Electrochemical cell with separator seal and method of making same

Abstract

To provide an electrochemical cell having a separator with a separator seal.SOLUTION: In some embodiments, an electrochemical cell includes an anode disposed on an anode current collector, a cathode disposed on a cathode current collector, a separator disposed between the anode and the cathode, and a separator seal coupled to the separator. The separator seal is impermeable to the movement of electroactive species therethrough. In some embodiments, the separator seal may comprise a tape and / or an adhesive. In some embodiments, the separator seal may include a material that penetrates into some pores of the separator. In some embodiments, the separator seal may be thermally bonded to the separator. In some embodiments, the electrochemical cell may include a pouch. In some embodiments, the separator may be coupled to the pouch. In some embodiments, the separator seal may be coupled to the pouch.SELECTED DRAWING: Figure 3A

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and benefit of U.S. Provisional Patent Application No. 62 / 929,408, entitled "DUAL ELECTROLYTE ELECTROCHEMICAL CELLS, SYSTEMS, AND METHODS OF MANUFACTURING THE SAME," filed November 1, 2019, and U.S. Provisional Patent Application No. 63 / 046,758, entitled "ELECTROCHEMICAL CELLS WITH SEPARATOR SEALS, AND METHODS OF MANUFACTURING THE SAME," filed July 1, 2020, the entire disclosures of each of which are incorporated herein by reference. [Background technology]

[0002] background

[0002] Embodiments described herein relate to electrochemical cells having separators with separator seals. Electrochemical cells are often designed using anodes with dimensions different from those of the cathodes. The anodes and cathodes can differ not only in thickness but also in length and width. Generally, electrochemical cell designs require the length and width dimensions of the anode and cathode to be as close as possible to maximize cell efficiency and utilization of electroactive species. However, lateral shift of the cathode can cause the cathode edge to extend beyond the anode edge, potentially resulting in plating of cathode material around the anode edge. Designing the anode to have length and width dimensions slightly larger than the cathode can prevent plating of cathode material around the outer edge of the anode. However, designing the anode length and width dimensions slightly larger than the cathode length and width dimensions can result in plating of anode material around the cathode edge. During discharge, positive ions migrate from the anode through the separator to the cathode. If the anode is longer and wider than the cathode, some positive ions may migrate from the portion of the anode that extends beyond the edge of the cathode. In other words, positive ions may migrate from the portion of the anode that is not collinear with the cathode. This can lead to a buildup of anode material on the cathode side of the separator. If enough anode material accumulates on the cathode side, the cathode may come into direct contact with the anode material, causing a partial or complete short circuit.

[0003] Another plating problem that can occur in electrochemical cells relates to coating quality. In electrochemical cells, electrode material can be coated onto a current collector, and coating quality is often poorer near the edge of the electrode than near the center. In some cases, material loading can be slightly lower at the edge of the electrode, allowing material from the counter electrode to plate near the edge of the electrode. This can result in partial or complete short circuits. Partially blocking the flow of anode or cathode material near the electrode edge helps prevent such short circuit events. Summary of the Invention [Means for solving the problem]

[0004] overview

[0004] Embodiments described herein relate to electrochemical cells having a separator with a separator seal. In some embodiments, the electrochemical cell includes an anode disposed on an anode current collector, a cathode disposed on a cathode current collector, a separator disposed between the anode and the cathode, and a separator seal bonded to the separator. The separator seal is impermeable to movement of electroactive species therethrough. In some embodiments, the separator seal may include tape and / or adhesive. In some embodiments, the separator seal may include a material that infiltrates into some pores of the separator. In some embodiments, the separator seal may be thermally bonded to the separator. In some embodiments, the electrochemical cell may include a pouch. In some embodiments, the separator may be bonded to the pouch. In some embodiments, the separator seal may be bonded to the pouch. [Brief explanation of the drawings]

[0005] BRIEF DESCRIPTION OF THE DRAWINGS [Figure 1]

[0005] Figure 1 shows an electrochemical cell suffering from a short circuit due to a buildup of anode material. [Figure 2]

[0006] FIG. 1 is a schematic diagram of an electrochemical cell having a separator with a separator seal, according to one embodiment. [Figure 3A]

[0007] 1 illustrates an electrochemical cell having a separator seal, according to one embodiment. [Figure 3B] 1 illustrates an electrochemical cell having a separator seal, according to one embodiment. [Figure 4A]

[0008] 1 illustrates an electrochemical cell having a separator seal, according to one embodiment. [Figure 4B] 1 illustrates an electrochemical cell having a separator seal, according to one embodiment. [Figure 5A]

[0009] 1 illustrates an electrochemical cell having a separator seal, according to one embodiment. [Figure 5B] 1 illustrates an electrochemical cell having a separator seal, according to one embodiment. [Figure 6A]

[0010] 1 illustrates an electrochemical cell having a separator seal, according to one embodiment. [Figure 6B] 1 illustrates an electrochemical cell having a separator seal, according to one embodiment. [Figure 7A]

[0011] 1 illustrates an electrochemical cell having a wound separator seal, according to one embodiment. [Figure 7B] 1 illustrates an electrochemical cell having a wound separator seal, according to one embodiment. [Figure 7C] 1 illustrates an electrochemical cell having a wound separator seal, according to one embodiment. [Figure 8A]

[0012] 1 shows a photograph of a disassembled electrochemical cell, according to one embodiment. [Figure 8B]

[0012] Figure 1 shows a photograph of a disassembled electrochemical cell according to one embodiment. [Figure 8C]

[0012] Figure 1 shows a photograph of a disassembled electrochemical cell according to one embodiment. [Figure 9A]

[0013] 1 shows a photograph of a disassembled electrochemical cell, according to one embodiment. [Figure 9B] 1 shows a photograph of a disassembled electrochemical cell according to one embodiment. [Figure 9C] 1 shows a photograph of a disassembled electrochemical cell according to one embodiment. [Figure 10A]

[0014] 1 shows a photograph of a disassembled electrochemical cell, according to one embodiment. [Figure 10B] 1 shows a photograph of a disassembled electrochemical cell according to one embodiment. [Figure 10C] 1 shows a photograph of a disassembled electrochemical cell according to one embodiment. [Figure 10D] 1 shows a photograph of a disassembled electrochemical cell according to one embodiment. [Figure 10E] 1 shows a photograph of a disassembled electrochemical cell according to one embodiment. [Figure 10F] 1 shows a photograph of a disassembled electrochemical cell according to one embodiment. [Figure 10G] 1 shows a photograph of a disassembled electrochemical cell according to one embodiment. [Figure 11A]

[0015] 1 illustrates an electrochemical cell having a separator seal, according to one embodiment. [Figure 11B] 1 illustrates an electrochemical cell having a separator seal, according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0006] Detailed Description

[0016] Embodiments described herein relate to electrochemical cells having separators with separator seals, and methods of fabricating the same. Short circuit events in electrochemical cells can often be caused by the buildup of anode material near the cathode or by the buildup of cathode material near the cathode. Once sufficient anode material accumulates near the cathode, or vice versa, physical contact between the anode and cathode materials can lead to a short circuit event. An example of this behavior is shown in FIG. 1 . FIG. 1 shows an electrochemical cell 100 having an anode 110 disposed on an anode current collector 120, a cathode 130 disposed on a cathode current collector 140, and a separator 150 disposed between the anode 110 and the cathode 130. Both the anode current collector 120 and the cathode current collector 140 are disposed on a pouch material 160. As shown, the anode 110 has a first section 112 and a second section 114. The first section 112 is collinear with the cathode 130, but the second section 114 is not collinear with the cathode 130. In other words, ions migrate from the first section 112 to the cathode 130 via line A. Ions migrate from the second section 114 via line B, but because the second section 114 is not collinear with the cathode 130, an anode material deposit 116 forms near the cathode 130 on either the surface of the cathode current collector 140 or the surface of the pouch material 160. If the anode material deposit 116 is large enough to physically contact the cathode 130, a partial or complete short circuit event can occur. Additionally, the anode material deposit 116 represents material that has separated from the anode 110, such that the material can no longer be used in cycling the electrochemical cell 100. This can adversely affect the cycling performance of the electrochemical cell 100.

[0007]

[0017] The use of separator seals or devices that can prevent ion flow through portions of the separator can significantly reduce the risk of short-circuit events. Reducing the risk of short-circuit events can be an economic benefit as well as a safety benefit. Removing anode material deposited near the cathode (or cathode material deposited near the anode) often requires opening a pouch to access the anode and cathode materials and carefully removing the deposited material without damaging the intact portions of the electrochemical cell. This is a labor-intensive process that results in downtime for the electrochemical cell. If the electrochemical cell is included in a battery pack with multiple electrochemical cells, each electrochemical cell in the battery pack will suffer downtime. In some cases, if the deposit of anode material near the cathode (or cathode material near the anode) is too large to remove, the electrochemical cell may be discarded or recycled. Preventing short-circuit events can also be a safety benefit. A short-circuit event often causes a rapid temperature increase in the electrochemical cell, potentially leading to thermal runaway, fire, or explosion.

[0008]

[0018] Incorporating a separator seal into the separator can direct the flow of ions through the separator so that the flow occurs only between the anode and cathode and prevents the electroactive material from accumulating in undesired locations. In some embodiments, the separator seal can be part of the separator. In other words, the separator and separator seal can be a single piece of material having a first portion that is permeable to the flow of ions and a second portion that is impermeable to the flow of ions. In some embodiments, the separator seal can be two separate pieces of material, with the separator seal bonded to the separator. In some embodiments, the separator can have multiple layers, with a first layer including a section that is substantially impermeable to ions and a second layer that does not include a section that is substantially impermeable to ions.

[0009]

[0019] In some embodiments, the separator can be a porous membrane separator (e.g., a porous polyolefin membrane). In some embodiments, the separator can allow for the movement of ionic charge carriers between the cathode and the anode. In some embodiments, the separator can be wetted by an electrolyte, allowing the electrolyte to communicate between the anode and the cathode. In some embodiments, the electrochemical cell can include a selectively permeable membrane. An example of an electrochemical cell including a separator with a selectively permeable membrane that can chemically and / or fluidly separate the anode from the cathode while facilitating ion movement during charging and discharging of the cell is described in U.S. Pat. No. 10,734,672, entitled "Electrochemical Cells Including Selectively Permeable Membranes, Systems and Methods of Manufacturing the Same," filed January 8, 2019 (the "'672 Patent"), the entire disclosure of which is incorporated herein by reference.

[0010]

[0020] In some embodiments, the electrodes described herein can include semi-solid materials. Examples of systems and methods that can be used to prepare semi-solid compositions and / or electrodes are described in U.S. Patent No. 9,484,569, entitled "Electrochemical Slurry Compositions and Methods for Preparing the Same," filed March 15, 2013 (hereinafter, the "'569 Patent"), U.S. Patent No. 8,993,159, entitled "Semi-Solid Electrodes Having High Rate Capability," filed April 29, 2013 (the "'159 Patent"), and U.S. Patent Publication No. 2016 / 0133916, entitled "Electrochemical Cells Having Semi-Solid Electrodes and Methods of Manufacturing the Same," filed November 4, 2015 (the "'916 Publication"), the entire disclosures of which are incorporated herein by reference.

[0011]

[0021] In some embodiments, the electrodes and / or electrochemical cells described herein can include a solid electrolyte. In some embodiments, the anodes described herein can include a solid electrolyte. In some embodiments, the cathodes described herein can include a solid electrolyte. In some embodiments, the electrochemical cells described herein can include a solid electrolyte in both the anode and the cathode. In some embodiments, the electrochemical cells described herein can include a unit cell structure with a solid electrolyte. In some embodiments, the solid electrolyte material can be a powder mixed with a binder and then processed (e.g., extrusion, casting, wet casting, spraying, etc.) to form a sheet of the solid electrolyte material. In some embodiments, the solid electrolyte material can be a garnet structure, a perovskite structure, a phosphate-based lithium superionic conductor (LISICON) structure, a glass structure, such as La 0.51 Li 0.34 TiO 2.94 , Li 1.3 Al 0.3 Ti 1.7 (PO4)3, Li 1.4 Al 0.4 Ti 1.6 (PO4)3, Li7La3Zr2O 12 , Li 6.6 6La3Zr 1.6 Ta 0.4 O 12,9 (LLZO), 50Li4SiO4 50Li3BO3, Li 2.9 PO 3.3 N 0.46 (Lithium phosphorus oxynitride, LiPON), Li 3.6 Si 0.6 P 0.4 Oxide-based solid electrolyte materials, including O4, Li3BN2, Li3BO3-Li2SO4, Li3BO3-Li2SO4-Li2CO3 (LIBSCO, pseudo-ternary system); and / or thio-LISICON structures, glass structures, and glass-ceramic structures, e.g., Li 1.07 Al 0.69 Ti 1.46 (PO4)3, Li1.5 Al 0.5 Ge 1.5 (PO4)3, Li 10 GeP2S 12 (LGPS), 30Li2S 26B2S3 44LiI, 63Li2S 36SiS2 1Li3PO4, 57Li2S 38SiS2 5Li4SiO4, 70Li2S 30P2S5, 50Li2S 50GeS2, Li7P3S 11 , Li3.25P 0.95 S4, and Li 9.54 Si 1.74 P 1.44 S 11.7 Cl 0.3 and / or closo-type complex hydrides, such as LiBH4-LiI, LiBH4-LiNH2, LiBH4-P2S5, Li(CB9H 10 )-LiI-sama's Li(CB X H X+1 )-LiI; and / or one or more of the lithium electrolyte salts bis(trifluoromethane)sulfonamide (TFSI), bis(pentafluoroethanesulfonyl)imide (BETI), bis(fluorosulfonyl)imide, lithium borooxalatophosphate (LiBOP), lithium bis(fluorosulfonyl)imide, amido-borohydride, LiBF, LiPF, LIF, or combinations thereof. In some embodiments, the electrodes described herein can comprise from about 40% to about 90% by weight of solid electrolyte material. Examples of electrochemical cells and electrodes including solid electrolytes are described in the '672 patent.

[0012]

[0022] In manufacturing, battery cells can be constructed by stacking alternating layers of electrodes (typically for fast-acting prismatic cells) or by winding long strips of electrodes into a "jelly roll" configuration (typically for cylindrical cells). The electrode stack or roll can be inserted into a gasket-sealed hard case (most commercially available cylindrical cells), a laser-welded hard case, or a foil pouch with heat-sealed seams (commonly referred to as a lithium-ion polymer cell).

[0013]

[0023] 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]

[0024] 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 linearity of the portion is desired, some nonlinearity may occur in the "substantially linear" portion. Such nonlinearity may result from manufacturing tolerances or other practical considerations (e.g., pressure or force applied to the support member, etc.). Thus, a geometric structure modified by the term "substantially" includes such geometric characteristics within a tolerance of plus or minus 5% of the stated 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]

[0025] As used herein, the terms "set" and "plurality" can refer to multiple features or a single 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 multiple, separate electrodes. Additionally, for example, when referring to multiple electrochemical cells, the multiple electrochemical cells can be considered multiple, 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 made separately and then bonded together (e.g., via mixing, adhesive, or any suitable method).

[0016]

[0026] 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]

[0027] As used herein, the term "conventional separator" means an ion-permeable membrane, film, or layer that provides electrical insulation between the anode and cathode while allowing charge-carrying ions to pass through. A conventional separator does not provide chemical and / or fluid separation of the anode and cathode.

[0018]

[0028] 2 is a schematic diagram of an electrochemical cell 200 according to one embodiment. The electrochemical cell 200 includes an anode 210 disposed on an anode current collector 220, a cathode 230 disposed on a cathode current collector 240, and a separator 250 disposed between the anode 210 and the cathode 230. As shown, the separator 250 includes a separator seal 255. In some embodiments, the separator seal 255 can block the flow of electroactive species through some portions of the separator 250. In some embodiments, the separator seal 255 can prevent or substantially prevent plating or accumulation of electroactive material near the anode 210 or the cathode 230. Preventing accumulation of electroactive material can improve retention of the electroactive material in the anode 210 and cathode 230 (i.e., electrodes), and therefore improve capacity retention of the electrochemical cell 200. Preventing the buildup of electroactive material may also prevent a short circuit event from occurring in electrochemical cell 200.

[0019]

[0029] In some embodiments, separator seal 255 may be made of a polymeric material. In some embodiments, separator seal 255 may be made of polyethylene, polypropylene, high-density polyethylene, polyethylene terephthalate, polystyrene, or any other suitable material. In some embodiments, separator seal 255 may be made of the same or substantially the same material as separator 250. In some embodiments, separator seal 255 may be made of a different material than separator 250. In some embodiments, separator seal 255 may be an adhesive material. In some embodiments, separator seal 255 may include cement, mucilage, adhesive, and / or paste. In some embodiments, separator seal 255 may include Kapton tape, inorganic insulating ceramic, alumina, silica, boehmite, silicon carbide, aluminum carbide, or any combination thereof. In some embodiments, separator seal 255 may be an organic material. In some embodiments, separator seal 255 may be oil. In some embodiments, separator 250 may include pores. In some embodiments, separator seal 255 can be a thermosetting polymer or resin, hi some embodiments, separator seal 255 can be a material that penetrates into the pores of separator 250 and blocks the flow of electroactive material therethrough.

[0020]

[0030] In some embodiments, separator seal 255 can include a coating material that coats a portion of separator 250. In some embodiments, the coating material can block the flow of electroactive species through pores in the portion of separator 250. In some embodiments, the coating material can include polyethylene, polypropylene, high-density polyethylene, polyethylene terephthalate, polystyrene, a thermosetting polymer, hard carbon, a thermosetting resin, a polyimide, or any other suitable coating material, or any combination thereof. In some embodiments, separator seal 255 can include an electrostatic coating. In some embodiments, separator seal 255 can be a tape bonded to one side of separator 250. In some embodiments, a portion of separator 250 can be melted and cured to close the pores in the portion of separator 250 and form separator seal 255. In some embodiments, a portion of separator 250 can be UV-cured to form separator seal 255. In some embodiments, separator seal 255 can be disposed on one side of separator 250. In some embodiments, separator seals 255 may be disposed on both sides of separator 250. In some embodiments, separator seals 255 may be tape bonded to both sides of separator 250. In some embodiments, separator seals 255 may be heat-bonded to separator 250. In some embodiments, separator 250 may be partially coated with an adhesive material. In some embodiments, a portion of separator 250 coated with an adhesive material may be heated and cured to form separator seal 255. In some embodiments, separator 250 may be partially coated with a ceramic coating, and the binder material of the ceramic coating may be melted and cured to form separator seal 255. In some embodiments, a portion of separator 250 may be mechanically pressed to close pores and form separator seal 255.

[0021]

[0031] In some embodiments, separator 250 can be bonded to anode 210 and / or cathode 230 to prevent lateral movement or displacement of anode 210 and / or cathode 230 during construction or shipping of electrochemical cell 200. In some embodiments, separator 250 can be adhesively bonded to anode 210 and / or cathode 230. In some embodiments, the adhesive bond between separator 250 and anode 210 can be separator seal 255 or part of separator seal 255. In some embodiments, the adhesive bond between separator 250 and anode 210 can be separate from separator seal 255. In some embodiments, the adhesive bond between separator 250 and cathode 230 can be separator seal 255 or part of separator seal 255. In some embodiments, the adhesive bond between separator 250 and cathode 230 can be separate from separator seal 255.

[0022]

[0032] In some embodiments, separator seal 255 may be bonded to separator 250. In some embodiments, separator seal 255 may be in physical contact with anode 210. In some embodiments, separator seal 255 may be in physical contact with cathode 230. In some embodiments, separator seal 255 may be in physical contact with both anode 210 and cathode 230. In some embodiments, separator seal 255 may be bonded to a pouch (not shown). In some embodiments, separator seal 255 may have a first side bonded to the pouch and a second side bonded to an electrode. In some embodiments, both sides of separator seal 255 may be bonded to the pouch.

[0023]

[0033] In some embodiments, separator 250 and separator seal 255 can be two separate pieces of material. For example, separator seal 255 can be a polymer that is thermally bonded to a portion of separator 250. In some embodiments, separator 250 and separator seal 255 can be two portions of the same piece of material. For example, separator 250 can have a porous section and a non-porous section, with the non-porous section functioning as separator seal 255. In some embodiments, separator seal 255 can be disposed around the perimeter of separator 250. In some embodiments, separator 250 can include multiple layers, with a first layer including separator seal 255 and a second layer providing additional structural reinforcement to separator 250.

[0024]

[0034] In some embodiments, separator seal 255 may cover at least about 5%, at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, or at least about 90% of the surface area of ​​separator 250. In some embodiments, separator seal 255 can cover about 95% or less, about 90% or less, about 85% or less, about 80% or less, about 75% or less, about 70% or less, about 65% or less, about 60% or less, about 55% or less, about 50% or less, about 45% or less, about 40% or less, about 35% or less, about 30% or less, about 25% or less, about 20% or less, about 15% or less, or about 10% or less of the surface area of ​​separator 250. Combinations of the above-referenced percentages of separator 250 covered by separator seal 255 are also possible (e.g., at least about 5% and about 95% or less, or at least about 10% and about 40% or less), including all values ​​and ranges therebetween. In some embodiments, the separator seal 255 may cover about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the surface area of ​​the separator 250.

[0025]

[0035] In some embodiments, separator seal 255 can cover a first percentage of a first side of separator 250 and a second percentage of a second side of separator 250, the second side being opposite the first side. In some embodiments, the first percentage can be the same or substantially similar to the second percentage. In some embodiments, the first percentage can be different from the second percentage. In some embodiments, the first side can be adjacent to anode 210, while the second side can be adjacent to cathode 230.

[0026]

[0036] In some embodiments, separator seal 255 can cover at least about 5%, at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, or at least about 90% of the surface area of ​​the first side of separator 250. In some embodiments, separator seal 255 can cover about 95% or less, about 90% or less, about 85% or less, about 80% or less, about 75% or less, about 70% or less, about 65% or less, about 60% or less, about 55% or less, about 50% or less, about 45% or less, about 40% or less, about 35% or less, about 30% or less, about 25% or less, about 20% or less, about 15% or less, or about 10% or less of the surface area of ​​the first side of separator 250. Combinations of the above-referenced percentages of the first side of separator 250 covered by separator seal 255 are also possible (e.g., at least about 5% and about 95% or less, or at least about 10% and about 40% or less), including all values ​​and ranges therebetween. In some embodiments, the separator seal 255 may cover about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the surface area of ​​the first side of the separator 250.

[0027]

[0037] In some embodiments, separator seal 255 can cover at least about 5%, at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, or at least about 90% of the surface area of ​​the second side of separator 250. In some embodiments, separator seal 255 can cover about 95% or less, about 90% or less, about 85% or less, about 80% or less, about 75% or less, about 70% or less, about 65% or less, about 60% or less, about 55% or less, about 50% or less, about 45% or less, about 40% or less, about 35% or less, about 30% or less, about 25% or less, about 20% or less, about 15% or less, or about 10% or less of the surface area of ​​the second side of separator 250. Combinations of the above-referenced percentages of the second side of separator 250 covered by separator seal 255 are also possible (e.g., at least about 5% and about 95% or less, or at least about 10% and about 40% or less), including all values ​​and ranges therebetween. In some embodiments, separator seal 255 may cover about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the surface area of ​​the second side of separator 250.

[0028]

[0038] 3A and 3B illustrate an electrochemical cell 300 according to one embodiment. The electrochemical cell 300 includes an anode 310 disposed on an anode current collector 320, a cathode 330 disposed on a cathode current collector 340, and a separator 350 disposed between the anode 310 and the cathode 330. As shown, the separator 350 includes a separator seal 355 facing around the outer edge of the separator 350. In some embodiments, the anode current collector 320 and / or the cathode current collector 340 may be bonded to a plastic film or pouch material (not shown). The anode 310 has an anode length L Aand anode width W A The cathode 330 has a cathode length L C and cathode width W C In some embodiments, L A L C In some embodiments, L A L C In some embodiments, W A is W C In some embodiments, W A is W C In some embodiments, L C L A In some embodiments, W C is W A may be the same as or substantially similar to

[0029]

[0039] The separator seal 355 has a characteristic length L SS and characteristic width W SS As shown in the figure, L SS L SS L A and L C 355. As shown, W represents the width dimension of the two portions of the separator seal 355 facing each other so as to be oriented in the same direction. SS is W SS W A and W C represents the width dimension of two portions of the separator seal 355 that face each other in the same direction. SS L A and L C In some embodiments, W SS is W A and W C In some embodiments, L SS is W SS In some embodiments, L SS is W SS may differ from

[0030]

[0040] If the dimensions of the anode 310 and cathode 330 are not matched, plating of the electroactive material around the perimeter of the electrodes may occur. A L C Bigger, W A is W C In such a cell design, as electroactive material flows from the anode 310 to the cathode 330, deposits or plates of electroactive species may form on the surface of the plastic film or pouch material around the periphery of the cathode 330 and cathode current collector 340. The separator seal 355 is configured to restrict the flow of ions through the separator 350. Restricting the flow of ions through the separator 350 can direct the flow of ions into the cathode 330 but prevent them from depositing around the periphery of the cathode 330. This may improve the cycling performance and capacity retention of the electrochemical cell 300 because less electroactive material is lost to this plating effect during operation of the electrochemical cell 300. The separator seal 355 is configured to restrict the flow of ions through the separator 350. A L C Smaller, W A W C The same applies to smaller sizes. A L C The same can be applied to the case where the separator seal 355 is the same as or substantially similar to the W. A W C The same can be applied when the same or substantially similar.

[0031]

[0041] Applying separator seal 355 to separator 350 can address the issue of degraded electrode material quality near the edges by blocking flow past each edge of the anode 310 and / or cathode 330 (i.e., the electrode). Blocking ion flow near the electrode's edges can help prevent plating problems if the electrode's coating quality is poorer at the electrode's edges. This prevention of ion movement near the electrode's edges can be particularly relevant when heating electrochemical cell 300 to expel gases (e.g., "hot-boxing" electrochemical cell 300), as ions can flow faster during hot-boxing. In some embodiments, applying separator seal 355 can prevent internal short-circuit events near the electrode's edges.

[0032]

[0042] In some embodiments, the incorporation of semi-solid electrode material into the anode 310 and / or cathode 330 can also help prevent near-edge plating or internal shorting events. This can be attributed to a relatively uniform pressure distribution along the length and width of the semi-solid electrode throughout fabrication and operation. The uniformly distributed pressure can help produce a uniformly distributed electrode material (i.e., uniform thickness and material concentration) on the anode current collector 320 and / or cathode current collector 340.

[0033]

[0043] As shown, separator seal 355 is disposed around the outer edge of separator 350. In some embodiments, separator seal 355 can be a tape or adhesive material adhered to the outer surface of separator 350. In some embodiments, separator seal 355 can be applied to the side of separator 350 adjacent to anode 310. In some embodiments, separator seal 355 can be applied to the side of separator 350 adjacent to cathode 330. In some embodiments, separator seal 355 can be applied to both the anode and cathode sides of separator 350. In some embodiments, separator seal 355 can be a material that penetrates into some pores of separator 350, thereby blocking the flow of material through those pores. In some embodiments, separator seal 355 can be a polymer. In some embodiments, separator seal 355 can be melted with separator 350 such that separator 350 and separator seal 355 are thermally bonded together. In some embodiments, separator seal 355 can be a gel. In some embodiments, separator seal 355 can be a high viscosity oil configured to fill pores within a portion of separator 350 and restrict the flow of electroactive material through the portion of separator 350. In some embodiments, separator seal 355 can include a bond between separator 350 and a pouch material or plastic film. In other words, one side of separator seal 355 can contact anode 310, while the other side of separator seal 355 can be bonded to the pouch material or plastic film. Conversely, one side of separator seal 355 can contact cathode 330, while the other side of separator seal 355 can be bonded to the pouch material or plastic film.

[0034]

[0044] In some embodiments, separator seal 355 can have the same or substantially similar melting temperature as separator 350, or portions of separator 350 that do not include separator seal 355. In some embodiments, separator seal 355 can have a higher melting temperature than separator 350, or portions of separator 350 that do not include separator seal 355. In some embodiments, separator seal 355 can have a melting temperature that is at least about 5° C., at least about 10° C., at least about 15° C., at least about 20° C., at least about 25° C., at least about 30° C., at least about 35° C., at least about 40° C., at least about 45° C., at least about 50° C., at least about 55° C., at least about 60° C., at least about 65° C., at least about 70° C., at least about 75° C., at least about 80° C., at least about 85° C., at least about 90° C., or at least about 95° C. higher than the melting temperature of separator 350 or the melting temperature of portions of separator 350 that do not include separator seal 355. In some embodiments, separator seal 355 can have a melting temperature that is about 100° C. or less, about 95° C. or less, about 90° C. or less, about 85° C. or less, about 80° C. or less, about 75° C. or less, about 70° C. or less, about 65° C. or less, about 60° C. or less, about 55° C. or less, about 50° C. or less, about 45° C. or less, about 40° C. or less, about 35° C. or less, about 30° C. or less, about 25° C. or less, about 20° C. or less, about 15° C. or less, or about 10° C. or less higher than the melting temperature of separator 350 or the melting temperature of portions of separator 350 that do not include separator seal 355. Combinations of the above-referenced differences between the melting temperature of separator seal 355 and separator 350 or portions of separator 350 not including separator seal 355 (e.g., at least about 5°C and not more than about 100°C, or at least about 40°C and not more than about 60°C) are also possible, including all values ​​and ranges between the values.In some embodiments, separator seal 355 can have a melting temperature that is about 5°C, 10°C, about 15°C, about 20°C, about 25°C, about 30°C, about 35°C, about 40°C, about 45°C, about 50°C, about 55°C, about 60°C, about 65°C, about 70°C, about 75°C, about 80°C, about 85°C, about 90°C, about 95°C, or about 100°C higher than the melting temperature of separator 350 or the melting temperature of the portion of separator 350 that does not include separator seal 355.

[0035]

[0045] In some embodiments, separator seal 355 can have a melting temperature that is at least about 5° C., at least about 10° C., at least about 15° C., at least about 20° C., at least about 25° C., at least about 30° C., at least about 35° C., at least about 40° C., at least about 45° C., at least about 50° C., at least about 55° C., at least about 60° C., at least about 65° C., at least about 70° C., at least about 75° C., at least about 80° C., at least about 85° C., at least about 90° C., or at least about 95° C. lower than the melting temperature of separator 350 or the melting temperature of a portion of separator 350 that does not include separator seal 355. In some embodiments, separator seal 355 can have a melting temperature that is about 100° C. or less, about 95° C. or less, about 90° C. or less, about 85° C. or less, about 80° C. or less, about 75° C. or less, about 70° C. or less, about 65° C. or less, about 60° C. or less, about 55° C. or less, about 50° C. or less, about 45° C. or less, about 40° C. or less, about 35° C. or less, about 30° C. or less, about 25° C. or less, about 20° C. or less, about 15° C. or less, or about 10° C. or less than the melting temperature of separator 350 or the melting temperature of portions of separator 350 that do not include separator seal 355. Combinations of the above-referenced differences (e.g., at least about 5° C. and not more than about 100° C., or at least about 40° C. and not more than about 60° C.) between the melting temperature of separator seal 355 and separator 350 or portions of separator 350 not including separator seal 355 are also possible, including all values ​​and ranges therebetween. In some embodiments, separator seal 355 can have a melting temperature that is about 5° C., 10° C., 15° C., 20° C., 25° C., 30° C., 35° C., 40° C., 45° C., 50° C., 55° C., 60° C., 65° C., 70° C., 75° C., 80° C., 85° C., 90° C., 95° C., or 100° C. lower than the melting temperature of separator 350 or portions of separator 350 not including separator seal 355.

[0036]

[0046] In some embodiments, the difference between the length of the anode 310 and the length of the cathode 330 (|L A -L C|) 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 A -L C |) 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. A -L C With respect to (|L), combinations of the above-referenced values ​​are possible (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. A -L C |) 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.

[0037]

[0047] In some embodiments, the difference between the width of the anode 310 and the width of the cathode 330 (|W A -W C |) 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, (|W A -W C |) 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. A -W C With respect to (|), combinations of the above-referenced values ​​are possible (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. A -WC |) 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.

[0038]

[0048] In some embodiments, L SS is (|L A -L C In some embodiments, (L SS -|L A -L C |) 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 SS -|L A -L C |) 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. SS -|L A -L C With respect to (L |), combinations of the above-referenced values ​​are also possible (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. SS -|L A -L C |) 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.

[0039]

[0049] In some embodiments, W SS is (|W A -W C In some embodiments, (W SS -|W A -W C|) 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, (W SS -|W A -W C |) 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. (W SS -|W A -W C With respect to (W |), combinations of the above-referenced values ​​are also possible (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. SS -|W A -W C |) 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.

[0040]

[0050] In some embodiments, separator seal 355 may be used in electrochemical cells assembled in a stacked configuration (i.e., an electrochemical cell stack). In some embodiments, separator seal 355 may include a degassing port (not shown). In some embodiments, separator seal 355 may have a degassing port fluidly coupled to anode 310 configured to vent gases from anode 310 to the exterior of electrochemical cell 300 through separator seal 355. In some embodiments, separator seal 355 may have a degassing port fluidly coupled to cathode 330 configured to vent gases from cathode 330 to the exterior of electrochemical cell 300 through separator seal 355. In some embodiments, separator seal 355 may include both a degassing port fluidly coupled to anode 310 and a degassing port fluidly coupled to cathode 330.

[0041]

[0051] 4A and 4B illustrate an electrochemical cell 400 according to one embodiment. The electrochemical cell 400 includes an anode 410 disposed on an anode current collector 420, a cathode 430 disposed on a cathode current collector 440, and a separator 450 disposed between the anode 410 and the cathode 430. As shown, the separator 450 includes a separator seal 455. In some embodiments, the anode current collector 420 and / or the cathode current collector 440 may be bonded to a plastic film or pouch material (not shown). The anode 410 has an anode length L A and anode width W A The cathode 430 has a cathode length L C and cathode width W C In some embodiments, L A L C In some embodiments, L A L C In some embodiments, W A is W C In some embodiments, W A is W C In some embodiments, L C L A In some embodiments, W C is W A In some embodiments, separator seal 455 can have the same or substantially similar physical characteristics as separator seal 355 as described above with reference to FIG. 3, including one or more degassing ports.

[0042]

[0052] The separator seal 455 has a characteristic length L SS and characteristic width W SS As shown in the figure, L SS L SS L A and L C455. As shown in the figure, W represents the width dimension of two portions of the separator seal 455 facing each other so as to face in the same direction. SS is W SS W A and W C represents the width dimension of two portions of the separator seal 455 that face each other in the same direction. SS L A and L C In some embodiments, W SS is W A and W C In some embodiments, L SS is W SS In some embodiments, L SS is W SS may differ from

[0043]

[0053] As shown, separator 450 extends beyond the length and width dimensions of both anode 410 and cathode 430. In other words, separator seal 455 does not extend to the edges of separator 450. In some embodiments, separator 450 can be bonded to a plastic film or pouch material (not shown). In some embodiments, both sides of separator seal 455 can include portions bonded to the pouch material or plastic film. In other words, separator seal 455 can both restrict the flow of electroactive material and provide a seal between separator 450 and the pouch material or plastic film on the anode side and / or cathode side of electrochemical cell 400. In some embodiments, separator seal 455 can extend to the edges of separator 450.

[0044]

[0054] In some embodiments, the difference between the length of the anode 410 and the length of the cathode 430 (|L A -L C|) 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 A -L C |) 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. A -L C With respect to (|L), combinations of the above-referenced values ​​are possible (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. A -L C |) 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.

[0045]

[0055] In some embodiments, the difference between the width of the anode 410 and the width of the cathode 430 (|W A -W C |) 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, (|W A -W C |) 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. A -W C With respect to (|), combinations of the above-referenced values ​​are possible (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. A -WC |) 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.

[0046]

[0056] In some embodiments, L SS is (|L A -L C In some embodiments, (L SS -|L A -L C |) 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 SS -|L A -L C |) 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. SS -|L A -L C With respect to (L |), combinations of the above-referenced values ​​are also possible (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. SS -|L A -L C |) 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.

[0047]

[0057] In some embodiments, W SS is (|W A -W C In some embodiments, (W SS -|W A -W C|) 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, (W SS -|W A -W C |) 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. (W SS -|W A -W C With respect to (W |), combinations of the above-referenced values ​​are also possible (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. SS -|W A -W C |) 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.

[0048]

[0058] 5A and 5B illustrate an electrochemical cell 500 according to one embodiment. The electrochemical cell 500 includes an anode 510 disposed on an anode current collector 520, a cathode 530 disposed on a cathode current collector 540, and a separator 550 disposed between the anode 510 and the cathode 530. As shown, the separator 550 includes a first layer 552 and a second layer 554. As shown, the first layer 552 includes a separator seal 555 having a boundary line C depicted as a dotted line, which indicates the boundary between the separator seal 555 and the remaining area of ​​the first layer 552. In some embodiments, the anode current collector 520 and / or the cathode current collector 540 may be bonded to a plastic film or pouch material (not shown). The anode 510 has an anode length L A and anode width W A The cathode 530 has a cathode length L C and cathode width WC In some embodiments, L A L C In some embodiments, L A L C In some embodiments, W A is W C In some embodiments, W A is W C In some embodiments, separator seal 555 can have the same or substantially similar physical characteristics as separator seal 355 as described above with reference to FIG. 3, including one or more degassing ports.

[0049]

[0059] The separator seal 555 has a characteristic length L SS and characteristic width W SS As shown in the figure, L SS L SS L A and L C 555. As shown in the figure, W represents the width dimension of two portions of the separator seal 555 facing each other so as to face in the same direction. SS is W SS W A and W C In some embodiments, L represents the width dimension of two portions of the separator seal 555 that face each other in the same direction. SS L A and L C In some embodiments, W SS is W A and W C In some embodiments, L SS is W SS In some embodiments, L SS is W SS may differ from

[0050]

[0060] In some embodiments, the anode 510, anode current collector 520, cathode 530, and cathode current collector 540 can be the same as or substantially similar to the anode 210, anode current collector 220, cathode 230, and cathode current collector 240 described above with reference to FIG. 2. Accordingly, certain aspects of the anode 510, anode current collector 520, cathode 530, and cathode current collector 540 are not described in further detail herein. In some embodiments, the L A , L C , W A , W C , L A , and W SS is the L as described above with reference to FIG. A , L C , W A , W C , L A , L SS , and W SS Therefore, L A , L C , W A , W C , L A , L SS , and W SS Certain aspects of are not described in further detail herein.

[0051]

[0061] As shown, separator 550 is a bilayer separator. In some embodiments, first layer 552 may be bonded to second layer 554 via adhesive, tape, heat sealing, or any other suitable bonding means or combinations thereof. In some embodiments, the application of heat to form separator seal 555 causes thermal damage to the area of ​​first layer 552 that comprises separator seal 555. In some embodiments, the area of ​​first layer 552 that comprises separator seal 555 may delaminate. In some embodiments, cracks may occur along boundary line C or elsewhere on first layer 552 or separator seal 555. Cracks or other damage to first layer 552 may cause electroactive material (e.g., anode 510, cathode 530) to leak through first layer 552. The inclusion of the second layer 554 of the separator 550 can further strengthen the separator 550 so that cracks or damage occurring in the first layer 552 will not result in a short circuit event (i.e., from contact between the anode 510 and the cathode 530) or leakage of the electroactive material.

[0052]

[0062] In some embodiments, the second layer 554 may be composed of a different material than the first layer 552. In some embodiments, the second layer 554 may be composed of a material having a higher melting temperature than the material comprising the first layer 552. In some embodiments, the second layer 554 may have greater heat resistance (i.e., greater resistance to heat damage) than the first layer 552. In some embodiments, the first layer 552 may be composed of polyethylene. In some embodiments, the second layer 554 may be composed of polypropylene. In some embodiments, the first layer 552 and / or the second layer 554 may be composed of polyethylene, polypropylene, high-density polyethylene, polyethylene terephthalate, polystyrene, thermoset polymers, hard carbon, thermoset resins, polyimide, ceramic-coated separators, inorganic separators, cellulose, fiberglass, or any other suitable material, or combinations thereof. In some embodiments, a first side of the first layer 552 can be coated with a ceramic, and a second side of the first layer 552 can be sealed to a second layer 554, the second side being opposite the first side. In some embodiments, an additional layer of material (not shown) can be coated on the first layer 552. In some embodiments, the additional layer can be opposite the second layer 554. In some embodiments, the additional layer can include a polymer of intrinsic microporosity (PIM). In some embodiments, the additional layer can include polypropylene. In some embodiments, the first layer 552 can have a high melting point such that melting a portion of the first layer 552 to form the separator seal 555 is impractical (e.g., if the first layer 552 is composed of polyimide, fiberglass, etc.). In some embodiments, a portion of the first layer 552 can be mechanically pressed to close the pores on the first layer 552 and establish the separator seal 555.

[0053]

[0063] In some embodiments, the second layer 554 can have a higher melting temperature than the first layer 552. In some embodiments, the melting temperature of the second layer 554 can be at least about 5° C., at least about 10° C., at least about 15° C., at least about 20° C., at least about 25° C., at least about 30° C., at least about 35° C., at least about 40° C., at least about 45° C., at least about 50° C., at least about 55° C., at least about 60° C., at least about 65° C., at least about 70° C., at least about 75° C., at least about 80° C., at least about 85° C., at least about 90° C., or at least about 95° C. greater than the melting temperature of the first layer 552. In some embodiments, the melting temperature of the second layer 554 can be about 100° C. or less, about 95° C. or less, about 90° C. or less, about 85° C. or less, about 80° C. or less, about 75° C. or less, about 70° C. or less, about 65° C. or less, about 60° C. or less, about 55° C. or less, about 50° C. or less, about 45° C. or less, about 40° C. or less, about 35° C. or less, about 30° C. or less, about 25° C. or less, about 20° C. or less, about 15° C. or less, or about 10° C. or less greater than the melting temperature of the first layer 552. Combinations of the above-referenced differences between the melting temperatures of the second layer 554 and the first layer 552 are also possible (e.g., at least about 5° C. and about 100° C. or less, or at least about 40° C. and about 60° C. or less), including all values ​​and ranges therebetween. In some embodiments, the melting temperature of the second layer 554 can be about 5°C, about 10°C, about 15°C, about 20°C, about 25°C, about 30°C, about 35°C, about 40°C, about 45°C, about 50°C, about 55°C, about 60°C, about 65°C, about 70°C, about 75°C, about 80°C, about 85°C, about 90°C, about 95°C, or about 100°C greater than the melting temperature of the first layer 552.

[0054]

[0064] In some embodiments, a portion of the first layer 552 may be selectively melted to the second layer 554 to form the separator seal 555. In other words, the selectively melted portion of the first layer 552 may be bonded to the second layer 554. For example, if the first layer 552 is composed of polyethylene and the second layer 554 is composed of polypropylene, a portion of the polyethylene layer may be melted and bonded to the polypropylene layer. In some embodiments, an outer edge of the first layer 552 may be melted to the second layer 554 to form the separator seal 555. In some embodiments, a portion of the first layer 552 and a portion of the second layer 554 may be selectively melted to form the separator seal 555. In some embodiments, a portion of the first layer 552 and a portion of the second layer 554 may be selectively melted and bonded together to form the separator seal 555. In some embodiments, an outer edge of the first layer 552 and an outer edge of the second layer 554 may be fused together to form a separator seal 555 .

[0055]

[0065] As shown, the portion of separator 550 that includes separator seal 555 (i.e., first layer 552) is on the side of electrochemical cell 500 adjacent to anode 510. In some embodiments, first layer 552 can be adjacent to cathode 530. As shown, the portion of separator 550 that strengthens separator 550 (i.e., second layer 554) is on the side of electrochemical cell 500 adjacent to cathode 530. In some embodiments, second layer 554 can be on the side of electrochemical cell 500 adjacent to anode 510.

[0056]

[0066] As shown, separator 550 has similar length and width dimensions as anode 510. In other words, the outer edge of separator 550 and the outer edge of separator seal 555 are shown as being approximately flush with the outer edge of anode 510. In some embodiments, separator 550 can extend beyond the length and width dimensions of both anode 510 and cathode 530, similar to separator 450 as described above with reference to FIG. 4. In some embodiments, separator seal 555 does not extend to the edges of separator 550. In some embodiments, separator 550 can be bonded to a plastic film or pouch material (not shown). In some embodiments, both sides of separator seal 555 can include a portion bonded to the pouch material or plastic film. In other words, the separator seal 555 can both restrict the flow of electroactive material and provide a seal between the separator 550 and the pouch material or plastic film on the anode and / or cathode side of the electrochemical cell 500. In some embodiments, the separator seal 555 can extend to the edge of the separator 550, while the separator 550 extends beyond the edge of the anode 510.

[0057]

[0067] 6A and 6B illustrate an electrochemical cell 600 according to one embodiment. The electrochemical cell 600 includes an anode 610 disposed on an anode current collector 620, a cathode 630 disposed on a cathode current collector 640, and a separator 650 disposed between the anode 610 and the cathode 630. As shown, the separator 650 includes a first layer 652, a second layer 654, and a third layer 656. As shown, the first layer 652 includes a separator seal 655 having a border C depicted as a dotted line, which indicates the boundary between the separator seal 655 and the remaining area of ​​the first layer 652. As shown, the third layer 656 includes a separator seal 657 having a border D depicted as a dotted line, which indicates the boundary between the separator seal 657 and the remaining area of ​​the third layer 657. In some embodiments, the anode current collector 620 and / or the cathode current collector 640 may be bonded to a plastic film or pouch material (not shown). The anode 610 has an anode length L A and anode width W A The cathode 630 has a cathode length L C and cathode width W C In some embodiments, L A L C In some embodiments, L A L C In some embodiments, W A is W C In some embodiments, W A is W C In some embodiments, separator seal 655 and / or separator seal 657 may have the same or substantially similar physical characteristics as separator seal 355 as described above with reference to FIG. 3, including one or more degassing ports.

[0058]

[0068] The separator seal 655 has a characteristic length L SS1 and characteristic width W SS1 As shown in the figure, L SS1 L SS1 LA and L C 655. As shown, W represents the width dimension of two portions of the separator seal 655 facing each other in the same direction. SS1 is W SS1 W A and W C In some embodiments, L represents the width dimension of two portions of the separator seal 655 that face each other in the same direction. SS1 L A and L C In some embodiments, W SS1 is W A and W C In some embodiments, L SS1 is W SS1 In some embodiments, L SS1 is W SS1 may differ from

[0059]

[0069] The separator seal 657 has a characteristic length L SS2 and characteristic width W SS2 As shown in the figure, L SS2 L SS2 L A and L C 657. As shown in the figure, W represents the width dimension of two portions of the separator seal 657 facing each other so as to face in the same direction. SS2 is W SS2 W A and W C represents the width dimension of two portions of the separator seal 657 that face each other in the same direction. SS2 L A and L C In some embodiments, W SS2 is W A and W C In some embodiments, L SS2 is W SS2 In some embodiments, L SS1is W SS2 may differ from

[0060]

[0070] In some embodiments, separator seal 655 can be the same as or substantially similar to separator seal 657. In some embodiments, separator seal 655 can be different from separator seal 657. In some embodiments, L SS1 L SS2 In some embodiments, L SS1 L SS2 In some embodiments, W SS1 is W SS2 In some embodiments, W SS1 is W SS2 may differ from

[0061]

[0071] In some embodiments, the anode 610, anode current collector 620, cathode 630, and cathode current collector 640 can be the same as or substantially similar to the anode 210, anode current collector 220, cathode 230, and cathode current collector 240 described above with reference to FIG. 2. Accordingly, certain aspects of the anode 610, anode current collector 620, cathode 630, and cathode current collector 640 are not described in further detail herein. In some embodiments, the L A , L C , W A , W C , and L A is the L as described above with reference to FIG. A , L C , W A , W C , and L A In some embodiments, L SS1 and W SS1 is the L as described above with reference to FIG. SS and W SS In some embodiments, L SS2 and W SS2 is the L as described above with reference to FIG.SS and W SS Therefore, L A , L C , W A , W C , L A , L SS1 , L SS2 , W SS1 , and W SS2 Certain aspects of are not described in further detail herein.

[0062]

[0072] As shown, separator 650 is a three-layer separator. In some embodiments, first layer 652 can be bonded to second separator 654 and / or third layer 656 can be bonded to second separator 654 via adhesive, tape, heat sealing, or any other suitable bonding means or combinations thereof. Similar to separator seal 555 as described above with reference to FIG. 5 , the application of heat to form separator seal 655 or separator seal 657 can cause heat damage to the areas of first layer 652 or third layer 656 that make up separator seal 655 or separator seal 657. The inclusion of second layer 654 can further strengthen separator 650 to prevent leakage or shorting of the electroactive material. In some embodiments, first layer 652 can be the same as or substantially similar to first layer 552 as described above with reference to FIG. 5 . In some embodiments, third layer 656 can be the same as or substantially similar to first layer 552 as described above with reference to FIG. 5. In some embodiments, second layer 654 can be the same as or substantially similar to second layer 554 as described above with reference to FIG. 5. In some embodiments, separator seal 655 can be the same as or substantially similar to separator seal 555 as described above with reference to FIG. 5. In some embodiments, separator seal 657 can be the same as or substantially similar to separator seal 555 as described above with reference to FIG. 5. Accordingly, certain aspects of first layer 652, second layer 654, third layer 656, separator seal 655, and separator seal 657 will not be described in further detail herein.

[0063]

[0073] In some embodiments, first layer 652 can be the same as or substantially similar to third layer 656. In some embodiments, first layer 652 can be different from third layer 656. For example, first layer 652 can have a different thickness and / or composition compared to third layer 656. In some embodiments, separator seal 655 can be the same as or substantially similar to separator seal 657. In some embodiments, separator seal 655 can be different from separator seal 657. In some embodiments, separator seal 655 can be implemented via a first mechanism and separator seal 657 can be implemented via a second mechanism. For example, separator seal 655 can be implemented via a heat seal, while separator seal 657 can be implemented via an adhesive. In some embodiments, W SS1 is W SS2 In some embodiments, W SS1 is W SS2 In some embodiments, L SS1 L SS2 In some embodiments, L SS1 is W SS2 may differ from

[0064]

[0074] As shown, separator 650 includes three layers. In some embodiments, separator 650 can include 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, or at least about 20 layers, including all values ​​and ranges therebetween. In some embodiments, separator 650 can include an assembly of alternating layers having separator seal portions (e.g., first layer 652, third layer 656) and layers not having separator seal portions (e.g., second layer 654). In some embodiments, separator 650 can include multiple layers with separator seal portions bonded together in sequence and / or multiple layers without separator seal portions bonded together in sequence.

[0065]

[0075] 7A-7C illustrate a wound electrochemical cell 700, according to one embodiment. FIG. 7A illustrates the components of the wound electrochemical cell 700 in an exploded state. FIG. 7B illustrates the wound electrochemical cell 700 formed into a cylindrical cell 700B. FIG. 7C illustrates the wound electrochemical cell 700 formed into a prismatic cell 700C. The wound electrochemical cell 700 includes an anode 710 disposed on an anode current collector 720, a cathode 730 disposed on a cathode current collector 740, and a separator 750 disposed between the anode 710 and the cathode 730. As shown, the separator 750 includes a separator seal 755. In some embodiments, the anode current collector 720 and / or the cathode current collector 740 may be bonded to a plastic film or pouch material (not shown). The anode 710 has an anode width W A The cathode 730 has a cathode width W C In some embodiments, W A is W C In some embodiments, W A is W C The separator seal 755 may have a width W SS In some embodiments, the anode 710, anode current collector 720, cathode 730, cathode current collector 740, separator 750, separator seal 755, WA , W C , and W SS 3A and 3B, the anode 310, anode current collector 320, cathode 330, cathode current collector 340, separator 350, separator seal 355, W A , W C , and W SS Accordingly, certain aspects of anode 710, anode current collector 720, cathode 730, cathode current collector 740, separator 750, and separator seal 755 will not be described in further detail herein.

[0066]

[0076] In some embodiments, separator seal 755 may be manufactured such that separator seal 755 is present on only two edges of separator 750 rather than on all four edges of separator 750. In some embodiments, separator 750 may be manufactured continuously as one long piece of material. In some embodiments, separator 750 may be manufactured including separator seal 755. In some embodiments, separator seal 755 may be incorporated into separator 750 after separator 750 is manufactured. In some embodiments, anode 710 and / or cathode 730 may be bonded to separator 750. In some embodiments, anode 710 and / or cathode 730 may be bonded to separator 750 via an adhesive. In some embodiments, bonding the anode 710 and / or cathode 730 to the separator 750 helps to avoid misalignment during winding of the wound electrochemical cell 700 to form the cylindrical cell 700B or the prismatic cell 700C.

[0067]

[0077] 8A-8C show diagrams of an exploded electrochemical cell 800, according to one embodiment. Visible in these figures are an anode 810, an anode current collector 820, a cathode 830, a cathode current collector 840, and a separator 850 having a permeable region 853 and a separator seal 855. The separator seal 855 is a frame member disposed around the outside of the separator 850. Pores around the edges of the separator 850 are sealed by the application of heat, which selectively melts portions of the separator 850, preventing lithium ion transport during operation of the electrochemical cell 800. The anode 810 is a graphite anode, while the cathode 830 is an NMC cathode. After the first cycle, an interior region 813 and a frame region 815 are visible on the anode 810, indicating where ion flow was blocked during the first cycle. Inner region 813 contains lithiated graphite that is golden in appearance, while the unlithiated graphite in frame region 815 appears black. Inner region 833 and frame region 835 are also visible on cathode 830, with frame region 835 indicating where ion flow was interrupted during initial cycling.

[0068]

[0078] 9A-9C show diagrams of an exploded electrochemical cell 900, according to one embodiment. Visible in these figures are an anode 910, an anode current collector 920, a cathode 930, a cathode current collector 940, and a separator 950 having a permeable region 953 and a separator seal 955. The anode 920 is a lithium metal anode. The separator seal 955 is a framing member disposed around the outside of the separator 950. Pores around the edges of the separator 950 are sealed by the application of heat, which selectively melts portions of the separator 950, preventing lithium ion transport during operation of the electrochemical cell 900. After the first cycle, an interior region 913 and a frame region 915 are visible on the anode 910, indicating where ion flow was blocked during the first cycle. The interior region 913 has a dark appearance. This is because the inner region 913 has been plated with NMC from the cathode 930, causing the electrode surface to appear dark due to the formation of a solid electrolyte interface (SEI). The frame region 915 still appears the color of lithium because NMC from the cathode 930 has been substantially prevented from contacting the frame region. Similarly, the permeable region 953 of the separator 950 has a darker appearance due to contact with NMC. The inner region 933 and frame region 935 are also visible on the cathode 930, with the frame region 935 indicating where ion flow was blocked during the first cycling.

[0069]

[0079] 10A-10G show diagrams of an exploded electrochemical cell 1000, according to one embodiment. Visible in these figures are an anode 1010, an anode current collector 1020, a cathode 1030, a cathode current collector 1040, and a separator 1050 with a separator seal 1055. The anode 1020 is a lithium metal anode. The separator seal 1055 is a resin framing member disposed around the outside of the separator 1050.

[0070]

[0080] 11A and 11B show an electrochemical cell 1100 according to one embodiment. The electrochemical cell 1100 includes an anode 1110 disposed on an anode current collector 1120, a cathode 1130 disposed on a cathode current collector 1140, and a separator 1150 disposed between the anode 1110 and the cathode 1130. As shown, the separator 1150 includes a separator seal 1155 facing around the outer edge of the separator 1150. In some embodiments, an edge coating member 1123 may be disposed on the anode current collector 1120. In some embodiments, the anode current collector 1120 and / or the cathode current collector 1140 may be bonded to a plastic film or pouch material (not shown). The anode 1110 has an anode length L A and anode width W A The cathode 1130 has a cathode length L C and cathode width W C The separator seal 1155 has a characteristic length L SS and characteristic width W SS The anode current collector 1120 has a characteristic length L ACC and characteristic width W ACC In some embodiments, the anode 1110, the anode current collector 1120, the cathode 1130, the cathode current collector 1140, the separator 1150, the separator seal 1155, the L A , W A , L C , W C , L SS , and W SS 3, includes an anode 310, an anode current collector 320, a cathode 330, a cathode current collector 340, a separator 350, a separator seal 355, and a L A , W A , L C , W C , L SS , and W SS Thus, the anode 1110, the anode current collector 1120, the cathode 1130, the cathode current collector 1140, the separator 1150, the separator seal 1155, the L A , W A , LC , W C , L SS , and W SS Certain aspects of are not described in further detail herein.

[0071]

[0081] As shown, L ACC L A Larger than W ACC is W A In other words, the anode current collector 1120 has larger length and width dimensions than the anode 1110. This difference in dimensions can have several advantages. The size difference between the anode current collector 1120 and the anode 1110 allows for the placement of an edge coating member 1123 around the outer periphery of the anode 1110. In some embodiments, the edge coating member 1123 may be less conductive than the anode 1110. In some embodiments, the combination of the edge coating member 1123 and the separator seal 1150 can provide improved performance in preventing plating of the electroactive material near the anode 1110. In some embodiments, the edge coating member 1123 can include a UV-cured material. In some embodiments, the edge coating member 1123 can be coated onto the separator 1150 to form all or part of the separator seal 1155. In some embodiments, the edge coating member 1123 can include an alloy with silicon and / or tin. In some embodiments, the edge coating member 1123 can include an intercalation compound. In some embodiments, the edge coating member 1123 can include hard carbon. In some embodiments, the edge coating member 1123 can have a potential higher than ground to be resistant to plating. In some embodiments, the edge coating member 1123 can include lithium titanate (LTO). In some embodiments, the edge coating member 1123 can include titanium dioxide (TiO). Further examples of edge coating members and framing members are described in U.S. Pat. No. 10,593,952 (the '952 patent), which is incorporated herein by reference in its entirety.

[0072]

[0082] In some embodiments, (W ACC -W A ) 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, (W ACC -W A ) 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. ACC -W A With respect to (W), combinations of the above-referenced values ​​are possible (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. ACC -W A ) 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.

[0073]

[0083] In some embodiments, (L ACC -L A ) 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 ACC -L A ) 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. ACC -L AWith respect to (L), combinations of the above-referenced values ​​are possible (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. ACC -L A ) 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.

[0074]

[0084] In some embodiments, the cathode current collector 1140 can have greater length and width dimensions than the cathode 1130. In some embodiments, the difference in dimensions between the cathode current collector 1140 and the cathode 1130 can be the same or substantially similar to those described above with respect to the anode 1110 and the anode current collector 1120. In some embodiments, a cathode edge coating member (not shown) can be disposed on the cathode current collector 1140.

[0075]

[0085] Various concepts may be embodied as one or more methods, at least one example of which is provided. Acts performed as part of a method may be ordered in any suitable manner. Thus, embodiments may be constructed in which acts are performed in an order different from that illustrated, which may include performing some acts simultaneously even though they are shown as ordered acts in an example embodiment. In other words, it should be understood that such functions are not necessarily limited to a particular order of execution, but rather may be any number of threads, processes, services, servers, etc., executing serially, asynchronously, concurrently, parallelly, simultaneously, synchronously, and / or in any manner consistent with the present disclosure. Thus, some of these functions may be mutually inconsistent, in that they cannot exist simultaneously in a single embodiment. Similarly, some functions may be applicable to one aspect of the innovation and inapplicable to other aspects.

[0076]

[0086] Additionally, the present disclosure may include other innovations not currently described. Applicant reserves all rights in such innovations, including the right to implement such innovations and to file additional applications, continuations, continuations-in-part, divisional applications, and the like. Accordingly, it should be understood that the advantages, embodiments, examples, functional, characteristic, logical, operational, organizational, structural, topological, and / or other aspects of the present disclosure should not be construed as limitations on the 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 configurations and / or relational models, data types, data transmission and / or network frameworks, syntax structures, and the like, various embodiments of the technology disclosed herein may be implemented in a manner that allows for great flexibility and customization, as described herein.

[0077]

[0087] All definitions defined and used herein should be understood to govern dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0078]

[0088] As used herein, the terms "about" and "approximately" generally mean plus or minus 10% of the stated value. For example, about 250 μm includes 225 μm to 275 μm, and about 1,000 μm includes 900 μm to 1,100 μm.

[0079]

[0089] As used herein, in certain 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 provided, it is understood that each value between the upper and lower limits of that range, to one-tenth of the unit of the lower limit unless expressly indicated otherwise, and any other stated or intervening value in the stated range, is encompassed within the disclosure. The upper and lower limits of these narrower ranges may independently be included in the narrower ranges, but any limit in the stated range may be specifically excluded. When a stated range includes one or both of the limits, ranges excluding either or both of those included limits are also encompassed within the disclosure.

[0080]

[0090] As used in the specification and embodiments, the phrase "and / or" should be understood to mean "one or both" of the elements so connected, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with "and / or" should be construed in the same manner, i.e., "one or more" of the elements so connected. Other elements aside from the elements specifically identified by the "and / or" clause may optionally be present, whether related to the elements specifically identified or not. Thus, as a non-limiting example, a reference to "A and / or B," when used in conjunction with open-ended language such as "comprising," may, in one embodiment, refer to A only (optionally including elements other than B); in another embodiment, refer to B only (optionally including elements other than A); in yet another embodiment, refer to both A and B (optionally including other elements); and so forth.

[0081]

[0091] 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 items in a list, "or" or "and / or" shall be interpreted as inclusive, i.e., including at least one of, but also including more than one of, a plurality of elements or a list of elements, and optionally including additional unlisted items. Only terms clearly indicating the contrary, such as "only one of" or "exactly one of," or, when used in the embodiments, "consisting of," shall refer to the inclusion of exactly one of a plurality of elements or a list of elements. In general, as used herein, the term "or" shall only be interpreted to indicate 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.

[0082]

[0092] As used in this specification and in the embodiments, the phrase "at least one" in connection with a list of one or more elements should be understood to mean at least one element selected from one or more of the elements in the list of elements, but not necessarily including at least one of every element specifically listed in the list of elements, and not excluding any combination of elements in the list of elements. This definition also allows for the optional presence of elements other than those specifically named in the list of elements to which the phrase "at least one" refers, whether related to those specifically named elements. Thus, as a 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 two or more As, in the absence of B (and optionally including elements other than B); in another embodiment, to at least one B, optionally two or more Bs, in the absence of A (and optionally including elements other than A); and in yet another embodiment, to at least one A, optionally two or more As, in the presence of at least one B, optionally two or more Bs (and optionally including other elements).

[0083]

[0093] In embodiments, as well as in the above specification, all transitional phrases such as "comprise," "include," "carry," "have," "contain," "accompany," "hold," "consist," and the like, should be understood to be open-ended, i.e., to mean 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 Section 2111.03 of the U.S. Patent and Trademark Office Manual of Patent Examining Procedures.

[0084]

[0094] While specific embodiments of the present disclosure have been outlined above, numerous 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 changes may be made without departing from the spirit and scope of the present disclosure. Where the methods and steps described above show particular events occurring in a particular order, those skilled in the art, having the benefit of this disclosure, will understand that the order of certain steps may be changed and that such changes are in accordance with variations of the invention. In addition, certain steps may be performed simultaneously in a parallel process, where possible, or sequentially as described above. While embodiments have been specifically shown and described, it will be understood that various changes in form and detail may be made.

Claims

1. 1. An electrochemical cell comprising: an anode disposed on an anode current collector; a cathode disposed on a cathode current collector; a separator disposed between the anode and the cathode, the separator having a first surface in contact with the anode and a second surface opposite the first surface in contact with the cathode, the separator configured to allow movement of electroactive species between the anode and the cathode; a separator seal coupled to the separator, the separator seal configured to block migration of electroactive species.

2. 10. The electrochemical cell of claim 1, wherein the separator has a length greater than a length of the anode and a width greater than a width of the anode such that a portion of the first surface of the separator does not contact the anode.

3. 2. The electrochemical cell of claim 1, wherein the separator has a length greater than a length of the cathode and a width greater than a width of the cathode such that a portion of the second surface of the separator does not contact the cathode.

4. 10. The electrochemical cell of claim 1, wherein the cathode has a length that is less than a length of the anode and the cathode has a width that is less than a width of the anode.

5. 5. The electrochemical cell of claim 4, wherein the length of the anode is the same as or substantially similar to the length of the separator and the width of the anode is the same as or substantially similar to the width of the separator, whereby the separator has a partially covered portion, the partially covered portion of the separator contacting the anode on the first surface of the separator and the partially covered portion of the separator not contacting the cathode on the second surface of the separator.

6. 6. The electrochemical cell of claim 4 or 5, wherein the separator seal is disposed around an outer periphery of the separator at the first surface of the separator and / or the second surface of the separator such that the separator seal covers all of the partially covered portion of the separator.

7. The electrochemical cell of any one of claims 1 to 6, wherein the separator seal comprises tape.

8. The electrochemical cell of any one of claims 1 to 7, wherein the separator seal comprises an adhesive.

9. The electrochemical cell of any one of claims 1 to 8, wherein the separator seal comprises an electrostatic coating.

10. 10. The electrochemical cell of claim 1, wherein the separator comprises pores.

11. 11. The electrochemical cell of claim 10, wherein the separator seal comprises a material disposed in the pores of a portion of the separator.

12. 11. The electrochemical cell of claim 10, wherein the separator seal comprises a coating material coating a portion of the separator.

13. 13. The electrochemical cell of claim 12, wherein the coating material comprises polyethylene, polypropylene, high density polyethylene, polyethylene terephthalate, polystyrene, a thermosetting polymer, hard carbon, a thermosetting resin, a polyimide, or any combination thereof.

14. 14. The electrochemical cell of claim 10, wherein the separator seal comprises a high viscosity oil disposed in the pores of a portion of the separator, the high viscosity oil restricting the flow of electroactive material through the portion of the separator.

15. 14. The electrochemical cell of claim 1, wherein the separator seal is thermally bonded to the separator.

16. a pouch, the first surface of the separator including a first seal portion, the first seal portion of the separator being coupled to the pouch; 16. The electrochemical cell of claim 1, wherein the second surface of the separator includes a second seal portion, the second seal portion of the separator being bonded to the pouch.

17. 17. The electrochemical cell of claim 16, wherein the separator seal is bonded to the pouch.

18. 18. The electrochemical cell of claim 1, wherein the anode and / or the cathode comprises a solid electrolyte.

19. an anode disposed on an anode current collector; a cathode disposed on a cathode current collector; a separator disposed between the anode and the cathode, the separator including a permeable portion configured to allow movement of electroactive species through the separator and an impermeable portion configured to prevent movement of electroactive species through the separator.

20. 20. The electrochemical cell of claim 19, wherein the separator has a length that is greater than a length of the anode and a width that is greater than a width of the anode, such that a portion of a surface of the separator adjacent the anode does not contact the anode.

21. 20. The electrochemical cell of claim 19, wherein the separator has a length that is greater than a length of the cathode and a width that is greater than a width of the cathode such that a portion of a surface of the separator adjacent the cathode does not contact the cathode.

22. 20. The electrochemical cell of claim 19, wherein the cathode has a length that is less than a length of the anode and the cathode has a width that is less than a width of the anode.

23. 23. The electrochemical cell of claim 22, wherein the length of the anode is the same as or substantially similar to the length of the separator and the width of the anode is the same as or substantially similar to the width of the separator, whereby the separator has a partially covered portion, the partially covered portion of the separator contacting the anode on a first surface of the separator and the partially covered portion of the separator not contacting the cathode on a second surface of the separator.

24. 24. The electrochemical cell of claim 22 or 23, wherein the impermeable portion is disposed around an outer periphery of the separator at the first surface of the separator and / or the second surface of the separator such that the impermeable portion covers all of the partially covered portion of the separator.

25. Electrochemical cell according to any one of claims 19 to 24, wherein the impermeable portion is UV cured.

26. 26. The electrochemical cell of claim 25, wherein a portion of the permeable portion is attached to a pouch.

27. 27. The electrochemical cell of any one of claims 19 to 26, wherein the separator comprises a first layer and a second layer, the first layer comprising an impermeable section.

28. 28. The electrochemical cell of claim 27, wherein substantially all of the second layer is permeable.

29. 29. The electrochemical cell of claim 27 or 28, wherein the second layer has a melting temperature greater than the melting temperature of the first layer.

30. 30. The electrochemical cell of any one of claims 27 to 29, wherein the first layer comprises polyethylene.

31. 31. The electrochemical cell of any one of claims 27 to 30, wherein the second layer comprises polypropylene.

32. 32. The electrochemical cell of any one of claims 27 to 31, wherein an outer edge of the first layer is selectively fused to the second layer to form the impermeable section.

33. 33. The electrochemical cell of any one of claims 19 to 32, wherein the anode and / or the cathode comprise a solid electrolyte.

34. 34. The electrochemical cell of any one of claims 37 to 33, wherein the separator comprises pores.

35. 35. The electrochemical cell of claim 34, wherein the impermeable portion of the separator includes a material disposed in the pores to prevent migration of electroactive species through the impermeable portion.

36. 36. The electrochemical cell of claim 35, wherein the material comprises a high viscosity oil.

37. a first electrode; a second electrode; and a separator disposed between the first electrode and the second electrode, the separator having a first surface in contact with the first electrode and a second surface opposite the first surface in contact with the second electrode, the separator configured to allow transfer of electroactive species between the first electrode and the second electrode; a separator seal coupled to the separator, the separator seal configured to block migration of electroactive species; A pouch, a pouch, wherein the first electrode, the second electrode, the separator, and the separator seal are disposed within the pouch.

38. 38. The electrochemical cell of claim 37, wherein the separator has a length that is greater than a length of the first electrode and a width that is greater than a width of the first electrode such that a portion of the first surface of the separator does not contact the first electrode.

39. 38. The electrochemical cell of claim 37, wherein the separator has a length that is greater than a length of the second electrode and a width that is greater than a width of the second electrode such that a portion of the second surface of the separator does not contact the second electrode.

40. 38. The electrochemical cell of claim 37, wherein the second electrode has a length that is less than a length of the first electrode and the second electrode has a width that is less than a width of the second electrode.

41. 41. The electrochemical cell of claim 40, wherein the length of the first electrode is the same as or substantially similar to the length of the separator and the width of the first electrode is the same as or substantially similar to the width of the separator, whereby the separator has a partially covered portion, the partially covered portion of the separator contacting the first electrode on the first surface of the separator and the partially covered portion of the separator not contacting the second electrode on the second surface of the separator.

42. 42. The electrochemical cell of claim 40 or 41, wherein the separator seal is disposed around an outer periphery of the separator at the first surface of the separator and / or the second surface of the separator such that the separator seal covers all of the partially covered portion of the separator.

43. 43. The electrochemical cell of any one of claims 37 to 42, wherein the separator seal comprises a material disposed in pores of a portion of the separator.

44. 44. The electrochemical cell of any one of claims 37 to 43, wherein the separator seal comprises tape.

45. 45. The electrochemical cell of any one of claims 37 to 44, wherein the separator seal comprises an adhesive.

46. 46. ​​The electrochemical cell of any one of claims 37 to 45, wherein the first electrode and / or the second electrode comprises a solid electrolyte.

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