Electrochemical cell with electrode material directly bonded to film and method of making same

Abstract

Embodiments described herein relate to electrochemical cells having one or more electrodes directly bonded to a film material and methods of making the same.SOLUTION: In some embodiments, the electrochemical cell includes a first electrode material provided on a first current collector, wherein the first current collector is coupled to a first non-conductive film. In some embodiments, the first tab is coupled to the first current collector. The electrochemical cell further comprises a second electrode material capable of taking up or releasing ions during operation of the electrochemical cell. The second electrode material is directly bonded to the second non-conductive film. The second tab is electronically coupled to the second electrode material. The separator is provided between the first electrode material and the second electrode material. In some embodiments, the second tab may be directly coupled to the second electrode material.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62 / 979,568, filed February 21, 2020, entitled "ELECTROCHEMICAL CELLS WITH ELECTRODE MATERIAL COUPLED DIRECTLY TO FILM AND METHODS OF MAKING THE SAME," the disclosure of which is incorporated herein by reference in its entirety.

[0002] STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] This invention was made with government support under Grant No. DE-AR0000774 awarded by the Department of Energy. The government has certain rights in this invention.

[0003] FIELD OF THE INVENTION

[0003] Embodiments described herein relate to electrochemical cells in which one or more electrodes are bonded directly to a film material and methods for making the same. [Background technology]

[0004]

[0004] A battery or electrochemical cell typically includes an anode material disposed on an anode current collector, a cathode material disposed on a cathode current collector, and a separator disposed between the anode and cathode materials. The current collectors are often bonded to weld tabs. In some cases, the aforementioned components are mounted in a pouch, with the weld tabs extending out of the pouch and serving as contacts for charging and discharging the electrochemical cell. The anode current collector is bonded to a first portion of the pouch, and the cathode current collector is bonded to a second portion of the pouch. The use of anode and cathode current collectors can assist in directing the flow of electrons into and out of the electrochemical cell. However, current collectors are often fabricated large enough to cover the entire surface of the electrodes. This amount of current collector material can result in significant material costs. Because large current collectors do not significantly contribute to the energy capacity of an electrochemical cell, their bulk inhibits the specific energy and power of the electrochemical cell. The use of multiple components in an electrochemical cell and the interfaces between the components can also generate large resistive overvoltage losses in the electrochemical cell. Chemical dissolution of current collectors after repeated cycling can also inhibit the performance of an electrochemical cell. Current collectors can also contribute to metallic contamination of the anode and / or cathode materials. Current collectors can also corrode, which can inhibit the energy efficiency of an electrochemical cell. Reducing the size of one or more of the current collectors or substantially eliminating them from an electrochemical cell can potentially reduce manufacturing costs, improve cell specific energy, improve cell specific power, reduce overvoltage losses, improve cyclability, and enhance the overall performance of the electrochemical cell. Summary of the Invention

[0005]

[0005] Embodiments described herein relate to electrochemical cells in which one or more electrodes are directly bonded to a film material, and methods for fabricating the same. In some embodiments, the electrochemical cell includes a first electrode material disposed on a first current collector, the first current collector bonded to a first non-conductive film. In some embodiments, a first tab is bonded to the first current collector. The electrochemical cell further includes a second electrode material capable of capturing or releasing ions during operation of the electrochemical cell. In some embodiments, the second electrode material can be sufficiently conductive such that the electrochemical cell can operate normally without being directly bonded to the current collector. In some embodiments, the second electrode material can be sufficiently conductive such that the electrochemical cell can operate normally without the addition of a conductive additive to the second electrode material. The second electrode material is bonded directly to the second non-conductive film. The second tab is electronically bonded to the second electrode material. A separator is disposed between the first electrode material and the second electrode material. In some embodiments, the second tab can be directly bonded to the second electrode material. In some embodiments, the second tab can be directly bonded to the second current collector, and the second current collector can be directly bonded to only a portion of the second electrode material. In some embodiments, the second current collector can be in physical contact with less than about 3% of the total surface area of ​​the second electrode material. In some embodiments, the second electrode material is not bonded to a current collector. In some embodiments, the first non-conductive film can be directly bonded to the second non-conductive film to form a pouch. In some embodiments, the electrochemical cell can have a specific energy of at least about 300 Wh / kg. In some embodiments, the first electrode material and / or the second electrode material can comprise a semi-solid, binder-free electrode material. [Brief explanation of the drawings]

[0006] [Figure 1] 6 is a schematic diagram of an electrochemical cell in which one or more electrode materials are bonded directly to a film material, according to one embodiment. [Figure 2]

[0007] 1 illustrates an electrochemical cell in which the anode is directly bonded to the film, according to one embodiment. [Figure 3]

[0008] 1 illustrates an anode directly bonded to a film, according to one embodiment. [Figure 4]

[0009] 1 illustrates an electrochemical cell in which the anode is directly bonded to the film, according to one embodiment. [Figure 5]

[0010] 1 illustrates an anode directly bonded to a film, according to one embodiment. [Figure 6]

[0011] 1 shows cycling data for an electrochemical cell in which the anode weld tab was directly bonded to the anode. DETAILED DESCRIPTION OF THE INVENTION

[0007]

[0012] Embodiments described herein relate to electrochemical cells in which one or more electrodes are directly bonded to a film material and methods for manufacturing the same. More specifically, electrochemical cells in which one or more electrodes are directly bonded to a film material can reduce the amount of material contained in the electrochemical cell by reducing the size of the electrochemical cell's current collectors or substantially eliminating current collectors from one or more electrodes. In addition to reducing manufacturing costs, reducing the amount of current collector material contained in an electrochemical cell can also increase the specific energy and / or specific power of the electrochemical cell by removing inactive materials. Chemical dissolution of current collectors is also a problem that can be alleviated by reducing the size of the electrochemical cell's current collectors or substantially eliminating current collectors from one or more electrodes. In addition, metal contamination of electrodes through current collectors can be reduced or substantially eliminated in electrochemical cells in which one or more electrodes are directly bonded to a film material. Substantially eliminating current collectors from one or more electrodes of an electrochemical cell can also simplify the process of recycling the electrochemical cell.

[0008]

[0013] In some embodiments, the electrochemical cell can include an anode material capable of taking up or releasing ions during operation of the electrochemical cell, the anode material being directly bonded to the film material. In some embodiments, a portion of the anode material surface area can be bonded to an anode current collector. In some embodiments, the anode current collector can have a length that is significantly shorter than the length of the anode material. In some embodiments, the anode current collector can be bonded to an anode tab. In some embodiments, the electrochemical cell may not have an anode current collector, and the anode material can be bonded directly to the anode tab. In some embodiments, the anode tab can be an anode weld tab.

[0009]

[0014] In some embodiments, the electrochemical cell can include a cathode material capable of capturing or releasing ions during operation of the electrochemical cell, the cathode material being directly bonded to the film material. In some embodiments, a portion of the cathode material surface area can be bonded to a cathode current collector. In some embodiments, the cathode current collector can have a length that is significantly shorter than the length of the cathode material. In some embodiments, the cathode current collector can be bonded to a cathode tab. In some embodiments, the electrochemical cell can be free of a cathode current collector, and the cathode material can be bonded directly to the cathode tab. In some embodiments, the cathode tab can be a cathode weld tab.

[0010]

[0015] In some embodiments, the electrochemical cells described herein can include a semi-solid cathode and / or a semi-solid anode. In some embodiments, the semi-solid electrodes described herein can be binder-free and / or can use less binder than typically used in conventional battery manufacturing. The semi-solid electrodes described herein can be formulated as a slurry, with the electrolyte included in the slurry formulation. This is in contrast to conventional electrodes, e.g., calendered electrodes, where the electrolyte is typically added to the electrochemical cell after the electrochemical cell is placed in a container, e.g., a pouch or can.

[0011]

[0016] In some embodiments, the electrode materials described herein can be flowable semi-solid or condensed liquid compositions. In some embodiments, a flowable semi-solid electrode can comprise a suspension of electrochemically active material (anode or cathode particles or particulates) and, optionally, an electronically conductive material (e.g., carbon) in a non-aqueous liquid electrolyte. In some embodiments, the active electrode particles and conductive particles can be co-suspended within the electrolyte to produce a semi-solid electrode. In some embodiments, the electrode materials described herein can comprise conventional electrode materials (e.g., including lithium metal).

[0012]

[0017] Examples of electrodes, electrolyte solutions, and methods that can be used to prepare them are described in U.S. Pat. No. 9,437,864, entitled "Asymmetric Battery Having a Semi-Solid Cathode and High Energy Density Anode," filed March 10, 2014 (hereinafter referred to as the "'864 patent"), the disclosure of which is incorporated herein by reference in its entirety. Additional examples of electrodes, electrolyte solutions, and methods that can be used to prepare them are described in U.S. Pat. No. 9,484,569, entitled "Electrochemical Slurry Compositions and Methods for Preparing the Same," filed March 15, 2013 (hereinafter referred to as the "'569 patent"), U.S. Pat. No. 10,637,038, entitled "Electrochemical Cells Having Semi-Solid Electrodes and Methods of Manufacturing the Same," filed November 4, 2015 (hereinafter referred to as the "'038 patent"), and U.S. Pat. No. 8,993,159, entitled "Semi-Solid Electrodes Having High Rate Capability," filed April 29, 2013 (hereinafter referred to as the "'159 patent"), the disclosures of which are incorporated herein by reference in their entireties.

[0013]

[0018] As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, the term "element" is intended to mean a single element or a combination of elements, and "material" is intended to mean one or more materials or combinations thereof.

[0014]

[0019] The term "substantially" when used in connection with "cylindrical," "linear," and / or other geometric relationships is intended to convey that the structure so defined is nominally cylindrical, linear, etc. As an example, a portion of a support member described as "substantially linear" is intended to convey that while it is desirable for the portion to be linear, some non-linearity may occur within the "substantially linear" portion. Such non-linearity may result from manufacturing tolerances or other practical considerations (e.g., pressure or force applied to the support member). Thus, a geometric structure modified by the term "substantially" includes such geometric characteristics within a tolerance of plus or minus 5% of the described geometric structure. For example, a "substantially linear" portion is one that defines an axis or centerline that is within plus or minus 5% of being linear.

[0015]

[0020] As used herein, the terms "set" and "plurality" can refer to multiple features or a singular feature having multiple portions. For example, when referring to a set of electrodes, the set of electrodes can be considered a single electrode having multiple portions, or the set of electrodes can be considered a plurality of separate electrodes. Additionally, when referring to, for example, a plurality of electrochemical cells, the plurality of electrochemical cells can be considered a plurality of separate electrochemical cells or a single electrochemical cell having multiple portions. Thus, a set of portions or multiple portions can include multiple portions that are either contiguous or discontinuous with one another. Multiple particles or multiple materials can also be made from multiple articles that are manufactured separately and later bonded together (e.g., via mixing, adhesive, or any suitable method).

[0016]

[0021] As used herein, the term "semi-solid" refers to a material that is a mixture of a liquid and a solid phase, such as, for example, a particle suspension, a slurry, a colloidal suspension, an emulsion, a gel, or a micelle.

[0017]

[0022] FIG. 1 is a schematic diagram of an electrochemical cell 100 in which one or more electrode materials are directly bonded to a film material. The electrochemical cell 100 includes an anode material 110 capable of taking up or releasing ions during operation of the electrochemical cell 100. In some embodiments, the anode material 110 can be directly bonded to the anode film 120 (i.e., the anode material 110 can be in direct contact with the anode film 120). The anode material 110 is electrically bonded to an anode tab 130. In some embodiments, the anode material 110 can be directly bonded to the anode tab 130. In some embodiments, the anode material 110 can be electrically bonded to the anode tab 130 via a direct bond between the anode material 110 and the anode current collector 140. In other words, the anode material 110 can be directly bonded to the anode current collector 140, and the anode current collector 140 can be directly bonded to the anode tab 130. The electrochemical cell 100 includes a cathode material 150. In some embodiments, the cathode material 150 can be directly bonded to the cathode film 160. The cathode material 150 is electrically bonded to the cathode tab 170. In some embodiments, the cathode material 150 can be directly bonded to the cathode tab 170. In some embodiments, the cathode material 150 can be electrically bonded to the cathode tab 170 via the cathode current collector 180. In other words, the cathode material 150 can be directly bonded to the cathode current collector 180, and the cathode current collector 180 can be directly bonded to the cathode tab 170. The electrochemical cell 100 further includes a separator 190 disposed between the anode material 110 and the cathode material 150. In some embodiments, the anode film 120 can be directly bonded to the cathode film 160 to form a pouch. In some embodiments, the separator 190 can be directly bonded to the anode film 120 and / or the cathode film 160.

[0018]

[0023] In some embodiments, the anode material 110 can include conventional electrode materials (e.g., lithium metal). In some embodiments, the anode material 110 can include any other anode active material, including graphite, lithium metal (Li), sodium metal (Na), silicon oxide (SiO), graphite, silicon, carbon, lithium-intercalated carbon, lithium nitride, lithium alloys, and lithium alloy-forming compounds of silicon, bismuth, boron, gallium, indium, zinc, tin, antimony, aluminum, titanium oxide, molybdenum, germanium, manganese, niobium, vanadium, tantalum, gold, platinum, iron, copper, chromium, nickel, cobalt, zirconium, yttrium, molybdenum oxide, germanium oxide, silicon carbide, silicon-graphite composites, or any combination thereof. In some embodiments, the anode material 110 can include a semi-solid electrode material. In some embodiments, the anode material 110 can include any of the materials with physical properties described in the '569, '038, '159, and / or '864 patents.

[0019]

[0024] In some embodiments, the anode material 110 can be directly bonded to the anode film 120. In some embodiments, the anode material 110 can be deposited on the anode film 120 via sputtering, vapor deposition, a sol-gel process, a physical spray process, electron beam deposition, electrochemical deposition, atomic layer deposition (ALD), chemical vapor deposition (CVD), electrophoretic deposition (EPD), pouring, electron beam induced deposition (EBD), slot die coating, MICROGRAVURE™ coating, Langmuir-Blodgett film coating, or any other suitable deposition method. In some embodiments, the anode material 110 can be directly bonded to the anode film 120 via an adhesive, glue, epoxy, a tube-based epoxy, a two-component epoxy putty, or any other suitable bonding material. In some embodiments, the anode material 110 may be directly bonded to the anode film 120 via a layer of material that can be activated to act as an adhesive under the application of heat, light such as UV or IR, or a mechanical or electrical perturbation such as ultrasound or sound waves, or radio frequency or microwaves, or any combination thereof.

[0020]

[0025] In some embodiments, the anode film 120 can be composed of an electronically non-conductive material. In some embodiments, the anode film 120 can be composed of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), nylon, high-density polyethylene (HDPE), oriented polypropylene (o-PP), polyvinyl chloride (PVC), polyimide (PI), polysulfone (PSU), cast polypropylene (c-PP), polyethylene (PE), ethylene vinyl acetate (EVA), PET, polyvinyl acetate (PVA), polyamide (PA), acrylic adhesive, ultraviolet (UV) / electron beam (EB) / infrared (IR) curable resin, polyether ether ketone (PEEK), polyethylene naphthalate (PEN), polyethersulfone (PES), polyimide (PI), polyphenylene sulfide (PPS), polyphenylene oxide (PPO), or any combination thereof. In some embodiments, the anode film 120 can have multiple layers. In some embodiments, the anode film 120 can include a first layer composed of a first material and a second layer composed of a second material. In some embodiments, the anode film 120 can include a first layer composed of a first material and a second layer composed of a second material. In some embodiments, the anode film 120 can include three, four, five, six, seven, eight, nine, ten, or more layers.

[0021]

[0026] In some embodiments, the anode film 120 has a thickness of at least about 1 nm, at least about 2 nm, at least about 3 nm, at least about 4 nm, at least about 5 nm, at least about 6 nm, at least about 7 nm, at least about 8 nm, at least about 9 nm, at least about 10 nm, at least about 20 nm, at least about 30 nm, at least about 40 nm, at least about 50 nm, at least about 60 nm, at least about 70 nm, at least about 80 nm, at least about 90 nm, at least about 100 nm, at least about 200 nm, at least about 300 nm, at least about 400 nm, at least about 500 nm, at least about 600 nm, at least about 700 nm , at least about 800 nm, at least about 900 nm, at least about 1 μm, at least about 2 μm, at least about 3 μm, at least about 4 μm, at least about 5 μm, at least about 6 μm, at least about 7 μm, at least about 8 μm, at least about 9 μm, at least about 10 μm, at least about 12 μm, at least about 14 μm, at least about 16 μm, at least about 18 μm, at least about 20 μm, at least about 25 μm, at least about 30 μm, at least about 35 μm, at least about 40 μm, at least about 45 μm, at least about 50 μm, at least about 100 μm, at least about 150 μm, or at least about 200 μm.In some embodiments, the anode film 120 has a thickness of about 250 μm or less, about 200 μm or less, about 150 μm or less, about 100 μm or less, about 50 μm or less, about 45 μm or less, about 40 μm or less, about 35 μm or less, about 30 μm or less, about 25 μm or less, about 20 μm or less, about 18 μm or less, about 16 μm or less, about 14 μm or less, about 12 μm or less, about 10 μm or less, about 9 μm or less, about 8 μm or less, about 7 μm or less, about 6 μm or less, about 5 μm or less, about 4 μm or less, about 3 μm or less, about 2 μm or less, about 1 μm or less, The anode film 120 can have a thickness of 900 nm or less, about 800 nm or less, about 700 nm or less, about 600 nm or less, about 500 nm or less, about 400 nm or less, about 300 nm or less, about 200 nm or less, about 100 nm or less, about 90 nm or less, about 80 nm or less, about 70 nm or less, about 60 nm or less, about 50 nm or less, about 40 nm or less, about 30 nm or less, about 20 nm or less, about 10 nm or less, about 9 nm or less, about 8 nm or less, about 7 nm or less, about 6 nm or less, about 5 nm or less, about 4 nm or less, about 3 nm or less, or about 2 nm or less. The thickness of the anode film 120 can also be combinations of the above-mentioned values ​​(e.g., at least about 1 nm and about 250 μm or less, or at least about 10 μm and about 50 μm or less), including all values ​​and ranges therebetween. In some embodiments, the anode film 120 has a thickness of about 1 nm, about 2 nm, about 3 nm, about 4 nm, about 5 nm, about 6 nm, about 7 nm, about 8 nm, about 9 nm, about 10 nm, about 20 nm, about 30 nm, about 40 nm, about 50 nm, about 60 nm, about 70 nm, about 80 nm, about 90 nm, about 100 nm, about 200 nm, about 300 nm, about 400 nm, about 500 nm, about 600 nm, about 700 nm, It can have a thickness of about 800 nm, about 900 nm, about 1 μm, about 2 μm, about 3 μm, about 4 μm, about 5 μm, about 6 μm, about 7 μm, about 8 μm, about 9 μm, about 10 μm, about 12 μm, about 14 μm, about 16 μm, about 18 μm, about 20 μm, about 25 μm, about 30 μm, about 35 μm, about 40 μm, about 45 μm, about 50 μm, about 100 μm, about 150 μm, about 200 μm, or about 250 μm.

[0022]

[0027] In some embodiments, the anode film 120 can have the same or substantially similar properties as those described in U.S. Pat. No. 10,181,587, entitled "Single Pouch Battery Cells and Methods of Manufacture," filed June 17, 2016 (hereinafter referred to as the "'587 patent"), the disclosure of which is incorporated herein by reference in its entirety.

[0023]

[0028] In some embodiments, the anode tab 130 can comprise a conductive material in the form of a substrate, sheet, or foil, or any other form factor. In some embodiments, the anode tab 130 can comprise a metal, such as aluminum, copper, lithium, nickel, stainless steel, tantalum, titanium, tungsten, vanadium, or a mixture, combination, or alloy thereof. In some embodiments, the anode tab 130 can comprise a non-metallic material, such as carbon, carbon nanotubes, or a metal oxide (e.g., TiN, TiB2, MoSi2, n-BaTiO3, Ti2O3, ReO3, RuO2, IrO2, etc.). In some embodiments, the anode tab 130 can comprise a conductive coating disposed on any of the aforementioned metallic and non-metallic materials. In some embodiments, the conductive coating can comprise a carbon-based material, a conductive metallic material, and / or a non-metallic material, including a composition or layered material.

[0024]

[0029] In some embodiments, the anode tab 130 may be directly bonded to the anode material 110. In some embodiments, the anode tab 130 may be directly bonded to the anode material 110 via mechanical compression, the use of conductive paste, chemical bonding, welding, brazing, soldering, crimping, or any other suitable bonding means.

[0025]

[0030] In some embodiments, the anode current collector 140 can comprise the same or substantially similar materials as those described above with respect to the anode tab 130. In some embodiments, the anode current collector 140 can have a first material composition, and the anode tab 130 can have a second material composition. In some embodiments, the anode current collector 140 can comprise the same or substantially similar materials as those described in the '587 patent.

[0026]

[0031] In some embodiments, the anode current collector 140 can be directly bonded to the anode material 110. In some embodiments, the anode current collector 140 can be directly bonded to the anode tab 130. In some embodiments, the anode current collector 140 can be a thin ribbon of conductive material that bonds the anode material 110 and the anode tab 130. In some embodiments, the anode current collector 140 can be directly bonded to the anode material 110 via mechanical compression, the use of conductive paste, chemical bonding, welding, brazing, soldering, crimping, or any other suitable bonding means. In some embodiments, the anode current collector 140 can be directly bonded to the anode tab 130 via mechanical compression, the use of conductive paste, chemical bonding, welding, brazing, soldering, crimping, or any other suitable bonding means. In some embodiments, the anode current collector 140 can have the same or substantially similar properties as those described in the '587 patent.

[0027]

[0032] In some embodiments, the cathode material 150 can include any other cathode active material, including lithium cobalt oxide (LCO), lithium nickel manganese cobalt oxide (NMC), lithium iron phosphate (LFP), or any combination thereof.

[0028]

[0033] In some embodiments, the cathode material 150 can be directly bonded to the cathode film 160. In some embodiments, the bond between the cathode material 150 and the cathode film 160 can be the same or substantially similar to the bond between the anode material 110 and the anode film 120 described above. In some embodiments, the anode material 110 can be directly bonded to the anode film 120, while the cathode material 150 is not directly bonded to the cathode film 160. In some embodiments, the cathode material 150 can be directly bonded to the cathode film 160, while the anode material 110 is not directly bonded to the anode film 120. In some embodiments, the anode material 110 can be directly bonded to the anode film 120, or the cathode material 150 can be directly bonded to the cathode film 160. In some embodiments, the cathode film 160 can have the same or substantially similar properties as the properties of the anode film 120 described above.

[0029]

[0034] In some embodiments, the cathode tab 170 can comprise a conductive material in the form of a substrate, sheet, or foil, or any other form factor. In some embodiments, the cathode tab 170 can comprise a metal, such as aluminum, copper, lithium, nickel, stainless steel, tantalum, titanium, tungsten, vanadium, or a mixture, combination, or alloy thereof. In some embodiments, the cathode tab 170 can comprise a non-metallic material, such as carbon, carbon nanotubes, or a metal oxide (e.g., TiN, TiB2, MoSi2, n-BaTiO3, Ti2O3, ReO3, RuO2, IrO2, etc.). In some embodiments, the cathode tab 170 can comprise a conductive coating disposed on any of the aforementioned metallic and non-metallic materials. In some embodiments, the conductive coating can comprise a carbon-based material, a conductive metal, and / or a non-metallic material, including a composition or layered material.

[0030]

[0035] In some embodiments, the cathode current collector 180 can comprise the same or substantially similar materials as those described above with respect to the cathode tab 170. In some embodiments, the cathode current collector 180 can have a first material composition, and the cathode tab 170 can have a second material composition. In some embodiments, the cathode current collector 180 can comprise the same or substantially similar materials as those described in the '587 patent.

[0031]

[0036] In some embodiments, the cathode current collector 180 may be bonded directly to the cathode material 150. In some embodiments, the bond between the cathode current collector 180 and the cathode material 150 may be the same or substantially similar to the bond between the anode current collector 140 and the anode material 110 described above. In some embodiments, the cathode current collector 180 may be bonded directly to the cathode tab 170. In some embodiments, the bond between the cathode current collector 180 and the cathode tab 170 may be the same or substantially similar to the bond between the anode current collector 140 and the anode tab 130 described above. In some embodiments, the cathode current collector 180 may have the same or substantially similar properties as those described in the '587 patent.

[0032]

[0037] In some embodiments, separator 190 can be a microporous thin film that electrically isolates anode material 110 from cathode material 150 but allows ions to pass through pores between anode material 110 and cathode material 150. In some embodiments, separator 190 can be directly bonded to anode film 120 and / or cathode film 160. In some embodiments, separator 190 can have the same or substantially similar properties as those described in the '587 patent.

[0033]

[0038] In some embodiments, the electrochemical cell 100 can include one or more electrolyte solutions, such as ethylene carbonate (EC), gamma-butyrolactone (GBL), lithium bis(fluorosulfonyl)imide (LiFSI), trioctyl phosphate (TOP), propylene carbonate (PC), dimethoxyethane (DME), bis(trifluoromethanesulfonyl)imide (TSFI), Li 1.4 Al 0.4 Ti 1.6 (PO4)3(LATP), and any combination thereof. Additional examples of active materials, conductive materials, and electrolyte solutions that can be incorporated into electrochemical cell 100 are described in the '569 patent.

[0034]

[0039] In some embodiments, electrochemical cell 100 can have a cell specific power output of at least about 300 W / kg, at least about 350 W / kg, at least about 400 W / kg, at least about 450 W / kg, at least about 500 W / kg, at least about 550 W / kg, at least about 600 W / kg, or at least about 650 W / kg, or at least about 700 W / kg, including all values ​​and ranges therebetween.

[0035]

[0040] In some embodiments, electrochemical cell 100 can have a cell specific energy density of at least about 250 W·h / kg when discharged at 1 C, at least about 300 W·h / kg when discharged at 1 C, at least about 350 W·h / kg when discharged at 1 C, at least about 400 W·h / kg when discharged at 1 C, at least about 450 W·h / kg when discharged at 1 C, at least about 500 W·h / kg, at least about 550 W·h / kg, at least about 600 W·h / kg, at least about 650 W·h / kg, at least about 700 W·h / kg, or at least about 750 W·h / kg, including all values ​​and ranges therebetween. In some embodiments, electrochemical cell 100 can have a cell specific energy density of at least about 250 W·h / kg when discharged at C / 2, at least about 300 W·h / kg when discharged at C / 2, at least about 350 W·h / kg when discharged at C / 2, at least about 400 W·h / kg when discharged at C / 2, at least about 450 W·h / kg when discharged at C / 2, at least about 500 W·h / kg, at least about 550 W·h / kg, at least about 600 W·h / kg, at least about 650 W·h / kg, at least about 700 W·h / kg, or at least about 750 W·h / kg, including all values ​​and ranges therebetween. In some embodiments, electrochemical cell 100 can have a cell specific energy density of at least about 250 W·h / kg when discharged at C / 4, at least about 300 W·h / kg when discharged at C / 4, at least about 350 W·h / kg when discharged at C / 4, at least about 400 W·h / kg when discharged at C / 4, or at least about 450 W·h / kg when discharged at C / 4, at least about 500 W·h / kg, at least about 550 W·h / kg, at least about 600 W·h / kg, at least about 650 W·h / kg, at least about 700 W·h / kg, or at least about 750 W·h / kg, including all values ​​and ranges therebetween.

[0036]

[0041] In some embodiments, the percentage of energy lost from electrochemical cell 100 due to resistive overpotential is less than about 40% when discharged at 1 C, less than about 35% when discharged at 1 C, less than about 30% when discharged at 1 C, less than about 25% when discharged at 1 C, less than about 20% when discharged at 1 C, less than about 18% when discharged at 1 C, less than about 16% when discharged at 1 C, less than about 14 ... The RH may be less than 12%, less than about 10% when discharged at 1C, less than about 9% when discharged at 1C, less than about 8% when discharged at 1C, less than about 7% when discharged at 1C, less than about 6% when discharged at 1C, less than about 5% when discharged at 1C, less than about 4% when discharged at 1C, less than about 3% when discharged at 1C, less than about 2% when discharged at 1C, or less than about 1% when discharged at 1C, including all values ​​and ranges therebetween. In some embodiments, the percentage of energy lost from electrochemical cell 100 due to resistive overpotential is less than about 40% when discharged at C / 2, less than about 35% when discharged at C / 2, less than about 30% when discharged at C / 2, less than about 25% when discharged at C / 2, less than about 20% when discharged at C / 2, less than about 18% when discharged at C / 2, less than about 16% when discharged at C / 2, less than about 14 ... The loss of charge may be less than about 12% when discharged at C / 2, less than about 10% when discharged at C / 2, less than about 9% when discharged at C / 2, less than about 8% when discharged at C / 2, less than about 7% when discharged at C / 2, less than about 6% when discharged at C / 2, less than about 5% when discharged at C / 2, less than about 4% when discharged at C / 2, less than about 3% when discharged at C / 2, less than about 2% when discharged at C / 2, or less than about 1% when discharged at C / 2, including all values ​​and ranges therebetween.In some embodiments, the percentage of energy lost from electrochemical cell 100 due to resistive overpotential is less than about 40% when discharged at C / 4, less than about 35% when discharged at C / 4, less than about 30% when discharged at C / 4, less than about 25% when discharged at C / 4, less than about 20% when discharged at C / 4, less than about 18% when discharged at C / 4, less than about 16% when discharged at C / 4, less than about 14 ...4% when discharged at C / 4, less than about 14% when discharged at C / 4, less than about 14% when discharged at C / 4, less than about 14% when discharged at C / 4, less than about 14% when discharged at C / 4, less than about 14% when discharged at C / 4, less than about 14% when discharged at C / 4, less than about 14% when discharged at C / 4, less than about 14% when discharged at C / 4, less than about 14 The loss may be less than 12%, less than about 10% when discharged at C / 4, less than about 9% when discharged at C / 4, less than about 8% when discharged at C / 4, less than about 7% when discharged at C / 4, less than about 6% when discharged at C / 4, less than about 5% when discharged at C / 4, less than about 4% when discharged at C / 4, less than about 3% when discharged at C / 4, less than about 2% when discharged at C / 4, or less than about 1% when discharged at C / 4, including all values ​​and ranges therebetween.

[0037]

[0042] 2 and 3 show perspective views of an electrochemical cell 200 and an anode 205 according to various embodiments. The electrochemical cell 200 includes an anode material 210 capable of taking up or releasing ions during operation of the electrochemical cell 200. As shown, the anode material 210 is directly bonded to an anode film 220. As shown, the anode material 210 is directly bonded to an anode tab 230. In some embodiments, the anode material 210 may be electrically coupled to the anode tab 230 via an anode current collector (not shown). The electrochemical cell 200 includes a cathode material 250. As shown, the cathode material 250 is directly bonded to a cathode current collector 280. As shown, the cathode current collector 280 is directly bonded to a cathode film 260 and a cathode tab 270. In some embodiments, the cathode material 250 may be directly bonded to the cathode film 260. In some embodiments, the cathode material 250 can be directly bonded to the cathode tab 270. The electrochemical cell 200 further includes a separator 290 disposed between the anode material 210 and the cathode material 250. In some embodiments, the anode film 220 can be directly bonded to the cathode film 260 to form a pouch. In some embodiments, the separator 290 can be directly bonded to the anode film 220 and / or the cathode film 260. FIG. 2 shows a cross-sectional view of the electrochemical cell 200 along surface A, where surface A is oriented to penetrate the anode tab 230. FIG. 3 shows an overhead view of the anode 205, where surface A appears as a line. As shown from the perspective of FIG. 2, the cathode tab 270 is positioned behind the anode tab 230. In other words, surface A is oriented to penetrate the anode tab 230 but not the cathode tab 270. In some embodiments, the cathode tab 270 can be aligned with the anode tab 230 so that surface A is oriented through the anode tab 230 and the cathode tab 270 .

[0038]

[0043] In some embodiments, the anode material 210, anode film 220, anode tab 230, cathode material 250, cathode film 260, cathode tab 270, cathode current collector 280, separator 290, and the bonds therebetween can be the same as or substantially similar to the anode material 110, anode film 120, anode tab 130, cathode material 150, cathode film 160, cathode tab 170, cathode current collector 180, separator 190, and the bonds therebetween, respectively, described above with respect to FIG. 1 .

[0039]

[0044] Designing an electrochemical cell in which one or more of the electrodes do not include a conventional current collector (as shown in FIGS. 2 and 3) can enable several technical advantages. First, material costs, particularly for the current collector material, can be reduced by at least 50%. Second, resistive overpotential losses can be significantly reduced compared to resistive overpotential losses in electrochemical cells in which both electrodes include conventional current collectors. Third, the construction of each electrochemical cell can be simplified in that fewer components are included in the assembly. Fourth, disassembly is simplified for ease of recycling the electrochemical cell, as one or more of the electrodes do not include a conventional current collector.

[0040]

[0045] As shown in FIGS. 2 and 3, the anode material 210 has a characteristic electrode material length L EM 3, a portion of the anode tab 230 overlaps a portion of the anode material 210. This overlap section has a characteristic tab-electrode overlap length L TEO In some embodiments, L TEOcan be at least about 1 μm, at least about 5 μm, at least about 10 μm, at least about 20 μm, at least about 30 μm, at least about 40 μm, at least about 50 μm, at least about 60 μm, at least about 70 μm, at least about 80 μm, at least about 90 μm, at least about 100 μm, at least about 200 μm, at least about 300 μm, at least about 400 μm, at least about 500 μm, at least about 600 μm, at least about 700 μm, at least about 800 μm, at least about 900 μm, at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 1 cm, at least about 2 cm, at least about 3 cm, or at least about 4 cm. TEO is approximately 5 cm or less, approximately 4 cm or less, approximately 3 cm or less, approximately 2 cm or less, approximately 1 cm or less, approximately 9 mm or less, approximately 8 mm or less, approximately 7 mm or less, approximately 6 mm or less, approximately 5 mm or less, approximately 4 mm or less , about 3 mm or less, about 2 mm or less, about 1 mm or less, about 900 μm or less, about 800 μm or less, about 700 μm or less, about 600 μm or less, about 500 μm or less, about 400 μm or less, about 30 The thickness may be 0 μm or less, about 200 μm or less, about 100 μm or less, about 90 μm or less, about 80 μm or less, about 70 μm or less, about 60 μm or less, about 50 μm or less, about 40 μm or less, about 30 μm or less, about 20 μm or less, about 10 μm or less, about 9 μm or less, about 8 μm or less, about 7 μm or less, about 6 μm or less, about 5 μm or less, about 4 μm or less, about 3 μm or less, or about 2 μm or less. TEO Combinations of the above-referenced values ​​are also possible for L (e.g., at least about 1 μm and not more than about 5 μm, or at least about 10 μm and not more than about 50 μm), including all values ​​and ranges therebetween. TEOare approximately 1μm, approximately 2μm, approximately 3μm, approximately 4μm, approximately 5μm, approximately 6μm, approximately 7μm, approximately 8μm, approximately 9μm, approximately 10μm, approximately 20μm, approximately 30μm, approx. 40μm, approx. 50μm, approx. 60μm, approx. 70μm, approx. 80μm, approx. 90μm, approx. 100μm, approx. 200μm, approx. 300μ m, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 1 cm, about 2 cm, about 3 cm, about 4 cm, or about 5 cm. In some embodiments, the anode 205 may have no or substantially no tab-electrode overlap (i.e., L TEO may be about 0 μm).

[0041]

[0046] In some embodiments, L TEO :L EM can be at least about 1:1000, at least about 1:900, at least about 1:900, at least about 1:800, at least about 1:700, at least about 1:600, at least about 1:500, at least about 1:400, at least about 1:300, at least about 1:200, at least about 1:100, at least about 1:90, at least about 1:80, at least about 1:70, at least about 1:60, at least about 1:50, at least about 1:40, at least about 1:30, at least about 1:20, at least about 1:10, at least about 1:9, at least about 1:8, at least about 1:7, at least about 1:6, at least about 1:5, at least about 1:4, at least about 1:3, at least about 1:2, at least about 1:1.9, at least about 1:1.8, at least about 1:1.7, or at least about 1:1.6. TEO :L EMThe ratio of L can be about 1:1.5 or less, about 1:1.6 or less, about 1:1.7 or less, about 1:1.8 or less, about 1:1.9 or less, about 1:2 or less, about 1:3 or less, about 1:4 or less, about 1:5 or less, about 1:6 or less, about 1:7 or less, about 1:8 or less, about 1:9 or less, about 1:10 or less, about 1:20 or less, about 1:30 or less, about 1:40 or less, about 1:50 or less, about 1:60 or less, about 1:70 or less, about 1:80 or less, about 1:90 or less, about 1:100 or less, about 1:200 or less, about 1:300 or less, about 1:400 or less, about 1:500 or less, about 1:600 ​​or less, about 1:700 or less, about 1:800 or less, or about 1:900 or less. TEO :L EM The ratio of L can be any combination of the above-referenced values ​​(e.g., at least about 1:1000 and not more than about 1:1.5, or at least about 1:100 and not more than about 1:50), including all values ​​and ranges therebetween. TEO :L EM can be about 1:1000, about 1:900, about 1:800, about 1:700, about 1:600, about 1:500, about 1:400, about 1:300, about 1:200, about 1:100, about 1:90, about 1:80, about 1:70, about 1:60, about 1:50, about 1:40, about 1:30, about 1:20, about 1:10, about 1:9, about 1:8, about 1:7, about 1:6, about 1:5, about 1:4, about 1:3, about 1:2, about 1:1.9, about 1:1.8, about 1:1.7, about 1:1.6 or about 1:1.5.

[0042]

[0047] In some embodiments, the cathode material 250 has a characteristic length L CM In some embodiments, L CM L EM In some embodiments, L CM L EM In some embodiments, (L EM -L CM) can be at least about 1 μm, at least about 5 μm, at least about 10 μm, at least about 50 μm, at least about 100 μm, at least about 500 μm, at least about 1 mm, at least about 5 mm, at least about 1 cm, or at least about 5 cm. In some embodiments, (L EM -L CM ) can be about 10 cm or less, about 5 cm or less, about 1 cm or less, about 5 mm or less, about 1 mm or less, about 500 μm or less, about 100 μm or less, about 50 μm or less, about 10 μm or less, or about 5 μm or less. EM -L CM ) can also include combinations of the above-mentioned values ​​(e.g., at least about 1 μm and not more than about 10 cm, or at least about 10 mm and not more than about 1 cm), including all values ​​and ranges therebetween. In some embodiments, (L EM -L CM ) can be about 1 μm, about 5 μm, about 10 μm, about 50 μm, about 100 μm, about 500 μm, about 1 mm, about 5 mm, about 1 cm, about 5 cm, or about 10 cm.

[0043]

[0048] Plating of electroactive material around the periphery of the anode material 210 and / or cathode material 250 is a potential problem when the dimensions of the anode material 210 and the cathode material 250 do not match. In such cell designs, as the electroactive material flows between the anode material 210 and the cathode material 250, deposition or plating of electroactive species can occur around the outer periphery of the anode material 210 and / or the cathode material. These deposits can potentially cause a short circuit in the electrochemical cell 200. In some embodiments, the separator 290 can include a separator seal 295 that can restrict the flow of ions through the separator 290. The restriction of the flow of ions through the separator 290 can direct the flow of ions into the anode material 210 and / or the cathode material 250, preventing them from depositing around the outer periphery of the anode material 210 and / or the cathode material 250. In some embodiments, separator seal 295 can be a tape or an adhesive adhered to the outer surface of separator 290. In some embodiments, separator seal 295 can be melted with separator 290, such that separator 290 and separator seal 295 are thermally bonded together. In some embodiments, separator seal 295 can be a gel, a viscous oil, and / or a material that penetrates into pores in portions of separator 290, thereby blocking the flow of materials through those pores.

[0044]

[0049] 2, the separator seal 295 defines first and second edges E1 and E2 of the active areas of the anode material 210 and cathode material 250. The active areas of the anode material 210 and cathode material 250 are areas through which ions can freely move between the anode material 210 and the cathode material 250. As shown, the separator seal 295 prevents or substantially inhibits the movement of ions through the portion of the separator 290 that does not have the separator seal 295. In some embodiments where the separator 290 does not include the separator seal 295, the first and second edges E1 and E2 of the active areas can be defined by the outer edges of the cathode material 250 (LCM L EM In some embodiments where the separator 290 does not include a separator seal 295, the first edge E1 and second edge E2 of the active area can be defined by the outer edges of the anode material 210 (L EM L CM As shown, the anode tab 230 does not extend into the active area of ​​the anode material 210. Keeping the anode tab 230 away from the active area of ​​the anode material 210 prevents plating of the electroactive material on the anode tab 230, thereby preventing short circuits.

[0045]

[0050] In some embodiments, the electrochemical cell 200 has a characteristic tab-to-active area length L, defined as the shortest distance between the edge of the anode tab 230 and the first edge E1 of the active area of ​​the anode material 210. TAR In some embodiments, L TAR can be at least about 1 μm, at least about 5 μm, at least about 10 μm, at least about 20 μm, at least about 30 μm, at least about 40 μm, at least about 50 μm, at least about 60 μm, at least about 70 μm, at least about 80 μm, at least about 90 μm, at least about 100 μm, at least about 200 μm, at least about 300 μm, at least about 400 μm, at least about 500 μm, at least about 600 μm, at least about 700 μm, at least about 800 μm, at least about 900 μm, at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 1 cm, at least about 2 cm, at least about 3 cm, or at least about 4 cm. TARis approximately 5 cm or less, approximately 4 cm or less, approximately 3 cm or less, approximately 2 cm or less, approximately 1 cm or less, approximately 9 mm or less, approximately 8 mm or less, approximately 7 mm or less, approximately 6 mm or less, approximately 5 mm or less, approximately 4 mm or less , about 3 mm or less, about 2 mm or less, about 1 mm or less, about 900 μm or less, about 800 μm or less, about 700 μm or less, about 600 μm or less, about 500 μm or less, about 400 μm or less, about 30 The thickness may be 0 μm or less, about 200 μm or less, about 100 μm or less, about 90 μm or less, about 80 μm or less, about 70 μm or less, about 60 μm or less, about 50 μm or less, about 40 μm or less, about 30 μm or less, about 20 μm or less, about 10 μm or less, about 9 μm or less, about 8 μm or less, about 7 μm or less, about 6 μm or less, about 5 μm or less, about 4 μm or less, about 3 μm or less, or about 2 μm or less. TAR Combinations of the above-referenced values ​​are also possible for L (e.g., at least about 1 μm and not more than about 5 μm, or at least about 10 μm and not more than about 50 μm), including all values ​​and ranges therebetween. TAR are approximately 1μm, approximately 2μm, approximately 3μm, approximately 4μm, approximately 5μm, approximately 6μm, approximately 7μm, approximately 8μm, approximately 9μm, approximately 10μm, approximately 20μm, approximately 30μm, approx. 40μm, approx. 50μm, approx. 60μm, approx. 70μm, approx. 80μm, approx. 90μm, approx. 100μm, approx. 200μm, approx. 300μ m, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 1 cm, about 2 cm, about 3 cm, about 4 cm, or about 5 cm.

[0046]

[0051] In some embodiments, L TAR :L EMcan be at least about 1:1000, at least about 1:900, at least about 1:900, at least about 1:800, at least about 1:700, at least about 1:600, at least about 1:500, at least about 1:400, at least about 1:300, at least about 1:200, at least about 1:100, at least about 1:90, at least about 1:80, at least about 1:70, at least about 1:60, at least about 1:50, at least about 1:40, at least about 1:30, at least about 1:20, at least about 1:10, at least about 1:9, at least about 1:8, at least about 1:7, at least about 1:6, at least about 1:5, at least about 1:4, at least about 1:3, at least about 1:2, at least about 1:1.9, at least about 1:1.8, at least about 1:1.7, or at least about 1:1.6. TAR :L EM The ratio of L can be about 1:1.5 or less, about 1:1.6 or less, about 1:1.7 or less, about 1:1.8 or less, about 1:1.9 or less, about 1:2 or less, about 1:3 or less, about 1:4 or less, about 1:5 or less, about 1:6 or less, about 1:7 or less, about 1:8 or less, about 1:9 or less, about 1:10 or less, about 1:20 or less, about 1:30 or less, about 1:40 or less, about 1:50 or less, about 1:60 or less, about 1:70 or less, about 1:80 or less, about 1:90 or less, about 1:100 or less, about 1:200 or less, about 1:300 or less, about 1:400 or less, about 1:500 or less, about 1:600 ​​or less, about 1:700 or less, about 1:800 or less, or about 1:900 or less. TAR :L EM The ratio of L can be any combination of the above-referenced values ​​(e.g., at least about 1:1000 and not more than about 1:1.5, or at least about 1:100 and not more than about 1:50), including all values ​​and ranges therebetween. TAR :L EMcan be about 1:1000, about 1:900, about 1:800, about 1:700, about 1:600, about 1:500, about 1:400, about 1:300, about 1:200, about 1:100, about 1:90, about 1:80, about 1:70, about 1:60, about 1:50, about 1:40, about 1:30, about 1:20, about 1:10, about 1:9, about 1:8, about 1:7, about 1:6, about 1:5, about 1:4, about 1:3, about 1:2, about 1:1.9, about 1:1.8, about 1:1.7, about 1:1.6 or about 1:1.5.

[0047]

[0052] As shown, the anode tab 230 is disposed between the anode material 210 and the anode film 220 (i.e., below the anode material 210 when viewed from the perspective of FIG. 3). In some embodiments, the anode tab 230 can be disposed between the anode material 210 and the separator 290 (i.e., above the anode material 210 when viewed from the perspective of FIG. 3). As shown, the anode material 210 is disposed on one side of the anode tab 230. In some embodiments, a second portion of the anode material 210 can be disposed on the anode tab 230 such that both sides of the anode tab 230 are directly bonded to portions of the anode material 210.

[0048]

[0053] As shown, the anode material 210 is bonded directly to the anode film 220, and thus the electrochemical cell 200 does not include an anode current collector. In some embodiments, the cathode material 250 can be bonded directly to the cathode film 260, and thus the electrochemical cell 200 may lack a cathode current collector. In some embodiments, the anode material 210 can be bonded directly to the anode film 220, and the cathode material 250 can be bonded directly to the cathode film 260, and thus the electrochemical cell 200 may lack an anode current collector and a cathode current collector. In some embodiments, the electrochemical cell 200 may lack a cathode current collector, and thus the L applied to the cathode. TEO The value of L TAR The value of L TEO :L EM The ratio of and L TAR :L EMThe ratio of L TEO The value of L TAR The value of L TEO :L EM The ratio of and L TAR :L EM The ratio may be the same as or substantially similar to the ratio of

[0049]

[0054] 4 and 5 show perspective views of an electrochemical cell 300 and an anode 305 according to various embodiments. The electrochemical cell 300 includes an anode material 310 capable of taking up or releasing ions during operation of the electrochemical cell 300. As shown, the anode material 310 is bonded directly to an anode film 320, which is bonded directly to an anode current collector 340, which is bonded directly to an anode tab 330. The electrochemical cell 300 includes a cathode material 350. As shown, the cathode material 350 is bonded directly to a cathode current collector 380, which is bonded directly to a cathode film 360 and a cathode tab 370. In some embodiments, the cathode material 350 may be bonded directly to the cathode film 360. The electrochemical cell 300 further includes a separator 390 disposed between the anode material 310 and the cathode material 350. In some embodiments, the anode film 320 can be bonded directly to the cathode film 360 to form a pouch. In some embodiments, the separator 390 can be bonded directly to the anode film 320 and / or the cathode film 360. FIG. 4 shows a cross-sectional view of the electrochemical cell 300 along surface B, where surface B is oriented to penetrate the anode tab 330. FIG. 5 shows an overhead view of the anode 305, where surface B appears as a line. As shown from the perspective of FIG. 4, the cathode tab 370 is positioned behind the anode tab 330. In other words, surface B is oriented to penetrate the anode tab 330 but not the cathode tab 370. In some embodiments, the cathode tab 370 can be aligned with the anode tab 330 so that surface B is oriented through the anode tab 330 and the cathode tab 370 .

[0050]

[0055] In some embodiments, the anode material 310, anode film 320, anode tab 330, anode current collector 340, cathode material 350, cathode film 360, cathode tab 370, cathode current collector 380, separator 390, and bonds therebetween can be the same as or substantially similar to the anode material 110, anode film 120, anode tab 130, anode current collector 140, cathode material 150, cathode film 160, cathode tab 170, cathode current collector 180, separator 190, and bonds therebetween, respectively, described above with respect to FIG. 1 .

[0051]

[0056] Electrochemical cell designs in which one or more of the electrodes (as shown in FIGS. 4 and 5) include smaller current collectors than conventional current collectors can enable several technical advantages. First, material costs, particularly for the current collector material, can be reduced by at least 25%. Second, conventional bonding methods for bonding between the electrode material and the current collector, as well as between the current collector and the tab, can be used in such designs. Third, the safety of such electrochemical cells can be improved because the maximum amount of current that can pass through the current collector is reduced compared to electrochemical cells with current collectors. This can minimize instances of thermal runaway in the event of an external short circuit.

[0052]

[0057] As shown in FIGS. 4 and 5, the anode material 310 has a characteristic electrode material length L EM In some embodiments, L EM The value of L is as described above with respect to Figures 2 and 3. EM may be the same as or substantially similar to the value of

[0053]

[0058] As shown in FIG. 5, the anode current collector 340 has a characteristic current collector length L CC In some embodiments, L CCcan be substantially shorter than the length of a conventional current collector. CC L EM In some embodiments, L CC can be at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 1 cm, at least about 2 cm, at least about 3 cm, at least about 4 cm, at least about 5 cm, at least about 6 cm, at least about 7 cm, at least about 8 cm, or at least about 9 cm. In some embodiments, L CC can be less than or equal to about 10 cm, less than or equal to about 9 cm, less than or equal to about 8 cm, less than or equal to about 7 cm, less than or equal to about 6 cm, less than or equal to about 5 cm, less than or equal to about 4 cm, less than or equal to about 3 cm, less than or equal to about 2 cm, less than or equal to about 1 cm, less than or equal to about 9 mm, less than or equal to about 8 mm, less than or equal to about 7 mm, less than or equal to about 6 mm, less than or equal to about 5 mm, less than or equal to about 4 mm, less than or equal to about 3 mm, or less than or equal to about 2 mm. L CC Combinations of the above-mentioned values ​​are also possible for L (e.g., at least about 1 mm and not more than about 10 cm, or at least about 10 mm and not more than about 1 cm), including all values ​​and ranges therebetween. CC can be about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 1 cm, about 2 cm, about 3 cm, about 4 cm, about 5 cm, about 6 cm, about 7 cm, about 8 cm, about 9 cm, or about 10 cm.

[0054]

[0059] As shown in FIG. 5, the anode 305 has a characteristic current collector-electrode overlap length L CCEO and characteristic tab-collector weight length L TCCO In some embodiments, L CCEO and / or L TCCOcan be at least about 1 μm, at least about 5 μm, at least about 10 μm, at least about 20 μm, at least about 30 μm, at least about 40 μm, at least about 50 μm, at least about 60 μm, at least about 70 μm, at least about 80 μm, at least about 90 μm, at least about 100 μm, at least about 200 μm, at least about 300 μm, at least about 400 μm, at least about 500 μm, at least about 600 μm, at least about 700 μm, at least about 800 μm, at least about 900 μm, at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 1 cm, at least about 2 cm, at least about 3 cm, or at least about 4 cm. CCEO and / or L TCCO is approximately 5 cm or less, approximately 4 cm or less, approximately 3 cm or less, approximately 2 cm or less, approximately 1 cm or less, approximately 9 mm or less, approximately 8 mm or less, approximately 7 mm or less, approximately 6 mm or less, approximately 5 mm or less, approximately 4 mm or less , about 3 mm or less, about 2 mm or less, about 1 mm or less, about 900 μm or less, about 800 μm or less, about 700 μm or less, about 600 μm or less, about 500 μm or less, about 400 μm or less, about 30 The thickness may be 0 μm or less, about 200 μm or less, about 100 μm or less, about 90 μm or less, about 80 μm or less, about 70 μm or less, about 60 μm or less, about 50 μm or less, about 40 μm or less, about 30 μm or less, about 20 μm or less, about 10 μm or less, about 9 μm or less, about 8 μm or less, about 7 μm or less, about 6 μm or less, about 5 μm or less, about 4 μm or less, about 3 μm or less, or about 2 μm or less. CCEO and / or L TCCO Combinations of the above-referenced values ​​are also possible for L (e.g., at least about 1 μm and not more than about 5 μm, or at least about 10 μm and not more than about 50 μm), including all values ​​and ranges therebetween. CCEO and / or L TCCOare approximately 1μm, approximately 2μm, approximately 3μm, approximately 4μm, approximately 5μm, approximately 6μm, approximately 7μm, approximately 8μm, approximately 9μm, approximately 10μm, approximately 20μm, approximately 30μm, approx. 40μm, approx. 50μm, approx. 60μm, approx. 70μm, approx. 80μm, approx. 90μm, approx. 100μm, approx. 200μm, approx. 300μ m, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 1 cm, about 2 cm, about 3 cm, about 4 cm, or about 5 cm. In some embodiments, the anode 305 may have no or substantially no current collector-electrode overlap (i.e., L CCEO In some embodiments, the anode 305 may have no or substantially no tab-current collector overlap (i.e., L TCCO may be about 0 μm).

[0055]

[0060] In some embodiments, L CC :L EM can be at least about 1:50, at least about 1:40, at least about 1:30, at least about 1:20, at least about 1:10, at least about 1:9, at least about 1:8, at least about 1:7, at least about 1:6, at least about 1:5, at least about 1:4, at least about 1:3, at least about 1:2, at least about 1:1.75, at least about 1:1.5, at least about 1:1.25, at least about 1:1, at least about 1:0.75, at least about 2:1, at least about 3:1, at least about 4:1, at least about 5:1, at least about 6:1, at least about 7:1, at least about 8:1, or at least about 9:1. In some embodiments, L CC :L EMThe ratio of L can be about 10:1 or less, about 9:1 or less, about 8:1 or less, about 7:1 or less, about 6:1 or less, about 5:1 or less, about 4:1 or less, about 3:1 or less, about 2:1 or less, about 1:0.75 or less, about 1:1 or less, about 1:1.25 or less, about 1:1.5 or less, about 1:1.75 or less, about 1:2 or less, about 1:3 or less, about 1:4 or less, about 1:5 or less, about 1:6 or less, about 1:7 or less, about 1:8 or less, about 1:9 or less, about 1:10 or less, about 1:20 or less, about 1:30 or less, or about 1:40 or less. CC :L EM The ratio of L can be any combination of the above-referenced values ​​(e.g., at least about 1:50 and not more than about 10:1, or at least about 1:10 and not more than about 1:1), including all values ​​and ranges therebetween. CC :L EM can be about 1:50, about 1:40, about 1:30, about 1:20, about 1:10, about 1:9, about 1:8, about 1:7, about 1:6, about 1:5, about 1:4, about 1:3, about 1:2, about 1:1.75, about 1:1.5, about 1:1.25, about 1:1, about 1:0.75, about 2:1, about 3:1, about 4:1, about 5:1, about 6:1, about 7:1, about 8:1, about 9:1 or about 10:1.

[0056]

[0061] In some embodiments, L TCCO :L CC can be at least about 1:1000, at least about 1:900, at least about 1:800, at least about 1:700, at least about 1:600, at least about 1:500, at least about 1:400, at least about 1:300, at least about 1:200, at least about 1:100, at least about 1:90, at least about 1:80, at least about 1:70, at least about 1:60, at least about 1:50, at least about 1:40, at least about 1:30, at least about 1:20, at least about 1:10, at least about 1:9, at least about 1:8, at least about 1:7, at least about 1:6, at least about 1:5, at least about 1:4, at least about 1:3, at least about 1:2, at least about 1:1.9, at least about 1:1.8, at least about 1:1.7, or at least about 1:1.6.TCCO :L CC The ratio of L can be about 1:1.5 or less, about 1:1.6 or less, about 1:1.7 or less, about 1:1.8 or less, about 1:1.9 or less, about 1:2 or less, about 1:3 or less, about 1:4 or less, about 1:5 or less, about 1:6 or less, about 1:7 or less, about 1:8 or less, about 1:9 or less, about 1:10 or less, about 1:20 or less, about 1:30 or less, about 1:40 or less, about 1:50 or less, about 1:60 or less, about 1:70 or less, about 1:80 or less, about 1:90 or less, about 1:100 or less, about 1:200 or less, about 1:300 or less, about 1:400 or less, about 1:500 or less, about 1:600 ​​or less, about 1:700 or less, about 1:800 or less, or about 1:900 or less. TCCO :L CC The ratio of L can be any combination of the above-referenced values ​​(e.g., at least about 1:1000 and not more than about 1:1.5, or at least about 1:100 and not more than about 1:50), including all values ​​and ranges therebetween. TCCO :L CC can be about 1:1000, about 1:900, about 1:800, about 1:700, about 1:600, about 1:500, about 1:400, about 1:300, about 1:200, about 1:100, about 1:90, about 1:80, about 1:70, about 1:60, about 1:50, about 1:40, about 1:30, about 1:20, about 1:10, about 1:9, about 1:8, about 1:7, about 1:6, about 1:5, about 1:4, about 1:3, about 1:2, about 1:1.9, about 1:1.8, about 1:1.7, about 1:1.6 or about 1:1.5.

[0057]

[0062] In some embodiments, L CCEO :L EMcan be at least about 1:1000, at least about 1:900, at least about 1:800, at least about 1:700, at least about 1:600, at least about 1:500, at least about 1:400, at least about 1:300, at least about 1:200, at least about 1:100, at least about 1:90, at least about 1:80, at least about 1:70, at least about 1:60, at least about 1:50, at least about 1:40, at least about 1:30, at least about 1:20, at least about 1:10, at least about 1:9, at least about 1:8, at least about 1:7, at least about 1:6, at least about 1:5, at least about 1:4, at least about 1:3, at least about 1:2, at least about 1:1.9, at least about 1:1.8, at least about 1:1.7, or at least about 1:1.6. CCEO :L EM The ratio of L can be about 1:1.5 or less, about 1:1.6 or less, about 1:1.7 or less, about 1:1.8 or less, about 1:1.9 or less, about 1:2 or less, about 1:3 or less, about 1:4 or less, about 1:5 or less, about 1:6 or less, about 1:7 or less, about 1:8 or less, about 1:9 or less, about 1:10 or less, about 1:20 or less, about 1:30 or less, about 1:40 or less, about 1:50 or less, about 1:60 or less, about 1:70 or less, about 1:80 or less, about 1:90 or less, about 1:100 or less, about 1:200 or less, about 1:300 or less, about 1:400 or less, about 1:500 or less, about 1:600 ​​or less, about 1:700 or less, about 1:800 or less, or about 1:900 or less. CCEO :L EM The ratio of L can be any combination of the above-referenced values ​​(e.g., at least about 1:1000 and not more than about 1:1.5, or at least about 1:100 and not more than about 1:50), including all values ​​and ranges therebetween. CCEO :L EMcan be about 1:1000, about 1:900, about 1:800, about 1:700, about 1:600, about 1:500, about 1:400, about 1:300, about 1:200, about 1:100, about 1:90, about 1:80, about 1:70, about 1:60, about 1:50, about 1:40, about 1:30, about 1:20, about 1:10, about 1:9, about 1:8, about 1:7, about 1:6, about 1:5, about 1:4, about 1:3, about 1:2, about 1:1.9, about 1:1.8, about 1:1.7, about 1:1.6 or about 1:1.5.

[0058]

[0063] In some embodiments, the anode current collector 340 can be in physical contact with only a portion of the total surface area of ​​the anode material 310. In some embodiments, the anode current collector 340 can be in physical contact with less than about 25%, less than about 20%, less than about 18%, less than about 16%, less than about 14%, less than about 12%, less than about 10%, less than about 9%, less than about 8%, less than about 7%, less than about 6%, less than about 5%, less than about 4%, less than about 3%, less than about 2%, less than about 1%, less than about 0.75%, less than about 0.5%, less than about 0.25%, less than about 0.1%, less than about 0.075%, less than about 0.05%, less than about 0.025%, or less than about 0.01% of the total surface area of ​​the anode material 310, including all values ​​and ranges therebetween.

[0059]

[0064] In some embodiments, the anode current collector 340 may be in physical contact with only a portion of the total surface area of ​​one side of the anode material 310 . In some embodiments, the anode current collector 340 can be in physical contact with less than about 50%, less than about 45%, less than about 40%, less than about 35%, less than about 30%, less than about 25%, less than about 20%, less than about 18%, less than about 16%, less than about 14%, less than about 12%, less than about 10%, less than about 9%, less than about 8%, less than about 7%, less than about 6%, less than about 5%, less than about 4%, less than about 3%, less than about 2%, less than about 1%, less than about 0.75%, less than about 0.5%, less than about 0.25%, less than about 0.1%, less than about 0.075%, less than about 0.05%, less than about 0.025%, less than about 0.01%, less than about 0.0075%, or less than about 0.005%, including all values ​​and ranges therebetween.

[0060]

[0065] In some embodiments, the anode material 310 may comprise a porous material, such that the total surface area of ​​the anode material 310 is significantly greater than the exterior surface area of ​​the anode material 310. In some embodiments, the area of ​​a tab of the anode material 310 may be defined as the equivalent surface area of ​​a smooth, non-porous material having the same form factor as the anode material 310. For example, if the anode material 310 comprises a porous material and is formed into the form factor of a rectangular prism, the exterior surface area may be calculated as the surface area of ​​a smooth, non-porous rectangular prism having the same dimensions as the anode material 310. In some embodiments, the anode current collector 340 can be in physical contact with less than about 25%, less than about 20%, less than about 18%, less than about 16%, less than about 14%, less than about 12%, less than about 10%, less than about 9%, less than about 8%, less than about 7%, less than about 6%, less than about 5%, less than about 4%, less than about 3%, less than about 2%, less than about 1%, less than about 0.75%, less than about 0.5%, less than about 0.25%, less than about 0.1%, less than about 0.075%, less than about 0.05%, less than about 0.025%, or less than about 0.01% of the area of ​​the tab of anode material 310, including all values ​​and ranges therebetween.

[0061]

[0066] In some embodiments, the anode current collector 340 can be in physical contact with less than about 50%, less than about 45%, less than about 40%, less than about 35%, less than about 30%, less than about 25%, less than about 20%, less than about 18%, less than about 16%, less than about 14%, less than about 12%, less than about 10%, less than about 9%, less than about 8%, less than about 7%, less than about 6%, less than about 5%, less than about 4%, less than about 3%, less than about 2%, less than about 1%, less than about 0.75%, less than about 0.5%, less than about 0.25%, less than about 0.1%, less than about 0.075%, less than about 0.05%, less than about 0.025%, less than about 0.01%, less than about 0.0075%, or less than about 0.005%, including all values ​​and ranges therebetween.

[0062]

[0067] In some embodiments, the anode material 310 has a characteristic length L EMIn some embodiments, the cathode material 350 can have a characteristic length L CM In some embodiments, L CM L EM In some embodiments, L CM L EM In some embodiments, (L EM -L CM ) can be at least about 1 μm, at least about 5 μm, at least about 10 μm, at least about 50 μm, at least about 100 μm, at least about 500 μm, at least about 1 mm, at least about 5 mm, at least about 1 cm, or at least about 5 cm. In some embodiments, (L EM -L CM ) can be about 10 cm or less, about 5 cm or less, about 1 cm or less, about 5 mm or less, about 1 mm or less, about 500 μm or less, about 100 μm or less, about 50 μm or less, about 10 μm or less, or about 5 μm or less. EM -L CM ) can also include combinations of the above-mentioned values ​​(e.g., at least about 1 μm and not more than about 10 cm, or at least about 10 mm and not more than about 1 cm), including all values ​​and ranges therebetween. In some embodiments, (L EM -L CM ) can be about 1 μm, about 5 μm, about 10 μm, about 50 μm, about 100 μm, about 500 μm, about 1 mm, about 5 mm, about 1 cm, about 5 cm, or about 10 cm.

[0063]

[0068] In some embodiments, the separator 390 can include a separator seal 395 that can restrict the flow of ions through the separator 390. The restriction of the flow path through the separator 390 can direct the flow of ions into the anode material 310 and / or the cathode material 350 and prevent them from being deposited around the exterior perimeter of the anode material 310 and / or the cathode material 350. In some embodiments, the separator seal 395 can be a tape or an adhesive that is adhered to the exterior surface of the separator 390. In some embodiments, the separator seal 395 can be meltable with the separator 390, thereby thermally bonding the separator 390 and the separator seal 395 together. In some embodiments, the separator seal 395 can be a gel, a high viscosity oil, and / or a material that penetrates into the pores of portions of the separator 390, thereby blocking the flow of materials through those pores.

[0064]

[0069] As shown in FIG. 4 , the separator seal 395 defines first and second edges E1 and E2 of the active areas of the anode material 310 and cathode material 350. The active areas of the anode material 310 and cathode material 350 are areas where ions can freely move between the anode material 310 and the cathode material 350. As shown, the separator seal 395 prevents or substantially inhibits the movement of ions through the portion of the separator 390 that does not have the separator seal 395. In some embodiments where the separator 390 does not include the separator seal 395, the first and second edges E1 and E2 of the active areas can be defined by the outer edges of the cathode material 350 (L CM L EM In some embodiments where the separator 390 does not include a separator seal 395, the first edge E1 and second edge E2 of the active area can be defined by the outer edges of the anode material 310 (L EM L CM (if it is shorter than

[0065]

[0070] As shown, the anode current collector 340 does not extend into the active area of ​​the anode material 310. In some embodiments, the anode current collector 340 may extend into the active area of ​​the anode material 310. In some embodiments, the electrochemical cell 300 has a characteristic current collector-active area length L, defined as the shortest distance between the edge of the anode current collector 340 and a first edge E1 of the active area of ​​the anode material 310. CCAR In some embodiments, L CCAR can be at least about 1 μm, at least about 5 μm, at least about 10 μm, at least about 20 μm, at least about 30 μm, at least about 40 μm, at least about 50 μm, at least about 60 μm, at least about 70 μm, at least about 80 μm, at least about 90 μm, at least about 100 μm, at least about 200 μm, at least about 300 μm, at least about 400 μm, at least about 500 μm, at least about 600 μm, at least about 700 μm, at least about 800 μm, at least about 900 μm, at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, at least about 1 cm, at least about 2 cm, at least about 3 cm, or at least about 4 cm. CCAR is approximately 5 cm or less, approximately 4 cm or less, approximately 3 cm or less, approximately 2 cm or less, approximately 1 cm or less, approximately 9 mm or less, approximately 8 mm or less, approximately 7 mm or less, approximately 6 mm or less, approximately 5 mm or less, approximately 4 mm or less , about 3 mm or less, about 2 mm or less, about 1 mm or less, about 900 μm or less, about 800 μm or less, about 700 μm or less, about 600 μm or less, about 500 μm or less, about 400 μm or less, about 30 The thickness may be 0 μm or less, about 200 μm or less, about 100 μm or less, about 90 μm or less, about 80 μm or less, about 70 μm or less, about 60 μm or less, about 50 μm or less, about 40 μm or less, about 30 μm or less, about 20 μm or less, about 10 μm or less, about 9 μm or less, about 8 μm or less, about 7 μm or less, about 6 μm or less, about 5 μm or less, about 4 μm or less, about 3 μm or less, or about 2 μm or less. CCARCombinations of the above-referenced values ​​are also possible for L (e.g., at least about 1 μm and not more than about 5 μm, or at least about 10 μm and not more than about 50 μm), including all values ​​and ranges therebetween. CCAR are approximately 1μm, approximately 2μm, approximately 3μm, approximately 4μm, approximately 5μm, approximately 6μm, approximately 7μm, approximately 8μm, approximately 9μm, approximately 10μm, approximately 20μm, approximately 30μm, approx. 40μm, approx. 50μm, approx. 60μm, approx. 70μm, approx. 80μm, approx. 90μm, approx. 100μm, approx. 200μm, approx. 300μ m, about 400 μm, about 500 μm, about 600 μm, about 700 μm, about 800 μm, about 900 μm, about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 1 cm, about 2 cm, about 3 cm, about 4 cm, or about 5 cm.

[0066]

[0071] In some embodiments, L CCAR :L EM can be at least about 1:1000, at least about 1:900, at least about 1:900, at least about 1:800, at least about 1:700, at least about 1:600, at least about 1:500, at least about 1:400, at least about 1:300, at least about 1:200, at least about 1:100, at least about 1:90, at least about 1:80, at least about 1:70, at least about 1:60, at least about 1:50, at least about 1:40, at least about 1:30, at least about 1:20, at least about 1:10, at least about 1:9, at least about 1:8, at least about 1:7, at least about 1:6, at least about 1:5, at least about 1:4, at least about 1:3, at least about 1:2, at least about 1:1.9, at least about 1:1.8, at least about 1:1.7, or at least about 1:1.6. CCAR :L EMThe ratio of L can be about 1:1.5 or less, about 1:1.6 or less, about 1:1.7 or less, about 1:1.8 or less, about 1:1.9 or less, about 1:2 or less, about 1:3 or less, about 1:4 or less, about 1:5 or less, about 1:6 or less, about 1:7 or less, about 1:8 or less, about 1:9 or less, about 1:10 or less, about 1:20 or less, about 1:30 or less, about 1:40 or less, about 1:50 or less, about 1:60 or less, about 1:70 or less, about 1:80 or less, about 1:90 or less, about 1:100 or less, about 1:200 or less, about 1:300 or less, about 1:400 or less, about 1:500 or less, about 1:600 ​​or less, about 1:700 or less, about 1:800 or less, or about 1:900 or less. CCAR :L EM The ratio of L can be any combination of the above-referenced values ​​(e.g., at least about 1:1000 and not more than about 1:1.5, or at least about 1:100 and not more than about 1:50), including all values ​​and ranges therebetween. CCAR :L EM can be about 1:1000, about 1:900, about 1:800, about 1:700, about 1:600, about 1:500, about 1:400, about 1:300, about 1:200, about 1:100, about 1:90, about 1:80, about 1:70, about 1:60, about 1:50, about 1:40, about 1:30, about 1:20, about 1:10, about 1:9, about 1:8, about 1:7, about 1:6, about 1:5, about 1:4, about 1:3, about 1:2, about 1:1.9, about 1:1.8, about 1:1.7, about 1:1.6 or about 1:1.5.

[0067]

[0072] As shown, the anode tab 330 is provided on the side of the anode current collector 340 at the end of the anode film 320 (i.e., on the upper side of the anode current collector 340 when viewed from the perspective of FIG. 5). In some embodiments, the anode tab 330 can be provided between the anode current collector 340 and the anode film 320 (i.e., on the lower side of the anode current collector 340 when viewed from the perspective of FIG. 5). As shown, the anode current collector 340 is provided on the lower side of the anode material 310 when viewed from the perspective of FIG. 5. In some embodiments, the anode current collector 340 can be provided on the upper side of the anode material 310 when viewed from the perspective of FIG. 5.

[0068]

[0073] As shown, anode material 310 is bonded directly to anode film 320, and anode current collector 340 is smaller than a conventional anode current collector. In some embodiments, cathode material 350 can be bonded directly to cathode film 360, allowing cathode current collector 380 to be smaller than a conventional cathode current collector. In some embodiments, anode material 310 can be bonded directly to anode film 320, and cathode material 350 can be bonded directly to cathode film 360, allowing anode current collector 340 to be smaller than a conventional anode current collector, and cathode current collector 380 to be smaller than a conventional cathode current collector. In some embodiments, cathode current collector 380 can be smaller than a conventional cathode current collector, allowing for the L applied to the cathode. CC The value of L CCEO The value of L TCCO The value of L TAR The value of L CC :L EM The ratio of L TCCO :L CC The ratio of L CCEO :L EM The ratio of and L CCAR :L EM The ratio of L CC The value of L CCEO The value of L TCCO The value of L TAR The value of L CC :L EM The ratio of L TCCO :L CC The ratio of L CCEO :L EM The ratio of and L CCAR :L EM The ratio may be the same as or substantially similar to: [Example]

[0069]

[0074] The electrochemical cell had a 2 μm thick lithium anode and a 200 μm thick LiNiMnCo(NMC)811 cathode and an energy density of 11 mAh / cm 2The electrochemical cell did not include an anode current collector; only the weld tab was directly attached to the anode. The electrochemical cell was operated at a discharge rate of 1 C and a charge rate of 2 mA / cm. 2 The cells were cycled 70 times between 4.3 V and 2.8 V at 25° C. Figure 6 shows the cycling data and capacity retention of the electrochemical cell over 70 cycles, with 100% capacity corresponding to a capacity of 170 mAh.

[0070]

[0075] Various concepts may be embodied as one or more methods, at least one example of which has been provided. Acts performed as part of a method may be ordered in any suitable manner. Accordingly, embodiments may be constructed to perform acts in different orders than those illustrated, including performing some acts simultaneously even though they are shown as sequential acts in the illustrated embodiments. Stated differently, it is understood that such features are not necessarily limited to a particular order of execution; rather, any number of threads, processes, services, servers, and / or the like may be performed serially, asynchronously, concurrently, in parallel, simultaneously, synchronously, and / or in a similar manner consistent with this disclosure. As such, some of these features may be mutually exclusive in that they may not simultaneously exist in a single embodiment. Similarly, some features may be applicable to one aspect of novelty and not to other aspects.

[0071]

[0076] Additionally, the present disclosure may include other novelty not presently described. The applicant reserves all rights to such novelty, including the right to embody such novelty and to file additional applications, continuations, continuations-in-part, divisional applications, and / or the like. Therefore, it is understood that the advantages, embodiments, examples, functional, characteristic, logical, operational, organizational, structural, topological, and / or other aspects of the present disclosure are not intended to be limitations on the present disclosure as defined by the embodiments or limitations on equivalents of the embodiments. Depending on the particular needs and / or characteristics of individual and / or business users, database organization and / or relational models, data types, data transmission and / or network frameworks, syntax structures, and / or the like, various embodiments of the technology disclosed herein can be implemented in a manner that allows for high flexibility and customization as described herein.

[0072]

[0077] All definitions defined and used herein are understood to take precedence over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0073]

[0078] As used herein, particularly in the embodiments, the term "about" or "approximately," when preceding a numerical value, indicates a range of plus or minus 10% of that value. When a range of values ​​is presented, unless the context clearly dictates otherwise, it is understood that each intervening value, to the nearest tenth of the lower limit, between the upper and lower limits of that range, and any other stated or intervening value in the stated range, is encompassed within the disclosure. The upper and lower limits of such smaller ranges may be independently included in the smaller ranges, and the upper and lower limits of such smaller ranges are also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. When a stated range includes one or both of the limits, ranges excluding either or both of those included ranges are also included within the disclosure.

[0074]

[0079] As used in the specification and embodiments, the term "and / or" should be understood to mean "either or both" of the elements so conjoined, i.e., elements that may be present conjunctively or disjunctively. Multiple elements listed with "and / or" should be construed in the same manner, i.e., "one or more" of the elements so conjoined. Other elements, related or unrelated to those specifically identified elements, may optionally be present in addition to the elements specifically identified by the "and / or" clause. Thus, as a non-limiting example, when used in connection with open-ended language such as "comprising," "A and / or B" may, in one embodiment, refer to only A (optionally including elements other than B); in another embodiment, refer to only B (optionally including elements other than A); in yet another embodiment, refer to both A and B (optionally including other elements); and so forth.

[0075]

[0080] As used herein and in the embodiments, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating listed items, "or" or "and / or" shall be interpreted as being inclusive, i.e., including not only a plurality of elements or at least one of the listed elements, but also including a plurality thereof, and optionally, additionally including unlisted items. Only terms clearly indicated otherwise, such as "only one of" or "exactly one of," or, when used in the embodiments, "consisting of," shall refer to the inclusion of a plurality of elements or exactly one of the listed elements. Generally, as used herein, the term "or" shall only be interpreted as indicating exclusive alternatives (i.e., "one or the other, but not both") when preceded by terms of exclusivity such as "either," "one of," "only one of," or "exactly one of." When used in the embodiments, "consisting essentially of" shall have its ordinary meaning as used in the field of patent law.

[0076]

[0081] As used herein and in the embodiments, the phrase "at least one" in reference to a list of one or more elements means at least one element selected from any one or more of the elements in the list of elements, but it should be understood that it does not necessarily include at least one of every element specifically listed in the list of elements, nor does it exclude any combination of elements in the list of elements. This definition also allows that elements other than those specifically identified in the list of elements to which the phrase "at least one" refers may optionally be present, whether related or unrelated to those specifically identified elements. Thus, as one non-limiting example, "at least one of A and B" (or, equivalently, "at least one of A or B" or, equivalently, "at least one of A and / or B") can refer in one embodiment to at least one A (optionally including multiple As) with no Bs (and optionally including elements other than B); in another embodiment to at least one B (optionally including multiple Bs) with no As (and optionally including elements other than A); in yet another embodiment to at least one A (optionally including multiple As) and at least one B (optionally including multiple Bs) (and optionally including other elements); and so on.

[0077]

[0082] In the embodiments and above, transitional phrases such as "comprise," "include," "hold," "have," "contain," "involve," "hold," "consisting of," and the like shall all be understood to be open-ended, i.e., meaning including but not limited to. Only the transitional phrases "consisting of" and "consisting essentially of" shall be closed or semi-closed transitional phrases, respectively, as set forth in the U.S. Patent Office Manual of Patent Examining Procedures, Section 2111.03.

[0078]

[0083] While specific embodiments of the present disclosure have been outlined above, many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, the embodiments described herein are intended to be illustrative and not limiting. Various modifications may be made without departing from the spirit and scope of the present disclosure. Where the methods and steps described above indicate particular events occurring in a particular order, those skilled in the art, having the benefit of this disclosure, will recognize that the ordering of certain steps may be modified and that such modifications are in accordance with variations of the present invention. In addition, where possible, certain steps may be performed simultaneously in a parallel process and may be performed in the order described above. While embodiments have been specifically illustrated and described, it will be understood that various changes in form and detail may be made.

Claims

1. 1. An electrochemical cell comprising: a first electrode material disposed on a first current collector bonded to a first non-conductive film; a first tab coupled to the first current collector; a second electrode material capable of taking up or releasing ions during operation of the electrochemical cell, the second electrode material being directly bonded to a second non-conductive film; and a second tab electronically coupled to the second electrode material; a separator provided between the first electrode material and the second electrode material; An electrochemical cell comprising:

2. 10. The electrochemical cell of claim 1, wherein the second electrode material is not bonded to a current collector.

3. 10. The electrochemical cell of claim 1, wherein the first non-conductive film is bonded to the second non-conductive film to create a pouch.

4. 10. The electrochemical cell of claim 1, wherein the second electrode material and the second tab are bonded to a second current collector.

5. 5. The electrochemical cell of claim 4, wherein the second current collector is in physical contact with less than about 3% of the total surface area of ​​the second electrode material.

6. 6. The electrochemical cell of claim 5, wherein the second current collector is bonded to a tab.

7. 10. The electrochemical cell of claim 1 having a specific energy of at least about 300 Wh / kg.

8. 10. The electrochemical cell of claim 1 having a cell specific energy of at least about 600 Wh / kg.

9. 2. The electrochemical cell of claim 1, wherein the first non-conductive film and / or the second non-conductive film comprises at least one of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), nylon, high density polyethylene (HDPE), oriented polypropylene (o-PP), polyvinyl chloride (PVC), polyimide (PI), polysulfone (PSU), cast polypropylene (c-PP), polyethylene (PE), ethylene vinyl acetate (EVA), PET, polyvinyl acetate (PVA), polyamide (PA), acrylic adhesive, ultraviolet (UV) / electron beam (EB) / infrared (IR) curable resin, polyether ether ketone (PEEK), polyethylene naphthalate (PEN), polyethersulfone (PES), polyimide (PI), polyphenylene sulfide (PPS), and polyphenylene oxide (PPO).

10. 10. The electrochemical cell of claim 1, wherein the first electrode material and / or the second electrode material comprises a semi-solid, binderless electrode material.

11. 1. An electrochemical cell comprising: an anode material bonded directly to the first non-conductive film; an anode tab directly bonded to the anode; a cathode material bonded to a cathode current collector that is bonded to a second non-conductive film; a cathode tab coupled to the cathode current collector; a separator disposed between the anode material and the cathode material; An electrochemical cell comprising:

12. 12. The electrochemical cell of claim 11 , wherein the anode material comprises a first surface bonded to the first non-conductive film and a second surface bonded to the separator, at least about 70% of the first surface in contact with the first non-conductive film.

13. 13. The electrochemical cell of claim 12, wherein at least about 80% of the first surface is in contact with the first non-conductive film.

14. 14. The electrochemical cell of claim 13, wherein at least about 90% of the first surface is in contact with the first non-conductive film.

15. 12. The electrochemical cell of claim 11, wherein the cathode material is not bonded to a current collector.

16. 12. The electrochemical cell of claim 11, wherein the first non-conductive film is bonded to the second non-conductive film to create a pouch.

17. 12. The electrochemical cell of claim 11, wherein the first non-conductive film and / or the second non-conductive film comprises at least one of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), nylon, high density polyethylene (HDPE), oriented polypropylene (o-PP), polyvinyl chloride (PVC), polyimide (PI), polysulfone (PSU), cast polypropylene (c-PP), polyethylene (PE), ethylene vinyl acetate (EVA), PET, polyvinyl acetate (PVA), polyamide (PA), acrylic adhesive, ultraviolet (UV) / electron beam (EB) / infrared (IR) curable resin, polyether ether ketone (PEEK), polyethylene naphthalate (PEN), polyethersulfone (PES), polyimide (PI), polyphenylene sulfide (PPS), and polyphenylene oxide (PPO).

18. 1. A method of forming an electrochemical cell, comprising: providing a first electrode material on a first current collector coupled to a first tab; providing the first current collector on a first non-conductive film; providing a second electrode material directly on the second non-conductive film, the second electrode material being capable of taking up or releasing ions during operation of the electrochemical cell; electronically coupling a second tab to the second electrode material; providing a separator between the first electrode material and the second electrode material; A method comprising:

19. 20. The method of claim 18, further comprising bonding the first non-conductive film to the second non-conductive film to form a pouch.

20. 20. The method of claim 18, further comprising directly bonding the second electrode material to a second current collector.

21. 21. The method of claim 20, wherein the second current collector is in physical contact with less than about 3% of the total surface area of ​​the second electrode material.

22. 20. The method of claim 18, wherein providing the second electrode material directly on the second non-conductive film is via at least one of sputtering, vapor deposition, a sol-gel process, a physical spray process, electrobeam deposition, electrochemical deposition, atomic layer deposition (ALD), chemical vapor deposition (CVD), electrophoretic deposition (EPD), pouring, electron beam induced deposition (EBD), slot die coating, MICROGRAVURE™ coating, or Langmuir-Blodgett film coating.

23. 20. The method of claim 18, wherein providing the second electrode material directly on the second non-conductive film is via a layer of material that can be activated to act as an adhesive under the application of a mechanical or electrical perturbation such as heat, light such as UV or IR, or ultrasonic or sonic waves, or radio frequency or microwaves.

24. 20. The method of claim 18, wherein electronically coupling the second tab to the second electrode material is via at least one of mechanical compression, use of a conductive paste, chemical bonding, welding, brazing, soldering, or crimping.

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