleation layer at least partially on the second surface of the anode layer; and (b2) treating at least one of the conductive layer and the nucleation layer;

[0254] In some embodiments, step (b2) includes treating at least one of the conductive layer and the nucleation layer by annealing, heat treating, melting, or oxidizing the conductive layer. For example, step (b2) can include annealing the conductive layer and at least one of the nucleation layer. In some embodiments, step (b2) includes heat treating the conductive layer and at least one of the nucleation layer. In other embodiments, step (b2) includes melting the conductive layer and at least one of the nucleation layer. And, in some embodiments, step (b2) includes oxidizing the conductive layer and at least one of the nucleation layer.

[0255] In some embodiments, step (c) comprises electrically coupling the anode current collector to the deposited layer with conductive tape, while in other embodiments, step (c) comprises electrically coupling the anode current collector to at least one of the conductive layer and the nucleation layer using conductive tape.

[0256] In some embodiments, step (c) comprises electrically coupling the anode current collector to the deposition layer by brazing with a brazing material. In other embodiments, step (c) comprises electrically coupling the anode current collector to at least one of the conductive layer and the nucleation layer by brazing with a brazing material. The brazing material may be any brazing material described herein. For example, the brazing material may include silver, gold, aluminum, bismuth, antimony, zinc, indium, copper, phosphorus, nickel, titanium, tungsten, chromium, silicon, vanadium, tantalum, zirconium, alloys thereof, or any combination thereof. In some embodiments, the deposition layer, the conductive layer, and / or the nucleation layer function as the brazing material for the anode current collector.

[0257] In some embodiments, the method further comprises: (d) disposing a sealing layer at least partially over the deposited layer, the sealing layer being substantially impermeable to liquids;

[0258] In some embodiments, step (d) includes disposing a sealing layer at least partially on at least one of the conductive layer and the nucleation layer, the sealing layer being substantially impermeable to liquids. In some embodiments, step (d) includes disposing the sealing layer at least partially on the conductive layer. In other embodiments, step (d) includes disposing the sealing layer at least partially on the nucleation layer. Also, in some embodiments, step (d) includes disposing the sealing layer at least partially on the conductive layer and the nucleation layer.

[0259] In some embodiments, step (d) further includes disposing a sealing layer at least partially on the deposition layer, the conductive layer, and / or the nucleation layer by cold-pressing, hot-pressing, melting, 3D-printing, or any combination thereof, a polymer at least partially on the deposition layer, the conductive layer, and / or the nucleation layer. For example, step (d) may include cold-pressing a polymer at least partially on the deposition layer, the conductive layer, and / or the nucleation layer. In some embodiments, step (d) includes hot-pressing a polymer at least partially on the deposition layer, the conductive layer, and / or the nucleation layer. In other embodiments, step (d) includes melting a polymer at least partially on the deposition layer, the conductive layer, and / or the nucleation layer. Also, in some embodiments, step (d) includes 3D-printing a polymer at least partially on the deposition layer, the conductive layer, and / or the nucleation layer.

[0260] The polymer can be any polymer as described herein. For example, the polymer can include polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof.

[0261] In another aspect, the present invention provides a method of forming an anode assembly, the method comprising: (a-1) providing a separator layer and an anode layer at least partially disposed on the separator layer, the anode layer having a first surface facing the separator layer and a second surface facing away from the separator layer, the anode layer including a SSE having pores; (b-1) at least partially disposing a conductive layer and a nucleation layer on the second surface of the anode layer; and (c-1) electrically coupling an anode current collector to at least one of the conductive layer and the nucleation layer to form the anode assembly.

[0262] In yet another aspect, the present invention provides a method of forming an anode assembly, the method including: (a-2) providing a separator layer and an anode layer at least partially disposed on the separator layer, the anode layer having a first surface facing the separator layer and a second surface facing away from the separator layer, the anode layer including a SSE having pores; (b-2) disposing a nucleation layer at least partially on the second surface of the anode layer; (c-2) disposing a conductive layer on at least a portion of the surface of the nucleation layer, the conductive layer facing away from the anode layer; and (d-2) electrically coupling an anode current collector to the conductive layer to form the anode assembly. [Example]

[0263] VI. Working Examples

[0264] In order that the invention described herein may be more fully understood, the following examples are set forth. The examples described in this application are provided to illustrate the methods and anode assemblies provided herein, and should not be construed as limiting the scope thereof in any way.

[0265] Example 1: Silver / nickel anode assembly

[0266] A separator layer and an anode layer disposed at least partially on the separator layer, the anode layer having a first surface facing the separator layer and a second surface facing away from the separator layer, were provided. The separator layer and the anode layer measured 1 cm x 1 cm. The separator layer included a lithium lanthanum zirconium oxide (LLZO) solid electrolyte (SSE) material. The anode layer included the LLZO SSE material. The pores of the anode layer were substantially free of metallic materials, such as lithium metal.

[0267] The separator layer and anode layer were placed in a device with a 7.2 mm x 7.2 mm square window on the bottom. The separator layer and anode layer were placed in the device so that a deposition layer was deposited on the anode layer by a visible thermal evaporation process using a Metra thermal evaporator. The deposition layer was deposited only on the anode layer within the area of ​​the 7.2 mm x 7.2 mm window, leaving a 1.4 mm border of the anode layer around the edge of the deposition layer free of deposition layer.

[0268] From a quiescent state under vacuum, the evaporation chamber of the thermal evaporator was repressurized to atmospheric pressure. One conductive boat was loaded with silver pellets, and the other with nickel pellets. Each conductive boat was connected to the electrical supports of the evaporation chamber. The device, including the separator layer and anode layer, was loaded into the evaporation chamber on top of the conductive boat, with the anode layer facing the boat. The chamber was then pumped at 3 x 100 rpm using a roughing pump and a turbine pump. -6 The chamber was evacuated to less than Torr. The conductive boat containing the silver was heated by increasing the current flowing through the boat until the silver melted. Once the silver melted, the shutter was opened, allowing the silver to evaporate and deposit on the anode layer. Once the desired thickness (approximately 100 nm, as measured by a quartz crystal) was achieved, the shutter was closed, and the silver was allowed to cool. After the silver was deposited on the anode layer, the boat containing the nickel was heated by increasing the current flow until the nickel melted. Once the nickel had melted, the shutter was opened again, allowing the nickel to evaporate and deposit on top of the silver previously deposited on the anode layer. Once the desired thickness (approximately 400 nm) was achieved, the shutter was closed, and the current was reduced, allowing the nickel to cool. Once cooled, the chamber was repressurized, and the device containing the separator layer and anode layer was removed from the thermal evaporator.

[0269] The anode assembly was completed in an argon-filled glove box by attaching a copper foil anode current collector to the deposited layer using a conductive adhesive transfer tape (supplied by 3M™) with a high-tack surface, a low-tack surface, and isotropic XYZ-axis electrical connectivity. The conductive tape was double-sided and first pressed onto the copper foil. The conductive tape was then pressed onto the deposited layer to form the anode assembly. The edges of the anode layer were sealed with a polymer via a fusion process to form a sealed anode assembly. A nickel tab was welded to the metal foil of the anode current collector to complete the sealed anode assembly.

[0270] Scanning electron microscope (SEM) images of the nickel layer 1342 and silver layer 1344 are shown in Figures 13A-13F and Figures 14A-14C. Figures 15A and 15B show the cycling voltage profile of the anode assembly (working electrode / separator) and lithium metal reference electrode. Cycling was performed at 20 μA / cm2 of the area of ​​the silver and nickel layers. 2 As shown in Figure 15C, the impedance was set at a cathodic current density of 20 μA / cm 2 After applying a voltage of 1.0 V for 8 hours, the open circuit potential of the assembled cell was measured in the frequency range of 2 MHz to 1 Hz.

[0271] Example 2: Battery Cell

[0272] A cathode assembly was prepared comprising a cathode layer comprising lithium nickel manganese cobalt oxide (NMC) and a cathode current collector comprising aluminum foil, with an aluminum tab welded to the aluminum foil of the cathode current collector.

[0273] The cathode layer was pressed onto the separator layer of the anode assembly and integrated into an aluminum foil / polypropylene pouch. The cathode layer was wetted with the cathode electrolyte. The pouch was sealed under vacuum conditions using an impulse / heat seal process to complete the battery cell.

[0274] 16A and 16B show the cycling voltage profile of the battery cell. The cycling was performed at 180 μA / cm2 of the cathode layer area. 2 As shown in Figure 16C, the impedance was set to 180 μA / cm 2 The open circuit potential of the assembled cell was measured in the frequency range of 10 kHz to 0.1 Hz after the first charging cycle of 12 hours at 1000 kJ / s.

[0275] Example 3: Copper / Indium Anode Assembly

[0276] The anode assembly of Example 3 was fabricated following substantially the same procedure as described in Example 1, except that a copper layer of about 3.2 μm was first deposited onto the anode layer, followed by an indium layer of about 800 nm. SEM images of the copper layer 1344 and the indium layer 1346 are shown in Figures 17A-17C and 18A-18C.

[0277] Example 4: Copper anode assembly

[0278] The anode assembly of Example 4 was fabricated following substantially the same procedure as described in Example 1, except that Cuprum 81 (CuNex series sintering paste manufactured by Schlenk) was applied onto the anode layer, followed by attachment of a copper current collector and anode sealing.

[0279] Cuprum 81 was mixed in a planetary mixer at 500 rpm for 5 minutes and then applied in excess to the porous surface of the anode layer using a fine-bristle paint brush (size = 000). While the Cuprum 81 was wet, the excess was carefully removed with a squeegee to provide a substantially uniform layer with a thickness between 5 and 8 μm.

[0280] The treated porous anode layer was dried under hot air (approximately 100°C) evenly applied over the entire surface for approximately 5 minutes to evaporate the solvent before sintering. The dried copper-treated anode and separator layers were placed (treated side up) in a box furnace in an inert environment (argon, nitrogen) without external pressure and heated at a rate of 30°C / min until sintering at a temperature of 500-700°C for approximately 2 hours. The furnace was then cooled to room temperature (30°C / min), and the sintered copper-treated anode and separator layers were removed from the furnace and placed on a copper current collector, with the copper-treated surface of the anode layer physically attached to the copper current collector by contact with the current collector. The copper anode assembly was completed by anode sealing according to Example 1 and incorporated into a test cell according to Example 2. Figure 19 shows the voltage as a function of time during cell cycling (i.e., charge and discharge), where the test cell was charged and discharged at a current of C / 10 for cycles 1–3, a current of C / 5 for cycles 4 and 5, and a current of C / 2 for cycles 6–9.

[0281] Example 5: Graphene anode assembly

[0282] The anode assembly of Example 5 was prepared following substantially the same procedure as described in Example 1, except that graphene (0.2 mg / mL) in DMF was deposited on the anode layer, followed by attaching a copper current collector and sealing the anode.

[0283] A solution of graphene in DMF (0.2 mg / mL) (Sigma-Aldrich) was placed under 3 Å molecular sieves for at least two weeks. The filtrate was decanted and vortexed for approximately 5 minutes on a benchtop vortex mixer before use. 30 μl of the resulting solution was dropped onto the center of the porous surface of the anode layer using a micropipette. The treated anode layer was dried at 140°C for approximately 10 minutes to remove the DMF, and the workpiece was then heated at 200°C for approximately 30 minutes to anneal the deposited graphene. The anode assembly was sintered, attached to a copper current collector, and sealed according to Example 4. The sealed anode assembly was integrated into a test cell according to Example 2 and subjected to charge cycling. Figure 20 shows the voltage as a function of time during cell cycling (i.e., charge and discharge), where the test cell was charged and discharged at a current of (a) C / 10 for cycles 1-3, (b) C / 5 for cycles 4 and 5, and (c) C / 2 for cycles 6-9.

[0284] Equivalents and Scope In the claims, articles such as "a," "an," and "the" can mean one or more unless indicated to the contrary or the context clearly indicates otherwise. A claim or description including "or" between one or more members of a group is considered to be satisfied if one, more than one, or all of the members of the group are present in, employed in, or otherwise relevant to a given product or process, unless indicated to the contrary or the context clearly indicates otherwise. The invention includes embodiments in which exactly one member of a group is present in, employed in, or otherwise relevant to a given product or process. The invention includes embodiments in which more than one, or all of the members of a group are present in, employed in, or otherwise relevant to a given product or process.

[0285] Furthermore, the present invention encompasses all variations, combinations, and substitutions in which one or more limitations, elements, clauses, and descriptive terms from one or more of the enumerated claims are introduced into another claim. For example, any claim that depends on another claim can be modified to include one or more limitations found in any other claim that depends on the same base claim. Where elements are presented as a list, e.g., in Markush group format, each subgroup of elements is also disclosed, and any element(s) may be removed from this group. Of course, when the invention, or aspects of the invention, are generally referred to as comprising certain elements and / or features, a particular embodiment of the invention or aspect of the invention consists of or consists essentially of such elements and / or features. For brevity, these embodiments have not been specifically described verbatim herein. It should also be noted that the terms "comprising" and "containing" are intended to be open-ended, allowing for the inclusion of additional elements or steps. Where ranges are given, endpoints are included. Furthermore, unless otherwise indicated or clearly meant otherwise from the context and the understanding of one of ordinary skill in the art, values ​​expressed as ranges can be considered to be any specific value or subrange within the stated ranges of different embodiments of the invention, down to one-tenth of the unit of the lower limit of the range, unless clearly meant otherwise by the context.

[0286] This application references various issued patents, published patent applications, journal articles, and other publications, all of which are incorporated herein by reference. In the event of a conflict between any of the incorporated references and this application, the present specification shall control. Moreover, any particular embodiment of the present invention within the prior art may be expressly excluded from any one or more of the claims. Such embodiments may be excluded even if the exclusion is not expressly set forth herein because they are deemed known to those of ordinary skill in the art. Any particular embodiment of the present invention may be excluded from any claim for any reason, whether related to the existence of prior art or not.

[0287] Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments described herein. The scope of the present embodiments described in this invention is not intended to be limited to the above specification, but rather is as set forth in the appended claims. Those skilled in the art will appreciate that various changes and modifications can be made to this specification without departing from the spirit or scope of the invention, as defined in the following claims.

Claims

1. 1. An anode assembly for a battery cell, comprising: a separator layer; an anode layer at least partially disposed on the separator layer, the anode layer having a first surface facing the separator layer and a second surface facing away from the separator layer, the anode layer comprising a porous solid electrolyte (SSE) material; a deposition layer disposed at least partially on the second surface of the anode layer, the deposition layer comprising at least one of a conductive material and a nucleation material; an anode current collector bonded to the deposition layer; The anode assembly comprising:

2. The deposition layer is a conductive layer disposed at least partially on the second surface of the anode layer, the conductive layer comprising the conductive material; a nucleation layer disposed at least partially on the second surface of the anode layer, the nucleation layer comprising the nucleation material; The anode assembly of claim 1 , wherein the anode current collector is bonded to the at least one of the conductive layer and the nucleation layer.

3. The anode assembly of claim 2 , wherein the deposited layer comprises the conductive layer.

4. 4. The anode assembly of claim 3, wherein the conductive material of the conductive layer comprises a metal, a metal oxide, a metal alloy, carbon black, carbon nanotubes, graphite, graphene, amorphous carbon, or any combination thereof.

5. 5. The anode assembly of claim 3 or 4, wherein the conductive layer is substantially free of metals or metal alloys that react with or form alloys with lithium metal at room temperature.

6. 6. The anode assembly of claim 5, wherein the conductive material of the conductive layer comprises copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof.

7. The anode assembly of any one of claims 3 to 6, wherein the conductive layer has a thickness of from about 1 nm to about 15 μm.

8. The anode assembly of claim 2 , wherein the deposition layer comprises the nucleation layer.

9. 10. The anode assembly of claim 8, wherein the nucleation material of the nucleation layer comprises silver, gold, aluminum, bismuth, antimony, indium, zinc, gallium, nickel oxide, titanium oxide, copper oxide, zinc oxide, graphene, graphite, carbon black, or any combination thereof.

10. 10. The anode assembly of claim 8, wherein the nucleation layer has a thickness of about 1 nm to about 1 μm.

11. The anode assembly of claim 2 , wherein the deposition layer comprises the conductive layer and the nucleation layer.

12. The anode assembly of claim 11 , wherein the nucleation layer is disposed between the anode layer and the conductive layer.

13. The anode assembly of claim 12 , wherein the conductive layer is disposed between the anode layer and the nucleation layer.

14. 14. The anode assembly according to claim 11, wherein the conductive material of the conductive layer comprises a metal, a metal oxide, a metal alloy, carbon black, carbon nanotubes, graphite, graphene, amorphous carbon, or any combination thereof.

15. 15. The anode assembly according to claim 11, wherein the conductive layer is substantially free of metals or metal alloys that react with or form alloys with lithium metal at room temperature.

16. 16. The anode assembly of claim 15, wherein the conductive material of the conductive layer comprises copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof.

17. The anode assembly of any one of claims 11 to 16, wherein the conductive layer has a thickness of from about 1 nm to about 15 μm.

18. 18. The anode assembly of any one of claims 11 to 17, wherein the nucleation material of the nucleation layer comprises silver, gold, aluminum, bismuth, antimony, indium, zinc, gallium, nickel oxide, titanium oxide, copper oxide, zinc oxide, graphene, graphite, carbon black, or any combination thereof.

19. The anode assembly of any one of claims 11 to 18, wherein the nucleation layer has a thickness of from about 1 nm to about 1 μm.

20. The anode assembly of any one of claims 2 to 19, wherein the conductive layer is substantially impermeable to liquids.

21. The anode assembly of any one of claims 2 to 20, wherein the nucleation layer is substantially impermeable to liquids.

22. 22. The anode assembly of claim 2, further comprising a sealing layer at least partially disposed on at least one of the conductive layer and the nucleation layer, the sealing layer being substantially impermeable to liquids.

23. The anode assembly of claim 22 , wherein the sealing layer comprises a polymer.

24. 24. The anode assembly of claim 23, wherein the polymer comprises polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof.

25. The anode assembly of any one of claims 22 to 24, wherein the sealing layer has a thickness of from about 1 μm to about 50 μm.

26. The anode assembly of any one of claims 2 to 25, wherein a conductive tape bonds the anode current collector to the at least one of the conductive layer and the nucleation layer.

27. 27. The anode assembly of any one of claims 2 to 26, wherein the conductive layer is further defined as a first conductive layer, and the anode assembly further comprises a second conductive layer at least partially disposed on the first conductive layer, the second conductive layer comprising a conductive material.

28. The anode assembly of any one of claims 1 to 27, wherein the separator layer is substantially pore-free.

29. The anode assembly of any one of claims 1 to 28, wherein the separator layer comprises an SSE material.

30. 30. The anode assembly of claim 29, wherein the SSE material of the separator layer comprises a polymer, a sulfide, an oxide, a chalcogenide, or any combination thereof.

31. The anode assembly of any one of claims 1 to 30, wherein the separator layer has a thickness of from about 1 µm to about 300 µm.

32. 32. An anode assembly according to any preceding claim, wherein the pores of the anode layer are substantially free of lithium material.

33. 33. The anode assembly of claim 32, wherein the lithium material comprises lithium metal.

34. 32. The anode assembly of claim 1, wherein the anode layer defines a first porous region between the first surface and the second surface of the anode layer, and a second porous region between the first porous region and the second surface of the anode layer.

35. 35. The anode assembly of claim 34, wherein the pores of the first porous region are substantially free of metallic material.

36. 36. The anode assembly of claim 35, wherein the pores of the first porous region are substantially free of lithium material.

37. 37. The anode assembly of claim 36, wherein the lithium material comprises lithium metal.

38. 38. The anode assembly of any one of claims 34 to 37, wherein at least some of the pores of the second porous region comprise a conductive material, a nucleating material, or any combination thereof.

39. 40. The anode assembly of claim 38, wherein the conductive material of the second porous region comprises a metal, a metal oxide, a metal alloy, carbon black, carbon nanotubes, graphite, graphene, amorphous carbon, or any combination thereof.

40. 40. The anode assembly of claim 38 or 39, wherein the nucleation material of the second porous region comprises silver, gold, aluminum, bismuth, antimony, indium, zinc, gallium, nickel oxide, titanium oxide, copper oxide, zinc oxide, carbon black, graphene, graphite, or any combination thereof.

41. The anode assembly of any one of claims 1 to 40, wherein the anode layer has a thickness of from about 1 µm to about 500 µm.

42. The anode assembly of any one of claims 1 to 41, wherein the anode current collector comprises a metal foil.

43. 43. The anode assembly of claim 42, wherein the metal foil comprises copper, nickel, titanium, stainless steel, an alloy thereof, or any combination thereof.

44. 44. The anode assembly of claim 42 or 43, wherein the metal foil has a tab configured for connection to an external circuit.

45. 42. The anode assembly of any one of claims 1 to 41, wherein the anode current collector includes a tab configured for connection to an external circuit.

46. The anode assembly of claim 1 , wherein the deposition layer is substantially impermeable to liquids.

47. 10. The anode assembly of claim 1, further comprising a sealing layer disposed at least partially on the deposition layer, the sealing layer being substantially impermeable to liquids.

48. 48. The anode assembly of claim 47, wherein the sealing layer comprises a polymer.

49. 49. The anode assembly of claim 48, wherein the polymer comprises polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof.

50. 50. The anode assembly of any one of claims 47 to 49, wherein the sealing layer has a thickness of from about 1 μm to about 50 μm.

51. 51. The anode assembly of any one of claims 47 to 50, wherein the sealing layer bonds the anode current collector to the deposition layer.

52. The anode assembly of claim 1 , wherein a conductive tape bonds the anode current collector to the deposited layer.

53. A battery cell, an anode assembly according to any one of claims 1 to 52; 1. A cathode assembly comprising: a cathode layer at least partially disposed on the separator layer of the anode assembly; and a cathode current collector coupled to the cathode layer; the cathode assembly comprising: The battery cell.

54. 54. The battery cell of claim 53, wherein the battery cell further comprises a liquid comprising an electrolyte, an anolyte, a catholyte, or any combination thereof.

55. 55. The battery cell of claim 54, wherein the liquid comprises a lithium salt, a linear carbonate, a cyclic carbonate, an ionic liquid, or any combination thereof.

56. 1. A method of forming an anode assembly, comprising: (a) providing a separator layer and an anode layer disposed at least partially on the separator layer, the anode layer having a first surface facing the separator layer and a second surface facing away from the separator layer, the anode layer comprising a solid electrolyte having micropores (SSE); (b) disposing at least one of a conductive layer and a nucleation layer at least partially on the second surface of the anode layer; (c) electrically coupling an anode current collector to said at least one of said conductive layer and said nucleation layer to form said anode assembly; The method comprising:

57. 57. The method of claim 56, wherein step (b) comprises disposing the conductive layer at least partially on the second surface of the anode layer.

58. 57. The method of claim 56, wherein step (b) comprises disposing the nucleation layer at least partially on the second surface of the anode layer.

59. 57. The method of claim 56, wherein step (b) comprises disposing the conductive layer and the nucleation layer at least partially on the second surface of the anode layer.

60. 60. The method of claim 59, wherein the conductive layer is disposed between the anode layer and the nucleation layer.

61. 60. The method of claim 59, wherein the nucleation layer is disposed between the anode layer and the conductive layer.

62. 62. The method of any one of claims 56-61, wherein step (b) comprises disposing the at least one of the conductive layer and the nucleation layer by thermal evaporation, sputtering, electron beam evaporation, molecular beam epitaxy, pulsed laser deposition, plasma-enhanced physical vapor deposition, atomic layer deposition, screen printing, inkjet printing, casting, coating, or any combination thereof.

63. Step (b) (b1) disposing at least one of a conductive layer and a nucleation layer at least partially on the second surface of the anode layer; (b2) treating the at least one of the conductive layer and the nucleation layer; 63. The method of any one of claims 56 to 62, further comprising:

64. 64. The method of claim 63, wherein step (b2) further comprises treating the at least one of the conductive layer and the nucleation layer by annealing, heat treating, melting, or oxidizing the at least one of the conductive layer and the nucleation layer.

65. 65. The method of any one of claims 56-64, wherein step (c) comprises electrically coupling the anode current collector to the at least one of the conductive layer and the nucleation layer with conductive tape.

66. 65. The method of any one of claims 56 to 64, wherein step (c) comprises electrically coupling the anode current collector to the at least one of the conductive layer and the nucleation layer by brazing with a brazing filler material.

67. 67. The method of claim 66, wherein the braze material comprises silver, gold, aluminum, bismuth, antimony, zinc, indium, copper, phosphorous, nickel, titanium, tungsten, chromium, silicon, vanadium, tantalum, zirconium, alloys thereof, or any combination thereof.

68. The method comprises: (d) disposing a sealing layer at least partially over the at least one of the conductive layer and the nucleation layer, the sealing layer being substantially impermeable to liquids; 67. The method of any one of claims 55 to 66, further comprising:

69. 69. The method of claim 68, wherein step (d) further comprises at least partially disposing a sealing layer on said at least one of said conductive layer and said nucleation layer by at least partially cold pressing, hot pressing, melting, 3D printing, or any combination thereof, a polymer onto said at least one of said conductive layer and said nucleation layer.

70. 70. The method of claim 69, wherein the polymer comprises polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene-acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof.

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