Porous current collector assembly and method for use in energy storage devices

Abstract

To provide improved electrodes, electrode assemblies, and energy storage devices that address weight, cost, and manufacturing challenges. [Solution] A porous current collector assembly for an energy storage device is provided, comprising a porous electrical insulating substrate including a first side and a second side, a first porous foil layer disposed on the first side of the porous electrical insulating substrate, and a second porous foil layer disposed on the second side of the porous electrical insulating substrate. The porous current collector assembly can enable simultaneous conduction of ions and electrons while maintaining selective electrical insulation of electrodes. Electrodes, electrode assemblies, and electrode assembly stacks, as well as configurations and methods of porous current collector assemblies in an energy storage device, are also described.

Description

[Technical Field]

[0001] [Cross-reference of related applications] This application claims priority to U.S. Patent Application No. 63 / 761,040, filed on 20 February 2025, entitled “POROUS CURRENT COLLECTOR ASSEMBLIES FOR USE IN ENERGY STORAGE DEVICES,” which is incorporated herein by reference in its entirety for all purposes. [Background technology]

[0002] In some energy storage device manufacturing processes, electrodes can be formed by placing electrode films on a current collector. Conventional energy storage devices typically require the electrodes to be separated by an electrically insulating substrate separator to prevent short circuits. However, this adds weight, cost, and manufacturing challenges. Therefore, improved electrodes, electrode assemblies, and energy storage devices are desirable. [Overview of the project] [Problems that the invention aims to solve]

[0003] For the purpose of summarizing the advantages achieved beyond the present invention and the prior art, specific objectives and advantages of the present invention are described herein. Not all such objectives or advantages can be achieved in any particular embodiment of the present invention. Therefore, for example, those skilled in the art will recognize that the present invention may be embodied or implemented to achieve or optimize one advantage or set of advantages taught herein, without necessarily achieving other objectives or advantages that may be taught or suggested herein. [Means for solving the problem]

[0004] In one embodiment, a porous current collector assembly for an energy storage device is described. The porous current collector assembly includes a porous electrical insulating substrate having a first side and a second side, a first porous foil layer disposed on the first side of the porous electrical insulating substrate, and a second porous foil layer disposed on the second side of the porous electrical insulating substrate.

[0005] In some embodiments, the first porous foil layer contains a different metal than the second porous foil layer. In some embodiments, the first porous foil layer and the second porous foil layer each independently contain a metal selected from the group consisting of Cu, Al, Ni, Li, Mn, Co, Fe, Cr and combinations thereof. In some embodiments, the first porous foil layer and the second porous foil layer each independently contain stainless steel.

[0006] In some embodiments, the first porous foil layer and the second porous foil layer each independently contain a foil layer porosity of about 5 to 75%. In some embodiments, the first porous foil layer and the second porous foil layer each independently contain a foil pore diameter of about 1 nm to about 1 cm. In some embodiments, the first porous foil layer and the second porous foil layer each independently contain a foil layer thickness of about 0.1 μm to about 10 μm.

[0007] In some embodiments, the porous electrical insulating substrate comprises a polymer selected from the group consisting of polyethylene, polypropylene, polystyrene, polyvinyl chloride, polytetrafluoroethylene, polyurethane, polyamide, polyimide, polyester, poly(vinylidene fluoride) aramid, polyether, copolymers thereof, and combinations thereof.

[0008] In some embodiments, the porous electrical insulating substrate has a substrate porosity of about 5% to about 75%. In some embodiments, the porous electrical insulating substrate has a substrate pore diameter of about 1 nm to about 1 cm. In some embodiments, the porous electrical insulating substrate has a substrate thickness of about 1 μm to about 30 μm. In some embodiments, the porous electrical insulating substrate has a substrate melting temperature of about 50°C to about 450°C.

[0009] In another embodiment, an electrode is described. The electrode comprises an electrode film and a porous current collector assembly, the electrode film being disposed on the porous current collector assembly.

[0010] In some embodiments, the electrode film is substantially free of solvent residue.

[0011] In another embodiment, an electrode assembly is described. The electrode assembly includes an electrode and a second electrode film, and a porous current collector assembly is positioned between the electrode film and the second electrode film.

[0012] In another embodiment, an electrode assembly stack is described. The electrode assembly stack includes an electrode assembly, a second electrode assembly, and a separator positioned between the electrode assembly and the second electrode assembly.

[0013] In some embodiments, the electrode film and the second electrode film have the same polarity.

[0014] In another embodiment, a dual electrode assembly stack is described. The dual electrode assembly stack includes an electrode assembly and a second electrode assembly, wherein one electrode film of the second electrode assembly is in contact with one electrode film of the electrode assembly or the second electrode film.

[0015] In some embodiments, the electrode film and the second electrode film have opposite polarities.

[0016] In another embodiment, an energy storage device is described. The energy storage device includes an electrode assembly, an electrolyte, and a housing, the electrode assembly and the electrolyte being located within the housing.

[0017] In another aspect, a method of forming a porous current collector assembly is described. The method comprises arranging a first porous foil layer on a first side of a porous electrically insulating substrate, and arranging a second porous foil layer on a second side of the porous electrically insulating substrate to form the porous current collector assembly.

[0018] In some embodiments, arranging the first porous foil layer comprises arranging the first porous foil layer on the first side of the porous electrically insulating substrate opposite to the second side thereof.

[0019] In another aspect, a method of forming an electrode is described. The method comprises forming a porous current collector assembly, calendering a dry electrode film mixture by a dry process to form an electrode film, and arranging the electrode film on the porous current collector assembly to form the electrode. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] [Figure 1] FIG. 1 is a schematic diagram illustrating a porous current collector assembly according to some embodiments.

[0021] [Figure 2] FIG. 2 is a schematic diagram illustrating an electrode assembly including a porous current collector assembly according to some embodiments.

[0022] [Figure 3] FIG. 3 is a schematic diagram illustrating a double electrode assembly stack according to some embodiments.

[0023] [Figure 4] FIG. 4 is a schematic diagram illustrating an electrode assembly stack including a separator according to some embodiments.

[0024] [Figure 5] FIG. 5 is a flowchart illustrating a method of forming a porous current collector assembly according to some embodiments.

[0025] However, it should be clearly understood that the examples and drawings are for illustrative purposes only and do not necessarily limit the scope of the present invention. [Modes for carrying out the invention]

[0026] While certain preferred embodiments and examples are disclosed below, the subject matter of the invention extends beyond the specifically disclosed embodiments to other alternative embodiments and / or uses, as well as their modifications and equivalents. Therefore, the appended claims are not limited by any of the specific embodiments described below. For example, in any method or process disclosed herein, the action or operation of the method or process may be performed in any suitable order, and is not necessarily limited to any specific disclosed order. Various operations may be described as multiple separate operations in a manner that may be helpful in understanding a particular embodiment. However, the order of description should not be construed to mean that these operations are order-dependent. Furthermore, the structures, systems, and / or devices described herein may be embodied as integrated components or as separate components. For the purpose of comparing various embodiments, specific aspects and advantages of these embodiments are described. Not all such aspects or advantages are necessarily achieved by a particular embodiment. Therefore, for example, various embodiments may be performed to achieve or optimize one advantage or set of advantages taught herein, without necessarily achieving other aspects or advantages that may be taught or suggested herein.

[0027] This paper describes porous current collector assemblies and their use in electrodes, electrode assemblies, and energy storage devices. A porous current collector assembly (or porous composite current collector assembly) includes a porous electrical insulating substrate and porous foil layers disposed on both sides of the porous electrical insulating substrate. Different configurations of porous current collector assemblies in electrodes, electrode assemblies, electrode assembly stacks, and energy storage devices can result in various improvements.

[0028] Conventional current collectors are typically non-porous, hindering ion conduction and limiting performance. Therefore, several configurations of porous current collector assemblies in electrodes, electrode assemblies, electrode assembly stacks, and energy storage devices disclosed herein offer improved design safety (e.g., increased safety against foil layer melting at localized hot spots), improved efficiency between electrodes (e.g., improved ion transport, expanded load tolerance), improved electrolyte motion (e.g., improved electrolyte wetting, filling, and retention over life), increased porosity for gas evacuation (e.g., mitigation of reliability risks such as trapped gas causing electrode film layer delamination or Li plating), and improved mechanical properties (e.g., porous electrical insulating substrates offer increased elongation at break, improved crack propagation resistance, and reduced risk of web breakage during the manufacturing process). Other configurations of porous current collector assemblies in electrodes, electrode assemblies, electrode assembly stacks, and energy storage devices disclosed herein demonstrate increased fast charging capability, enabling thicker electrodes (e.g., significantly reducing ion diffusion path length by approximately 50%). Further configurations (e.g., two sides of the porous current collector having different polarities) allow for the elimination of conventional separators within the electrode assembly stack, thereby increasing energy capacity (e.g., by approximately 5-10%) and reducing cost and complexity.

[0029] [Porous current collector assembly] A porous current collector assembly, including a porous electrical insulating substrate and a porous foil layer, may be manufactured or formed in various configurations. For example, Figure 1 is a schematic diagram of a porous current collector assembly 100. As shown in Figure 1, the porous current collector assembly 100 includes a porous electrical insulating substrate 110 having a first side surface 120 and a second side surface 130, a first porous foil layer 140, and a second porous foil layer 150. The first porous foil layer 140 and the second porous foil layer 150 are arranged along the length of the porous electrical insulating substrate 110 such that the first porous foil layer 140 is positioned on the first side surface 120 and the second porous foil layer 150 is positioned on the second side surface 130.

[0030] In some embodiments, the first porous foil layer is located on the first side of the porous electrical insulating substrate opposite to the second side. In some embodiments, the first porous foil layer is located on the second side of the porous electrical insulating substrate opposite to the first side. In some embodiments, the second porous foil layer is located on the first side of the porous electrical insulating substrate opposite to the second side. In some embodiments, the second porous foil layer is located on the second side of the porous electrical insulating substrate opposite to the first side.

[0031] In some embodiments, the porous electrical insulating substrate comprises a polymer selected from the group consisting of polyethylene, polypropylene, polystyrene, polyvinyl chloride, polytetrafluoroethylene, polyurethane, polyamide, polyimide, polyester, poly(vinylidene fluoride) aramid, polyether, copolymers thereof, and combinations thereof.

[0032] In some embodiments, the porous electrical insulating substrate is made up of 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, Substrate porosity of 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, and 90%, or substrate porosity in any range of values ​​between them, or including about, at, or at least about that substrate porosity. In some embodiments, a porous electrical insulating substrate includes a substrate porosity of about 5–75%.

[0033] In some embodiments, the porous electrical insulating substrate includes substrate thicknesses of 0.5 μm, 1 μm, 2 μm, 3 μm, 4 μm, 5 μm, 6 μm, 7 μm, 8 μm, 9 μm, 10 μm, 11 μm, 12 μm, 13 μm, 14 μm, 15 μm, 16 μm, 17 μm, 18 μm, 19 μm, 20 μm, 21 μm, 22 μm, 23 μm, 24 μm, 25 μm, 26 μm, 27 μm, 28 μm, 29 μm, 30 μm, 31 μm, 32 μm, 33 μm, 34 μm, 35 μm, 36 μm, 37 μm, 38 μm, 39 μm, and 40 μm, or substrate thicknesses in any range of values ​​between them, or approximately, at least, at least approximately, maximum, or maximum approximately that substrate thickness. In some embodiments, the porous electrical insulating substrate includes a substrate thickness of approximately 1 to 30 μm.

[0034] In some embodiments, the porous electrical insulating substrate is 0.5nm, 1nm, 5nm, 10nm, 50nm, 100nm, 150nm, 200nm, 250nm, 300nm, 350nm, 400nm, 450nm, 500nm, 550nm, 600nm, 650nm, 700nm, 750nm, 800nm, 850nm, 900nm, 950nm, 1μm, 5μm, 10μm, 50μm, 100μm, 150μm, 200μm, 250μm Substrate pore diameters of m, 300 μm, 350 μm, 400 μm, 450 μm, 500 μm, 550 μm, 600 μm, 650 μm, 700 μm, 750 μm, 800 μm, 850 μm, 900 μm, 950 μm, 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm and 1 cm, or substrate pore diameters in any range of values ​​between them, or including about, at, at least, at least about, maximum, or maximum about that substrate pore diameter. In some embodiments, the porous electrical insulating substrate includes substrate pore diameters of about 1 nm to 1 cm.

[0035] In some embodiments, the porous electrical insulating substrate is used at 50°C, 55°C, 60°C, 65°C, 70°C, 75°C, 80°C, 85°C, 90°C, 95°C, 100°C, 105°C, 110°C, 115°C, 120°C, 125°C, 130°C, 135°C, 140°C, 145°C, 150°C, 155°C, 160°C, 165°C, 170°C, 175°C, 180°C, 185°C, 190°C, 195°C, 200°C, 205°C, 210°C, 215°C, 220°C, 225°C, 230°C, 235°C, 240°C, 245°C, 250°C, 255°C, 260°C, 265°C, 270°C, 275°C, and 28°C. Substrate melting temperatures of 0°C, 285°C, 290°C, 295°C, 300°C, 305°C, 310°C, 315°C, 320°C, 325°C, 330°C, 335°C, 340°C, 345°C, 350°C, 355°C, 360°C, 365°C, 370°C, 375°C, 380°C, 385°C, 390°C, 395°C, 400°C, 405°C, 410°C, 415°C, 420°C, 425°C, and 430°C, 435°C, 440°C, 445°C, and 450°C, or a range of any values ​​between them, or including approximately, at least, at least about, maximum, or maximum about that temperature.

[0036] In some embodiments, the first porous foil layer comprises a different material from the second porous foil layer. In some embodiments, the first and second porous foil layers comprise the same material. In some embodiments, the material of the first and / or second porous foil layers comprises a metal. In some embodiments, the porous foil layer comprises a metal selected from the group consisting of copper (Cu), aluminum (Al), nickel (Ni), lithium (Li), manganese (Mn), cobalt (Co), iron (Fe), chromium (Cr), and combinations thereof. In some embodiments, the first and second porous foil layers each independently comprise a metal selected from the group consisting of Cu, Al, Ni, Li, Mn, Co, Fe, Cr, and combinations thereof. In some embodiments, the porous foil layer comprises stainless steel. In some embodiments, the stainless steel may comprise elements such as iron, chromium, molybdenum, carbon, nickel, nitrogen, manganese, silicon, titanium, vanadium, copper, and combinations thereof. In some embodiments, the porous foil layer comprises a cathode active material.

[0037] In some embodiments, the porous foil layer is made up of 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52% The foil layer porosity includes 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, and 90%, or a range of values ​​between them, or approximately, at least, or at least approximately that foil layer porosity. In some embodiments, the porous foil layer includes a foil layer porosity of approximately 5–75%.

[0038] In some embodiments, the porous foil layer is 0.1μm, 0.2μm, 0.3μm, 0.4μm, 0.5μm, 0.6μm, 0.7μm, 0.8μm, 0.9μm, 1μm, 1.1μm, 1.2μm, 1.3μm, 1.4μm, 1.5μm, 1.6μm, 1.7μm, 1.8μm, 1.9μm, 2μm, 2.1μm, 2.2μm, 2.3μm, 2.4μm, 2.5μm, 2 .6μm, 2.7μm, 2.8μm, 2.9μm, 3μm, 3.1μm, 3.2μm, 3.3μm, 3.4μm, 3.5μm, 3.6μm, 3.7μm, 3.8μm, 3.9μm, 4μ m, 4.1μm, 4.2μm, 4.3μm, 4.4μm, 4.5μm, 4.6μm, 4.7μm, 4.8μm, 4.9μm, 5μm, 5.1μm, 5.2μm, 5.3μm, 5.4μm , 5.5μm, 5.6μm, 5.7μm, 5.8μm, 5.9μm, 6μm, 6.1μm, 6.2μm, 6.3μm, 6.4μm, 6.5μm, 6.6μm, 6.7μm, 6.8μm, 6.9μm, 7μm, 7.1μm, 7.2μm, 7.3μm, 7.4μm, 7.5μm, 7.6μm, 7.7μm, 7.8μm, 7.9μm, 8μm, 8.1μm, 8.2μm, 8.3 The foil layer thicknesses include μm, 8.4μm, 8.5μm, 8.6μm, 8.7μm, 8.8μm, 8.9μm, 9μm, 9.1μm, 9.2μm, 9.3μm, 9.4μm, 9.5μm, 9.6μm, 9.7μm, 9.8μm, 9.9μm, 10μm, or any range of values ​​between them, or include about, at, at least, at least about, maximum, or maximum about that foil layer thickness. In some embodiments, the porous foil layer includes a foil layer thickness of about 0.1 to 10μm.

[0039] In the first embodiment, the porous foil layer is 0.5nm, 1nm, 5nm, 10nm, 50nm, 100nm, 150nm, 200nm, 250nm, 300nm, 350nm, 400nm, 450nm, 500nm, 550nm, 600nm, 650nm, 700nm, 750nm, 800nm, 850nm, 900nm, 950nm, 1μm, 5μm, 10μm, 50μm, 100μm, 150μm, 200μm, 250μm , 300μm, 350μm, 400μm, 450μm, 500μm, 550μm, 600μm, 650μm, 700μm, 750μm, 800μm, 850μm, 900μm, 950μm, 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm and 1cm foil pore diameters, or foil pore diameters in any range of values ​​between them, or including about, at, at least, at least about, maximum, or maximum about that foil pore diameter. In some embodiments, the porous foil layer includes foil pore diameters of about 1nm to 1cm.

[0040] In some embodiments, the porous foil layer is deposited by a chemical deposition process. In some embodiments, the chemical deposition process is selected from the group consisting of chemical vapor deposition, chemical bath deposition, electroplating, and combinations thereof. In some embodiments, the porous foil layer is deposited by a physical deposition process. In some embodiments, the physical deposition process is selected from the group consisting of physical vapor deposition, electron beam physical vapor deposition, arc deposition, pulsed laser deposition, sputtering, evaporation deposition, and combinations thereof.

[0041] [Electrode assembly with porous current collector assembly] The electrodes may include electrode films disposed on a porous current collector assembly. An electrode assembly, including electrode films (e.g., a cathode electrode film, an anode electrode film) and a porous current collector assembly disposed between the electrode films, can be manufactured or formed in various configurations. For example, Figure 2 is a schematic diagram of an electrode assembly 200. As shown in Figure 2, the electrode assembly 200 includes a first electrode film 210, a second electrode film 220, a porous electrical insulating substrate 230 having a first side surface 235 and a second side surface 237, a first porous foil layer 240 having a first opposing surface 245, and a second porous foil layer 250 having a second opposing surface 255. The first porous foil layer 240 and the second porous foil layer 250 are arranged along the length of the porous electrical insulating substrate 230 such that the first porous foil layer 240 is positioned on the first side surface 235 and the second porous foil layer 250 is positioned on the second side surface 237. The first electrode film 210 is positioned along the length of the first porous foil layer 240 such that the first electrode film 210 is positioned on the first opposing surface 245. The second electrode film 220 is positioned along the length of the second porous foil layer 250 such that the second electrode film 220 is positioned on the second opposing surface 255.

[0042] In some embodiments, the first and second electrode films are cathode electrode films. In some embodiments, the first and second electrode films are anode electrode films. In some embodiments, the first electrode film is a cathode electrode film and the second electrode film is an anode electrode film. In some embodiments, the first electrode film is an anode electrode film and the second electrode film is a cathode electrode film. In some embodiments, the energy storage device includes an electrode assembly.

[0043] In some embodiments, multiple electrode assemblies may be stacked on top of each other to form an electrode assembly stack. In some embodiments, since the porous current collector assembly is both porous and conductive, the porous current collector assembly enables various electrode assembly stack configurations that may or may not include a typical separator placed between the anode and cathode. A double electrode assembly stack, including an electrode assembly placed on a second electrode assembly, can be manufactured or formed in various configurations. For example, Figure 3 is a schematic diagram of a double electrode assembly stack 300. As shown in Figure 3, the double electrode assembly stack 300 includes an electrode assembly 301 and a second electrode assembly 351.

[0044] The electrode assembly 301 includes a first anode electrode film 305, a first porous electrical insulating substrate 310 having a first side surface 312 and a second side surface 314, a first porous foil layer 315 having a first anode-facing surface 317, and a second porous foil layer 320 having a first cathode-facing surface 322. The first porous foil layer 315 and the second porous foil layer 320 are arranged along the length of the first porous electrical insulating substrate 310 such that the first porous foil layer 315 is positioned on the first side surface 312 and the second porous foil layer 320 is positioned on the second side surface 314. The first anode electrode film 305 is arranged along the length of the first porous foil layer 315 such that the first anode electrode film 305 is positioned on the first anode-facing surface 317. The first cathode electrode film 330 is positioned along the length of the second porous foil layer 320 such that the first cathode electrode film 330 is positioned on the first cathode-facing surface 322.

[0045] The second electrode assembly 351 includes a second cathode electrode film 355, a second porous electrical insulating substrate 360 ​​having a third side surface 362 and a fourth side surface 364, a third porous foil layer 365 having a second cathode-facing surface 367, a fourth porous foil layer 370 having a second anode-facing surface 372, and a second anode electrode film 380. The third porous foil layer 365 and the fourth porous foil layer 370 are arranged along the length of the second porous electrical insulating substrate 360 ​​such that the third porous foil layer 365 is positioned on the third side surface 362 and the fourth porous foil layer 370 is positioned on the fourth side surface 364. The second cathode electrode film 355 is arranged along the length of the third porous foil layer 365 such that the second cathode electrode film 355 is positioned on the second cathode-facing surface 367. The second anode electrode film 380 is positioned along the length of the fourth porous foil layer 370 such that the second anode electrode film 380 is positioned on the second anode-facing surface 372. The second cathode electrode film 355 of the second electrode assembly 351 is in contact with the first cathode electrode film 330 of the electrode assembly 301.

[0046] In some embodiments, the first and second anode electrode films are positioned in the locations where the first and second cathode electrode films are positioned within the double electrode assembly stack, such that the first and second cathode electrode films are positioned in the locations where the first and second anode electrode films are positioned.

[0047] In some embodiments, any electrode film may be a multilayer electrode film (e.g., two or more electrode films arranged in stacks). In some embodiments, the electrode films of an electrode assembly have the same polarity. In some embodiments, the electrode films of a second electrode assembly have the same polarity. In some embodiments, the electrode films of a second electrode assembly have opposite polarity.

[0048] An electrode assembly stack including a separator positioned between an electrode assembly and a second electrode assembly can be manufactured or formed in various configurations. For example, Figure 4 is a schematic diagram of an electrode assembly stack having a separator 400. As shown in Figure 4, the electrode assembly stack having a separator 400 includes an electrode assembly 401 and a second electrode assembly 451. The separator 450, having a first separator side 455 and a second separator side 457, is positioned between the electrode assembly 401 and the second electrode assembly 451 such that the electrode assembly 401 is positioned along the length of the first separator side 455 and the second electrode assembly 451 is positioned along the length of the second separator side 457.

[0049] The electrode assembly 401 includes a first cathode electrode film 405, a first porous electrical insulating substrate 410 having a first side surface 412 and a second side surface 414, a first porous foil layer 420 having a first cathode-facing surface 430, and a second porous foil layer 425 having a second cathode-facing surface 435. The first porous foil layer 420 and the second porous foil layer 425 are arranged along the length of the first porous electrical insulating substrate 410 such that the first porous foil layer 420 is positioned on the first side surface 412 and the second porous foil layer 425 is positioned on the second side surface 414. The first cathode electrode film 405 is arranged along the length of the first porous foil layer 420 such that the first cathode electrode film 405 is positioned on the first cathode-facing surface 430. The second cathode electrode film 445 is positioned along the length of the second porous foil layer 425 such that the second cathode electrode film 445 is positioned on the second cathode-facing surface 435.

[0050] The second electrode assembly 451 includes a first anode electrode film 460, a second porous electrical insulating substrate 470 having a third side surface 472 and a fourth side surface 474, a third porous foil layer 480 having a first anode-facing surface 490, a fourth porous foil layer 485 having a second anode-facing surface 495, and a second anode electrode film 407. The third porous foil layer 480 and the fourth porous foil layer 485 are arranged along the length of the second porous electrical insulating substrate 470 such that the third porous foil layer 480 is positioned on the third side surface 472 and the fourth porous foil layer 485 is positioned on the fourth side surface 474. The first anode electrode film 460 is arranged along the length of the third porous foil layer 480 such that the first anode electrode film 460 is positioned on the first anode-facing surface 490. The second anode electrode film 407 is positioned along the length of the fourth porous foil layer 485 such that the second anode electrode film 407 is positioned on the second anode-facing surface 495.

[0051] In some embodiments, the first porous foil layer comprises a different material from the second porous foil layer. In some embodiments, the first and second porous foil layers comprise the same material. In some embodiments, the third porous foil layer comprises a different material from the fourth porous foil layer. In some embodiments, the third and fourth porous foil layers comprise the same material.

[0052] In some embodiments, a first porous foil layer is placed between a first cathode electrode film and a first porous electrical insulating substrate. In some embodiments, a second porous foil layer is placed between a second cathode electrode film and a first porous electrical insulating substrate. In some embodiments, a first porous foil layer is placed between a second cathode electrode film and a first porous electrical insulating substrate. In some embodiments, a second porous foil layer is placed between a first cathode electrode film and a first porous electrical insulating substrate.

[0053] In some embodiments, a third porous foil layer is placed between the first anode electrode film and the second porous electrical insulating substrate. In some embodiments, a third porous foil layer is placed between the second anode electrode film and the second porous electrical insulating substrate. In some embodiments, a fourth porous foil layer is placed between the first anode electrode film and the second porous electrical insulating substrate. In some embodiments, a fourth porous foil layer is placed between the second anode electrode film and the second porous electrical insulating substrate.

[0054] In some embodiments, the electrode films of the electrode assembly have opposite polarity. In some embodiments, the electrode films of the electrode assembly have the same polarity. In some embodiments, the electrode films of the second electrode assembly have the same polarity. In some embodiments, the electrode films of the second electrode assembly have opposite polarity.

[0055] [Method for forming a porous current collector assembly] Figure 5 is a flowchart of a method 500 for forming a porous current collector assembly. As shown in Figure 5, in step 510, a first porous foil layer is placed on a first side surface of a porous electrical insulating substrate. In step 520, a second porous foil layer is placed on a second side surface of the porous electrical insulating substrate to form a porous current collector assembly.

[0056] In some embodiments, the placement of a first porous foil layer on a first side surface of a porous electrical insulating substrate is performed before, after, or simultaneously with the placement of a second porous foil layer on a second side surface of the porous electrical insulating substrate.

[0057] In some embodiments, the first and second porous foil layers are positioned on opposing surfaces of the porous electrical insulating substrate such that the first side faces the second side. In some embodiments, this method may further include positioning an additional porous foil layer on the first and / or second porous foil layer. In some embodiments, positioning one of the porous foil layers includes at least partially covering the sides of the porous electrical insulating substrate. In some embodiments, positioning one of the porous foil layers includes completely covering the sides of the porous electrical insulating substrate.

[0058] A method for forming a porous current collector assembly may be used to form an electrode. The method for forming an electrode includes forming a porous current collector assembly by arranging a first porous foil layer on a first side surface of a porous electrical insulating substrate and a second porous foil layer on a second side surface of the porous electrical insulating substrate; forming an electrode film by calendering a dry electrode film mixture in a dry process; and forming an electrode by arranging the electrode film on the porous current collector assembly.

[0059] Electrode assemblies, electrode assembly stacks, dual electrode assembly stacks, and / or energy storage devices may be formed using processes disclosed herein. In some embodiments, any one or more components may be arranged in various orders and configurations.

[0060] A method for forming an electrode assembly includes arranging an electrode film on a first side surface of a porous current collector assembly and arranging a second electrode film on a second side surface of the porous current collector assembly to form an electrode assembly.

[0061] A method for forming a double electrode assembly stack includes arranging a first anode electrode film on a first side surface of a first porous current collector assembly, arranging a first cathode electrode film on a second side surface of the first porous current collector assembly, arranging a first cathode electrode film on a first side surface of a second cathode electrode film, arranging a second cathode electrode film on a first side surface of a second porous current collector assembly opposite to the first side surface of the second cathode electrode film, and arranging a second anode electrode film on a second side surface of the second porous current collector assembly to form a double electrode assembly stack.

[0062] A method for forming an electrode assembly stack using a separator includes arranging an electrode assembly on a first side surface of a separator and arranging a second electrode assembly on a second side surface of a separator to form an electrode assembly stack.

[0063] [Electrode film materials and electrode films] This specification describes electrode film mixtures and electrode films formed using materials (e.g., cathode active material, anode active material). In some embodiments, the components of the active layer or electrode film may include particles such as composite materials. The particles for forming the active layer or electrode film may be combined with materials for providing the electrode film mixture. In some embodiments, the active layer or electrode film may be formed from the electrode film mixture such that the weight percentage of the components of the active layer or electrode film is substantially the same as the weight percentage of the components of the electrode film mixture.

[0064] The active material (e.g., cathode active material, anode active material) may be used to fabricate electrode films and / or electrodes for energy storage devices.

[0065] In some embodiments, the active material is a cathode active material. In some embodiments, the cathode active material is selected from at least one of metal oxides, metal sulfides, sulfur-carbon composites, lithium metal oxides, and sulfur-containing materials. In some embodiments, the cathode active material is lithium iron phosphate (i.e., LiFePO₄ or "LFP"), lithium manganese iron phosphate (e.g., LiMn 0.6 Fe 0.4 PO₄ or "LMFP"), lithium nickel manganese cobalt oxide (i.e., LiNi x Mn y Co 1-x-y O₂ or "NMC"), lithium nickel cobalt aluminum oxide (i.e., LiNi x Co y Al z O₂ or "NCA"), lithium manganese oxide ("LMO"), lithium nickel manganese oxide ("LNMO"), lithium cobalt oxide ("LCO"), lithium titanate ("LTO"), or a combination thereof. In some embodiments, the cathode active material comprises at least two of LFP, LMFP, NMC, NCA, LMO, LNMO, LCO, LTO, and combinations thereof. In some embodiments, the cathode active material is an iron phosphate-based active material. In some embodiments, the iron phosphate-based active material includes LiFePO₄ (i.e., "lithium iron phosphate" and "LFP") and LiMn 1-x Fe x PO₄ (i.e., "lithium manganese iron phosphate" and "LMFP") (e.g., LiMn 0.6 Fe 0.4 PO₄ or LiMn 0.8 Fe 0.2 PO₄). In some embodiments, the iron phosphate-based active material comprises LFP. In some embodiments, the iron phosphate-based active material comprises LMFP. In some embodiments, the iron phosphate-based active material comprises LFP and / or LMFP. In some embodiments, the cathode active material is polycrystalline, single crystalline, or a combination thereof.

[0066] In some embodiments, the active material is an anode active material. In some embodiments, the anode active material may be, for example, an insert material (such as carbon, lithium titanate ("LTO"), graphite, and / or graphene), an alloying / dealloying material (e.g., silicon, silicon oxide, tin, and / or tin oxide), a metallic alloy or compound (e.g., Si-Al and / or Si-Sn), and / or a conversion material (e.g., manganese oxide, molybdenum oxide, nickel oxide, and / or copper oxide). The anode active material may be used alone or mixed together to form a multiphase material (e.g., Si-C, Sn-C, SiOx-C, SnOx-C, Si-Sn, Si-SiOx, Sn-SnOx, Si-SiOx-C, Sn-SnOx-C, Si-Sn-C, SiOx-SnOx-C, Si-SiOx-Sn, or Sn-SiOx-SnOx). Anode active materials include common natural graphite, synthetic or artificial graphite, surface-modified graphite, spherical graphite, flake graphite, as well as blends or combinations of these types of graphite, metallic elements and their compounds, and metal-C composites for anodes.

[0067] In some embodiments, the electrode film mixture and / or electrode film contains an amount of active material of 70% by weight, 75% by weight, 80% by weight, 85% by weight, 86% by weight, 87% by weight, 88% by weight, 89% by weight, 90% by weight, 91% by weight, 92% by weight, 93% by weight, 94% by weight, 95% by weight, 96% by weight, 97% by weight, 98% by weight, 98.5% by weight, 99% by weight, 99.5% by weight, 99.8% by weight or 99.9% by weight, or an amount of active material in any range of values ​​between those, or about, at, or at least about that amount.

[0068] In some embodiments, the electrode film mixture and / or electrode film comprises a carbon material configured to reversibly intercalate lithium ions. In some embodiments, the lithium intercalate carbon is selected from graphitic carbon, graphite, hard carbon, soft carbon, and combinations thereof. For example, the electrode film of an electrode may include a binder material, one or more graphitic carbons, graphite, graphene-containing carbon, hard carbon, and soft carbon, as well as a conductivity-enhancing material. In some embodiments, the electrode is mixed with lithium metal and / or lithium ions. In some embodiments, the electrode comprises a total amount of carbon material of 20% by weight, 15% by weight, 10% by weight, 9% by weight, 8% by weight, 7% by weight, 6% by weight, 5% by weight, 4% by weight, 3% by weight, 2% by weight, 1% by weight, or a total amount of carbon material in any range of values ​​between these, or about, maximum, or maximum about that total amount.

[0069] In some embodiments, the electrode film mixture and / or electrode film includes a conductive additive. In some embodiments, the conductive additive may include a conductive carbon additive such as carbon black. In some embodiments, the conductive additive may include a conductive carbon additive. In some embodiments, the conductive carbon additive includes carbon black, carbon nanotubes. In some embodiments, the conductive additive is selected from conductive carbon, carbon nanotubes, and combinations thereof. In some embodiments, the conductive carbon additive includes carbon black, carbon nanotubes, e.g., single-walled carbon nanotubes (SWCNTs), few-walled carbon nanotubes (FWCNTs), and multi-walled carbon nanotubes (MWCNTs). In some embodiments, the electrode film mixture and / or electrode film contains a total amount of conductive additive in the range of 10% by weight, 9% by weight, 8% by weight, 7% by weight, 6% by weight, 5% by weight, 4% by weight, 3% by weight, 2% by weight, 1% by weight, 0.5% by weight, 0.25% by weight, 0.1% by weight, or any range of values ​​between them, or about, maximum, or maximum about that total amount. In some embodiments, each of the conductive additive is in the amount of 10% by weight, 9% by weight, 8% by weight, 7% by weight, 6% by weight, 5% by weight, 4% by weight, 3% by weight, 2% by weight, 1% by weight, 0.5% by weight, 0.25% by weight, 0.1% by weight of the electrode film, or any range of values ​​between them, or about, maximum, or maximum about that amount. In some embodiments, the conductive additive is carbon black.

[0070] In some embodiments, the electrode film mixture and / or electrode film comprises a binder or binder material. In some embodiments, the binder may include polytetrafluoroethylene (PTFE), polyolefins, polyalkylenes, polyethers, styrene-butadiene, polysiloxane copolymers and polysiloxanes, branched polyethers, polyvinyl ethers, carboxymethylcellulose (CMC), copolymers thereof, and / or combinations thereof. In some embodiments, the polyolefin may include polyethylene (PE), polypropylene (PP), polyvinylidene fluoride (PVDF), copolymers thereof, and / or combinations thereof. For example, the binder may include polyvinyl chloride, poly(phenylene oxide) (PPO), polyethylene-block-poly(ethylene glycol), poly(ethylene oxide) (PEO), poly(phenylene oxide) (PPO), polyethylene-block-poly(ethylene glycol), polydimethylsiloxane (PDMS), polydimethylsiloxane-coalkylmethylsiloxane, polyalkylene, polyether, styrene-butadiene, styrene-butadiene rubber (SBR), copolymers of polysiloxanes and polysiloxanes, branched polyethers, polyvinyl ethers, copolymers thereof, and / or combinations thereof. In some embodiments, the binder may include thermoplastic materials. In some embodiments, the binder includes fibrillable and / or fibrillated polymers. In certain embodiments, the binder includes, essentially consists of, or comprises a single fibrillable and / or fibrillated binder such as PTFE. In some embodiments, the electrode film mixture and / or electrode film contains 0.2% by weight, 0.4% by weight, 0.6% by weight, 0.8% by weight, 1% by weight, 2% by weight, 3% by weight, 4% by weight, 5% by weight, 6% by weight, 7% by weight, 8% by weight, 9% by weight, 10% by weight of a binder, or a binder in any range of values ​​between those, or about, maximum, or maximum about that binder.

[0071] In some embodiments, the electrode film may be a wet-processed electrode film. In some embodiments, the electrode film is manufactured by a wet or slurry-based electrode manufacturing process. In some embodiments, the electrode film of this disclosure may be a dry-processed electrode film. In some embodiments, the electrode film is manufactured by a dry electrode manufacturing process. As used herein, a dry electrode manufacturing process may refer to a process for forming a dry electrode film without using or substantially without using a solvent. For example, the components of an active layer or electrode film, comprising a carbon material and a binder, may include, consist of, or essentially consist of dry particles. Dry particles for forming an active layer or electrode film may be combined to provide a dry particle active layer mixture. In some embodiments, the active layer or electrode film may be formed from a dry particle active layer mixture such that the weight percentage of the components of the active layer or electrode film is substantially the same as the weight percentage of the components of the dry particle active layer mixture. In some embodiments, the active layer or electrode film formed from a dry particle active layer mixture using a dry manufacturing process may be free of or substantially free of any processing additives, such as solvents and the resulting solvent residues. In some embodiments, the electrode film is substantially free of or free of solvent residues. In some embodiments, the resulting active layer or electrode film is a self-supporting film formed using a dry process from a dry particle mixture. In some embodiments, the resulting active layer or electrode film is a self-supporting film formed using a dry process from a dry particle mixture. The process for forming the active layer or electrode film may include fibrillating fibrillable binder components so that the film contains a fibrillating binder. In further embodiments, the self-supporting active layer or electrode film may be formed in the absence of a current collector. In further embodiments, the active layer or electrode film may include a fibrillated polymer matrix so that the film is self-supporting. It is conceivable that a matrix, lattice, or web of fibrils can be formed to provide mechanical structure to the electrode film.

[0072] In some embodiments, a binder is combined with an active material and calendered to form an electrode film. In some embodiments, a binder is combined with an active material and calendered without the use of a solvent to form a dry electrode film. In some embodiments, forming an electrode film involves calendering, pressing, and / or laminating the electrode film mixture.

[0073] In some embodiments, an electrode film is placed on a current collector to form an electrode. In some embodiments, the current collector may include a metallic material such as aluminum, nickel, copper, or a combination thereof. In some embodiments, the current collector is made of pure metal. In some embodiments, the current collector includes a metallized polymer film or a metal-coated polymer film. In some embodiments, the polymer includes polyethylene terephthalate (PET), biaxially oriented polypropylene (BOPP), or a combination thereof. In some embodiments, the metal coating includes aluminum. In some embodiments, coating the final electrode film mixture includes forming a uniform electrode film mixture coating. In some embodiments, the current collector may include thicknesses of 200 μm, 100 μm, 50 μm, 40 μm, 30 μm, 20 μm, 15 μm, 10 μm, 5 μm, or any range of values ​​between them, or approximately, maximum, or maximum approximately that thickness.

[0074] [Energy storage devices] Energy storage devices comprising porous current collector assemblies disclosed herein are described. The energy storage device comprises a positive electrode (i.e., a cathode), a negative electrode (i.e., an anode), a porous current collector assembly, and an electrolyte disposed within a housing. In some embodiments, the energy storage device includes a separator disposed between the anode and the cathode. Each electrode includes an electrode film disposed on a current collector or porous current collector assembly. In some embodiments, the electrode includes an electrode film disposed on a porous current collector assembly. In some embodiments, the electrode includes an electrode film disposed on a current collector. In some embodiments, the current collector is foil. In some embodiments, the current collector is aluminum foil, copper foil, or a combination thereof. In some embodiments, the current collector may include metallic materials such as materials containing aluminum, nickel, copper, or combinations thereof. In some embodiments, the current collector consists of pure metal. In some embodiments, the current collector includes a metallized polymer film or a metal-coated polymer film. In some embodiments, the polymer includes polyethylene terephthalate (PET), biaxially oriented polypropylene (BOPP), or a combination thereof. In some embodiments, the metal coating includes aluminum. In some embodiments, coating the final electrode film mixture involves forming a uniform electrode film mixture coating. In some embodiments, the current collector has a thickness of 200 μm, 100 μm, 50 μm, 40 μm, 30 μm, 20 μm, 15 μm, 10 μm, 5 μm, or any range of values ​​between them, or approximately, maximum, or up to approximately that thickness. In some embodiments, the active layer is disposed on both sides of the current collector or porous current collector assembly.

[0075] In some embodiments, the electrode is a double-sided electrode. In some embodiments, the double-sided electrode includes two electrode films. In some embodiments, the double-sided electrode may include a current collector or porous current collector assembly, an upper electrode film, and a lower electrode film. In some embodiments, each of the two electrode films may have any suitable shape, size, and thickness.

[0076] In some embodiments, the energy storage device includes a porous current collector assembly, an anode electrode, a cathode electrode, an electrolyte, and a housing, wherein the electrolyte, the porous current collector assembly, the anode electrode, and the cathode electrode are arranged within the housing. In some embodiments, the energy storage device includes a separator positioned between the anode electrode and the cathode electrode. In some embodiments, the energy storage device is formed by arranging the electrolyte, the porous current collector assembly, the anode electrode, and the cathode electrode described herein within the housing.

[0077] The electrode assembly includes a cathode, an anode, and a porous current collector assembly. In some embodiments, the electrode assembly includes a separator positioned between the anode and the cathode. In some embodiments, the electrode assembly is a wound electrode (i.e., rolled electrode) assembly (e.g., a jelly roll). In some embodiments, the energy storage device is selected from the group consisting of cylindrical energy storage devices, laminated prism-type energy storage devices, and helically wound prism-type energy storage devices.

[0078] The electrodes disclosed herein may be used in energy storage devices. In some embodiments, the energy storage device comprises a porous current collector assembly, an anode electrode, a cathode electrode, an electrolyte, and a housing, wherein the electrolyte, the porous current collector assembly, the anode electrode, and the cathode electrode are arranged within the housing. In some embodiments, the energy storage device is formed by arranging the electrolyte, the porous current collector assembly, the anode electrode, and the cathode electrode described herein within the housing. In some embodiments, the energy storage device includes a separator positioned between the anode electrode and the cathode electrode. In some embodiments, the energy storage device includes an anode electrode positioned between two cathode electrodes. In some embodiments, the anode electrode and / or cathode electrode includes a molded electrode film. In some embodiments, the energy storage device is a lithium-ion battery. In some embodiments, the energy storage device may be a battery, a capacitor, a capacitor-battery hybrid, a fuel cell, or a combination thereof. In some embodiments, the energy storage system or energy storage device may be used in electromobility. In some embodiments, the energy storage device may be used in vehicles including hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), and / or electric vehicles (EVs). In some embodiments, the energy storage device used in vehicles including hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), and / or electric vehicles (EVs) reduces greenhouse gas emissions.

[0079] In some embodiments, the energy storage device is charged with a suitable electrolyte (e.g., a lithium-containing electrolyte). For example, the energy storage device may contain a lithium salt and a solvent such as a non-aqueous solvent or an organic solvent. Generally, the lithium salt contains a redox-stable anion. In some embodiments, the anion may be monovalent. In some embodiments, the lithium salt is lithium hexafluorophosphate (LiPF6), lithium bis(trifluoromethanesulfonyl)imide (LiTFSI), lithium tetrafluoroborate (LiBF4), lithium perchlorate (LiClO4), lithium bis(trifluoromethanesulfonyl)imide (LiN(SO2CF3)2), lithium trifluoromethanesulfonate (LiSO3CF3), lithium bis(oxalato)borate (LiB(C2O4)2), lithium bis(fluorosulfonyl)imide (LiN(SO2F)2 ("LiFSI")), lithium difluoro(oxalato)borate (LiC2BF2O4), lithium difluorophosphate (LiDFP), lithium bis(oxalato)borate (LiBOB), lithium The electrolyte is selected from difluoro(bisoxalate) phosphates (LiDFOP) and combinations thereof. In some embodiments, the electrolyte may include a quaternary ammonium cation and an anion selected from the group consisting of hexafluorophosphate, tetrafluoroborate, and iodide. In some embodiments, the salt concentration may be about 0.1 mol / L (M) to about 5 M, about 0.2 M to about 3 M, or about 0.3 M to about 2 M. In further embodiments, the salt concentration of the electrolyte may be about 0.7 M to about 2 M. In certain embodiments, the salt concentration of the electrolyte may be about 0.2 M, about 0.3 M, about 0.4 M, about 0.5 M, about 0.6 M, about 0.7 M, about 0.8 M, about 0.9 M, about 1 M, about 1.1 M, about 1.2 M, 1.3 M, 1.4 M, 1.5 M, or values ​​in between.In some embodiments, the salt is used as an additive in the electrolyte system in amounts of 0.1% by weight, 0.2% by weight, 0.3% by weight, 0.4% by weight, 0.5% by weight, 0.6% by weight, 0.7% by weight, 0.8% by weight, 0.9% by weight, 1% by weight, 1.1% by weight, 1.2% by weight, 1.3% by weight, 1.4% by weight, 1.5% by weight, 1.6% by weight, 1.7% by weight, 1.8% by weight, 1.9% by weight, 2% by weight, 2.1% by weight, and 2.2% by weight. It can be used in individual or total concentrations of wt%, 2.3 wt%, 2.4 wt%, 2.5 wt%, 2.6 wt%, 2.7 wt%, 2.8 wt%, 2.9 wt%, 3 wt%, 4 wt%, 5 wt%, 6 wt%, 7 wt%, 8 wt%, 9 wt%, or 10 wt%, or in any range of values ​​between them, or in terms of approximately, maximum, or maximum approximately that individual or total concentration.

[0080] In some embodiments, the energy storage device may include a liquid solvent. The solvent does not need to dissolve all components of the electrolyte, nor does it need to completely dissolve any component. In further embodiments, the solvent may be an organic solvent. In some embodiments, the solvent or liquid cosolvent may include one or more functional groups selected from dioxathiolanes (e.g., 1,3,2-dioxathiolane-2,2-dioxide (i.e., "DTD")), carbonates, ethers, and / or esters. In some embodiments, the solvent may include a carbonate. In further embodiments, the carbonate can be selected from cyclic carbonates, such as ethylene carbonate (EC), propylene carbonate (PC), vinylethylene carbonate (VEC), vinylene carbonate (VC), fluoroethylene carbonate (FEC), and combinations thereof, or from acyclic carbonates, such as dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC), 1,3-propensultone (PRS), and combinations thereof. In some embodiments, the solvent can be an ester. In some embodiments, the ester can be selected from methyl acetate (MA), methyl propionate (MP), ethyl acetate (EA), methyl butyrate (MB), and combinations thereof. In some embodiments, the liquid cosolvent can be an acetate. In some embodiments, the acetate can be selected from methyl acetate (MA), ethyl acetate (EA), and combinations thereof. In some embodiments, the solvent can be a nitrile (e.g., acetonitrile ("AN")). In some embodiments, the solvent may include EC, PC, VEC, VC, FEC, DMC, DEC, EMC, MA, MP, EA, MB, DTD, PRS, acetonitrile, and combinations thereof. In some embodiments, the solvent may include EC, DMC, DEC, EMC, MA, and combinations thereof. In some embodiments, the solvent may include EC:DMC:EMC ratios of 10-30:0-90:0-70.

[0081] In some embodiments, one or more solvents can be used at concentrations of 15% by weight, 20% by weight, 30% by weight, 35% by weight, 40% by weight, 45% by weight, 50% by weight, 55% by weight, 60% by weight, 65% by weight, 70% by weight, 75% by weight, 80% by weight, 85% by weight, or 90% by weight, or one or more solvents at concentrations in any range between those values, or one or more solvents at about, at least, or at least about those concentrations. In some embodiments, the solvent is used as an additive in the electrolyte system and can be used at concentrations of 0.1% by weight, 0.2% by weight, 0.3% by weight, 0.4% by weight, 0.5% by weight, 0.6% by weight, 0.7% by weight, 0.8% by weight, 0.9% by weight, 1% by weight, 1.1% by weight, 1.2% by weight, 1.3% by weight, 1.4% by weight, 1.5% by weight, 1.6% by weight, 1.7% by weight, 1.8% by weight, 1.9% by weight, 2% by weight, 2.1% by weight, 2.2% by weight, 2.3% by weight, 2.4% by weight, 2.5% by weight, 2.6% by weight, 2.7% by weight, 2.8% by weight, 2.9% by weight, 3% by weight, 4% by weight, 5% by weight, 6% by weight, 7% by weight, 8% by weight, 9% by weight, or 10% by weight, or any range of values ​​in between, or at approximately, maximum, or up to approximately that concentration. For example, in some embodiments, the amount of additive in the electrolyte is one of the following ranges, or approximately the following ranges: 0.1–10% by weight, 1–6% by weight, 2–5% by weight, 0.1–6% by weight, 2–8% by weight, 2–3% by weight, or 1–4% by weight.

[0082] In some embodiments, the energy storage device is fabricated such that one electrode (e.g., the anode) is larger than and overhangs the other electrode (e.g., the cathode). One electrode may overhang the other in the winding direction and / or non-winding direction of the electrode assembly. Such electrode overhangs can avoid yield losses. In some embodiments, if there is no or substantially no overlap and / or mixing of the separator and the molded electrode film (e.g., the cathode electrode film), the boundary of the molded electrode film is easier to identify, and therefore the ability to form a counter electrode (e.g., the anode electrode) with an overhang is improved.

[0083] While specific embodiments of the present invention have been described, these embodiments are presented merely as examples and are not intended to limit the scope of this disclosure. In fact, the novel methods and systems described herein can be embodied in a variety of other forms. Furthermore, various omissions, substitutions, and modifications of the systems and methods described herein may be made without departing from the spirit of this disclosure. The appended claims and their equivalents are intended to encompass forms or modifications that fall within the scope and spirit of this disclosure. Accordingly, the scope of the present invention is defined solely by reference to the appended claims.

[0084] Features, materials, properties, or groups described in relation to a particular aspect, embodiment, or example should be understood to be applicable to any other aspect, embodiment, or example described in this section or other sections of this Spec. All features disclosed herein (including the accompanying claims, abstract, and drawings) and / or all steps of any method or process disclosed herein may be combined in any combination, except for any combination in which at least some of such features and / or steps are mutually exclusive. Protection is not limited to the details of any of the aforementioned embodiments. Protection extends to any novel features or any novel combination of features disclosed herein (including the accompanying claims, abstract, and drawings), or any novel steps or any novel combination of any method or process disclosed herein.

[0085] Furthermore, certain features described in this disclosure in relation to separate embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in relation to a single embodiment may also be implemented separately in multiple embodiments or in any suitable partial combination. Furthermore, features may be described above as acting in a particular combination, but one or more features from a claimed combination may, in some cases, be removed from the combination, and the combination may be claimed as a partial combination or a variation of a partial combination.

[0086] Furthermore, while operations may be shown in the drawings or described herein in a specific order, such operations do not need to be performed in the specific order shown or in a sequential order, or not all operations need to be performed, in order to achieve the desired result. Other operations not shown or described may be incorporated into exemplary methods and processes. For example, one or more additional operations may be performed before, after, simultaneously with, or in between any of the described operations. Furthermore, operations may be rearranged or reordered in other embodiments. Those skilled in the art will understand that in some embodiments, the actual steps performed in the illustrated and / or disclosed processes may differ from those shown in the drawings. Depending on the embodiment, certain steps among the above steps may be omitted, or other steps may be added. Furthermore, the features and attributes of the particular embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of this disclosure. Also, the separation of various system components in the above embodiments should not be understood as requiring such separation in all embodiments, and the described components and systems may generally be integrated together in a single product or packaged in multiple products. For example, any component of the energy storage system described herein may be provided separately or integrated (e.g., packaged together or mounted together) to form the energy storage system.

[0087] For the purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not all such advantages can necessarily be achieved according to any particular embodiment. Therefore, for example, a person skilled in the art will recognize that this disclosure may be embodied or implemented to achieve one advantage or set of advantages taught herein, without necessarily achieving other advantages that can be taught or suggested herein.

[0088] Conditional language such as "can," "could," "might," or "may" is generally intended to convey that a particular embodiment includes certain features, elements, and / or steps, but other embodiments do not, unless otherwise specified or understood in the context in which they are used. Therefore, such conditional language is generally not intended to imply that features, elements, and / or steps are required in some form in one or more embodiments, or that one or more embodiments necessarily include logic for determining whether these features, elements, and / or steps should be included or performed in any particular embodiment, with or without user input or prompting.

[0089] Conjunctions such as the phrase "at least one of X, Y, and Z" are generally understood in contexts where they are commonly used to convey that an item, term, etc., could be any of X, Y, or Z, unless otherwise specified. Therefore, such conjunctions are generally not intended to imply that a particular embodiment requires the presence of at least one X, at least one Y, and at least one Z.

[0090] The terms "approximately," "about," "generally," and "substantially" as used herein represent values, quantities, or characteristics close to the stated values, quantities, or characteristics that still perform the desired function or achieve the desired result. For example, the terms "approximately," "about," "generally," and "substantially" may refer to quantities less than 10%, less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the stated quantity, depending on the desired function or desired result.

[0091] The scope of this disclosure is not intended to be limited by any specific disclosure of preferred embodiments in this section or other sections of this Spec, and may be defined by the claims as presented in this section or other sections of this Spec, or as presented in the future. The language of the claims should be interpreted broadly on the basis of the language used in the claims, and should not be limited to the examples described herein or during the examination of the application, and the examples should be interpreted as non-exclusive.

Claims

1. A porous electrical insulating substrate including a first side and a second side, A first porous foil layer disposed on the first side surface of the porous electrical insulating substrate, A second porous foil layer disposed on the second side surface of the porous electrical insulating substrate, A porous current collector assembly for energy storage devices, including...

2. The porous current collector assembly according to claim 1, wherein the first porous foil layer contains a metal different from that of the second porous foil layer.

3. The porous current collector assembly according to claim 1, wherein the first porous foil layer and the second porous foil layer each independently contain a metal selected from the group consisting of Cu, Al, Ni, Li, Mn, Co, Fe, Cr and combinations thereof.

4. The porous current collector assembly according to claim 1, wherein the first porous foil layer and the second porous foil layer each independently contain stainless steel.

5. The porous current collector assembly according to claim 1, wherein the first porous foil layer and the second porous foil layer each independently contain a foil layer porosity of about 5 to 75%.

6. The porous current collector assembly according to claim 1, wherein the first porous foil layer and the second porous foil layer each independently contain foil pores with a diameter of approximately 1 nm to approximately 1 cm.

7. The porous current collector assembly according to claim 1, wherein the first porous foil layer and the second porous foil layer each independently have a foil layer thickness of about 0.1 μm to about 10 μm.

8. The porous current collector assembly according to claim 1, wherein the porous electrical insulating substrate comprises a polymer selected from the group consisting of polyethylene, polypropylene, polystyrene, polyvinyl chloride, polytetrafluoroethylene, polyurethane, polyamide, polyimide, polyester, poly(vinylidene fluoride), aramid, polyether, copolymers thereof, and combinations thereof.

9. The porous current collector assembly according to claim 1, wherein the porous electrical insulating substrate has a substrate porosity of about 5% to about 75%.

10. The porous current collector assembly according to claim 1, wherein the porous electrical insulating substrate includes substrate pore diameters of about 1 nm to about 1 cm.

11. The porous current collector assembly according to claim 1, wherein the porous electrical insulating substrate has a substrate thickness of about 1 μm to about 30 μm.

12. The porous current collector assembly according to claim 1, wherein the porous electrical insulating substrate has a substrate melting temperature of approximately 50°C to approximately 450°C.

13. Electrode film and, The porous current collector assembly according to claim 1 and An electrode comprising the electrode film, wherein the electrode film is disposed on the porous current collector assembly.

14. The electrode according to claim 13, wherein the electrode film substantially does not contain solvent residue.

15. The electrode according to claim 13, The second electrode film, An electrode assembly comprising the porous current collector assembly, wherein the porous current collector assembly is positioned between the electrode film and the second electrode film.

16. The electrode assembly according to claim 15, The second electrode assembly, A separator is positioned between the electrode assembly and the second electrode assembly, An electrode assembly stack, including the electrode assembly stack.

17. The electrode assembly stack according to claim 16, wherein the electrode film and the second electrode film have the same polarity.

18. The electrode assembly according to claim 16, The second electrode assembly, A double electrode assembly stack comprising, wherein one electrode film of the second electrode assembly is in contact with either one electrode film of the electrode assembly or the second electrode film.

19. The double electrode assembly stack according to claim 18, wherein the electrode film and the second electrode film have opposite polarities.

20. The electrode assembly according to claim 15, Electrolytes, Housing and An energy storage device comprising the electrode assembly and the electrolyte, wherein the electrode assembly and the electrolyte are located within the housing.

21. The steps include: placing a first porous foil layer on a first side surface of a porous electrical insulating substrate; The steps include: arranging a second porous foil layer on the second side surface of the porous electrical insulating substrate to form a porous current collector assembly; A method for forming a porous current collector assembly, including the following:

22. The method according to claim 21, wherein the step of arranging the first porous foil layer includes arranging the first porous foil layer on the first side surface of the porous electrical insulating substrate opposite to the second side surface.

23. The steps of forming the porous current collector assembly described in claim 21, The process involves a step of calendering a dry electrode film mixture in a dry process to form an electrode film, The steps include: arranging the electrode film on the porous current collector assembly to form an electrode; A method for forming electrodes, including the following.

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