Anode assembly for battery cells

Abstract

This disclosure provides an anode assembly for a battery cell. The anode assembly comprises a separator layer and an anode layer. The anode layer is at least partially disposed on the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer contains a solid electrolyte (SSE) material defining pores adapted to receive the anode material. Also, the absolute pressure P within the pores 細孔 P is the absolute pressure of the environment outside the anode layer. env Smaller than. This disclosure also provides a method for forming an anode assembly for a battery cell.

Description

[Technical Field]

[0001] Cross-reference of related applications This PCT application claims the benefits of U.S. Provisional Patent Application No. 63 / 493,340, filed on 31 March 2023. This document is incorporated herein by reference in its entirety.

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

[0003] Solid-state and hybrid solid-state battery cells may include one or more porous electrode layers. Such electrode layers are plated and removed with electrode material (e.g., lithium metal) during charging and discharging of the battery cell. For example, an anode material may migrate from the cathode layer to the anode layer during charging of the battery cell and be plated onto it. This plating of the anode material increases the volume of the anode layer. Similarly, during stripping of the anode material (e.g., during discharging of the battery cell), the volume of the anode layer decreases. To promote uniform plating of the anode material within the pores of the anode layer and to prevent the formation of pores within the plated anode material, a mechanical force may be applied to one or more components of the battery cell. For example, an external force may be applied to the battery cell or one or more components thereof to compress the components of the battery cell. This approach requires an additional component to apply mechanical force to one or more components of the battery cell, thereby reducing the specific energy density and volumetric energy density of the battery cell. Furthermore, in battery applications where weight and / or space are limited, the additional component may make packaging / integration difficult.

[0004] Therefore, there is still a need to provide improved anode assemblies for battery cells. [Overview of the project] [Means for solving the problem]

[0005] In one aspect, the present invention provides an anode assembly for a battery cell. The anode assembly includes a separator layer and an anode layer. The anode layer is at least partially disposed on the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer includes a solid-state electrolyte (SSE) material that defines pores adapted to receive an anode material. Also, the absolute pressure P env , , Penv ,

[0007] , env , , ,

[0008] , , 細孔 , 細孔 , 細孔 in the pores is less than the absolute pressure P env of the environment outside the anode layer.

[0006] In some embodiments, P 細孔 is less than about 101,325 Pa. For example, P 細孔 can be from about 1 Pa to about 101,324 Pa. In some embodiments, P 細孔 is from about 100 Pa to about 1,000 Pa. In other embodiments, P 細孔 is such that P 細孔 is from about 1,000 Pa to about 10,000 Pa. In some embodiments, P 細孔 is from about 10,000 Pa to about 101,324 Pa. In other embodiments, the pore P is from about 100 Pa to about 2,000 Pa. In some embodiments, P 細孔 is also from about 500 Pa to about 1,500 Pa. Also, in some embodiments, P 細孔 is from about 750 Pa to about 1,250 Pa.

[0007] In some embodiments, the pressure difference between P 細孔 and P env is from about 100 Pa to about 100,000 Pa. In other embodiments, the pressure difference between P 細孔 and Penv is from about 1,000 Pa to about 100,000 Pa. Also, in some embodiments, the pressure difference between P 細孔 and P env is from about 10,000 Pa to about 100,000 Pa. <00OO834>

[0008] In some embodiments, the separator layer is substantially poreless. In some embodiments, the separator layer comprises an SSE material. For example, the SSE material of the separator layer may include polymers, sulfides, oxides, chalcogenides, or any combination thereof. Also, in some embodiments, the separator layer has a thickness of about 1 μm to about 300 μm.

[0009] In some embodiments, the anode assembly further includes an anode material disposed in at least a portion of the pores of the anode layer. For example, the anode material may include lithium metal, sodium metal, magnesium metal, or any combination thereof. In some embodiments, the anode material also includes lithium metal.

[0010] In some embodiments, the anode layer comprises a garnet material. In some embodiments, the anode layer has a thickness of about 1 μm to about 500 μm.

[0011] In some embodiments, the anode current collector includes a metal foil. For example, the metal foil may include copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof. Also, in some embodiments, the metal foil has tabs configured to connect to an external circuit.

[0012] In some embodiments, the anode assembly does not include any components that apply substantial mechanical force to one or more of the anode layer, separator layer, and anode current collector.

[0013] In another embodiment, the present invention provides an anode assembly for a battery cell. The anode assembly comprises a separator, an anode layer, and a barrier. The anode layer is at least partially disposed on the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer contains a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The barrier is disposed around the outer surface of the anode layer and defines the interior and exterior. The barrier is impermeable to liquids and gases. The anode layer is located inside the barrier. Also, the absolute pressure P inside the barrier int This is the absolute pressure P outside the barrier. ext It is smaller than that.

[0014] In some embodiments, the P of the barrier int It is less than approximately 101,325 Pa. For example, the P of the barrier int The pressure can range from approximately 1 Pa to approximately 101,324 Pa. In some embodiments, the P of the barrier int The pressure is approximately 100 Pa to approximately 1,000 Pa. In other embodiments, the P of the barrier int The pressure is approximately 1,000 Pa to approximately 10,000 Pa. In some embodiments, the P of the barrier int This is approximately 10,000 Pa to approximately 101,324 Pa. In other embodiments, the P of the barrier int The pressure is approximately 100 Pa to approximately 2,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 500 Pa to approximately 1,500 Pa. In addition, in some embodiments, the P of the barrier int The pressure range is approximately 750 Pa to 1,250 Pa.

[0015] In some embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 100 Pa to approximately 100,000 Pa. In some embodiments, the P of the barrier int and P extThe pressure difference between them is approximately 1,000 Pa to approximately 100,000 Pa. In some embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 10,000 Pa to 100,000 Pa.

[0016] In some embodiments, the separator layer is located inside the barrier. In some embodiments, the separator layer is substantially poreless. In some embodiments, the separator layer comprises an SSE material. For example, the SSE material of the separator layer may include polymers, sulfides, oxides, chalcogenides, or any combination thereof. Also, in some embodiments, the separator layer has a thickness of about 1 μm to about 300 μm.

[0017] In some embodiments, the anode layer further comprises an anode material disposed in at least a portion of the pores of the anode layer. In other embodiments, the anode material includes lithium metal, sodium metal, magnesium metal, or any combination thereof. For example, the anode material may include lithium.

[0018] In some embodiments, the anode layer comprises a garnet material. In some embodiments, the anode layer has a thickness of about 1 μm to about 500 μm.

[0019] In some embodiments, the anode assembly further includes an anode current collector bonded to the entire second surface of the anode layer. In some embodiments, the anode current collector is located inside a barrier. In some embodiments, the anode current collector includes a metal foil. In some embodiments, the anode current collector includes a metal foil. For example, the metal foil may include copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof. Also, in some embodiments, the metal foil has tabs configured to connect to an external circuit.

[0020] In some embodiments, the barrier is a seal comprising a sealant material. In some embodiments, the seal is at least partially located on the anode current collector. In other embodiments, the seal is at least partially located on the outer surface of the anode layer. Also in some embodiments, the seal is at least partially located on the separator layer.

[0021] In some embodiments, the separator layer has a front surface facing the anode layer, a back surface facing away from the anode layer, and an outer surface extending from the front surface to the back surface. In some embodiments, the seal may be at least partially on the outer surface of the separator layer.

[0022] In some embodiments, the separator layer defines a recess, and the seal is placed within that recess.

[0023] In some embodiments, the anode layer defines a first porous region between the center and the outer surface of the anode layer, and a second porous region between the first porous region and the outer surface of the anode layer. In such embodiments, the pores of the first porous region do not need to contain substantially any sealant material. In some embodiments, at least some of the pores of the second porous region contain sealant material.

[0024] In some embodiments, the anode layer further includes an anode current collector bonded to the entire second surface of the anode layer. The separator layer has a front surface facing the anode layer, a back surface facing away from the anode layer, and an outer surface extending from the front surface to the back surface. The anode current collector has an inner surface facing the anode layer, an outer surface facing away from the anode layer, and an outer surface extending from the inner surface to the outer surface. Seals are also provided at least partially on the outer surfaces of the anode layer, the separator layer, and the anode current collector.

[0025] In some embodiments, the sealant material includes a non-conductive polymer, a non-conductive glass, or any combination thereof. In other embodiments, the sealant material includes polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof. Also in some embodiments, at least a portion of the seal has a thickness of about 1 μm to about 50 μm.

[0026] In some embodiments, the anode assembly does not include any components that apply substantial mechanical force to one or more of the anode layer, separator layer, seal, and anode current collector.

[0027] In another embodiment, the present invention provides a battery cell comprising an anode assembly, an anode current collector, a cathode layer, and a cathode current collector. The anode assembly may be any anode assembly described herein. The anode current collector is coupled to a second surface of the anode layer. The cathode layer is at least partially located on the separator layer. The cathode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The cathode current collector is coupled to the second surface of the cathode layer.

[0028] In some embodiments, the battery cell further comprises a housing having a plurality of inner walls that define an interior, and an anode assembly, an anode current collector, a cathode layer, and a cathode current collector are disposed inside the housing. In some embodiments, the battery cell further includes a catholite disposed in the cathode layer. Also, in some embodiments, the battery cell does not include a component that applies a substantial mechanical force to one or more of the anode layer, the separator layer, the seal, the anode current collector, the cathode layer, and the cathode current collector.

[0029] In another aspect, the present invention provides a method of forming the anode assembly described herein.

[0030] The following figures are exemplary and do not limit the scope of the claims of the present invention.

Brief Description of the Drawings

[0031] [Figure 1] It is a side view showing a first exemplary embodiment of the anode assembly.

[0032] [Figure 2A] It is a cross-sectional view of a second exemplary embodiment of the anode assembly for a battery cell.

[0033] [Figure 2B] It is a front view of the anode assembly of FIG. 2A.

[0034] [Figure 3A] It is a cross-sectional view of a third exemplary embodiment of the anode assembly for a battery cell.

[0035] [Figure 3B] It is an enlarged view of a part of the anode assembly of FIG. 3A according to one embodiment.

[0036] [Figure 3C] It is an enlarged view of a part of the anode assembly of FIG. 3A according to another embodiment.

[0037] [Figure 3D] It is an enlarged view of a part of the anode assembly of FIG. 3A according to a further embodiment.

[0038] [Figure 3E] It is also an enlarged view of a part of the anode assembly of FIG. 3A according to yet another further embodiment.

[0039] [Figure 4A] It is a cross-sectional view of a fourth exemplary embodiment of an anode assembly for a battery cell.

[0040] [Figure 4B] It is a front view of the anode assembly of FIG. 4A.

[0041] [Figure 5A] It is a cross-sectional view of a fifth exemplary embodiment of an anode assembly for a battery cell.

[0042] [Figure 5B] It is a cross-sectional view of a sixth exemplary embodiment of an anode assembly for a battery cell.

[0043] [Figure 6A] It is a cross-sectional view of a seventh exemplary embodiment of an anode assembly for a battery cell.

[0044] [Figure 6B] It is a front view of the anode assembly of FIG. 6A.

[0045] [Figure 7A] It is a cross-sectional view of an eighth exemplary embodiment of an anode assembly for a battery cell.

[0046] [Figure 7B] It is a front view of the anode assembly of FIG. 7A.

[0047] [Figure 8A] This is a cross-sectional view of a first exemplary embodiment of a battery cell.

[0048] [Figure 8B] Figure 8A is a front view of the battery cell.

[0049] [Figure 8C] This is a cross-sectional view of a second exemplary embodiment of a battery cell.

[0050] [Figure 8D] Figure 8C is a front view of the battery cell.

[0051] [Figure 9A] This is a cross-sectional view of a third exemplary embodiment of a battery cell.

[0052] [Figure 9B] Figure 9A is a front view of the battery cell.

[0053] [Figure 9C] This is a cross-sectional view of a fourth exemplary embodiment of a battery cell.

[0054] [Figure 9D] Figure 9C is a front view of the battery cell.

[0055] [Figure 10A] This is a cross-sectional view of a fifth exemplary embodiment of a battery cell.

[0056] [Figure 10B] Figure 10A is a front view of the battery cell.

[0057] [Figure 10C] This is a cross-sectional view of a sixth exemplary embodiment of a battery cell.

[0058] [Figure 10D] Figure 10C is a front view of the battery cell.

[0059] [Figure 11] This is a flowchart of a method for forming an anode assembly according to one embodiment of the present invention.

[0060] In each figure, the same reference number indicates the same element. For example, the separator layer may be referred to as 102 in Figure 1, 602 in Figure 6A, and 802 in Figure 8A. In other examples, the anode assembly may be referred to as 100 in Figure 1, 200 in Figure 2, 600 in Figure 6A, 700 in Figure 7, and 900 in Figure 9. In other examples, the anode layer may also be referred to as 104 in Figure 1, 204 in Figure 2, 304 in Figure 3, 404 in Figure 4, 504 in Figure 5, 604 in Figure 6, 704 in Figure 7, 804 in Figure 8, 904 in Figure 9, and 1004 in Figure 10. In other examples, the front surface of the separator layer may be referred to as 106 in Figure 1, 2046 in Figure 2, 306 in Figure 3, 406 in Figure 4, 506 in Figure 5, 606 in Figure 6, 706 in Figure 7, 806 in Figure 8, 906 in Figure 9, and 1006 in Figure 10. In other examples, the back surface of the separator layer may be referred to as 108 in Figure 1, 208 in Figure 2, 308 in Figure 3, and 908 in Figure 9. In other examples, the outer surface of the separator may be referred to as 110 in Figure 1, 210 in Figure 2, and 310 in Figure 3. In other examples, the outer surface of the anode layer may be referred to as 118 in Figure 1, 218 in Figure 2, 318 in Figure 3, and 518 in Figure 5. In other examples, the first surface of the anode layer may be referred to as 114 in Figure 1, 214 in Figure 2, and 314 in Figure 3. In other examples, the second surface of the anode layer may be referred to as 116 in Figure 1 and 316 in Figure 3. In other examples, the seal may be referred to as 242 in Figure 2, 342 in Figure 3, 442 in Figure 4, 542 in Figure 5, 642 in Figure 6, 742 in Figure 7, 842 in Figure 8, 942 in Figure 9, and 1042 in Figure 10. In other examples, the anode current collector may be referred to as 230 in Figure 2, 330 in Figure 3, 430 in Figure 4, 530 in Figure 5, 630 in Figure 6, 730 in Figure 7, 830 in Figure 8, 930 in Figure 9, and 1030 in Figure 10. In other examples, the tabs may be referred to as 240 in Figure 2, 340 in Figure 3, 440 in Figure 4, 540 in Figure 5, 640 in Figure 6, 740 in Figure 7, 840 in Figure 8, 940 in Figure 9, and 1040 in Figure 10. [Modes for carrying out the invention]

[0061] The present invention provides an anode assembly for a battery cell, a battery cell including such an anode assembly, and a method for forming such an anode assembly.

[0062] As used herein, unless otherwise specified, the following definitions shall apply:

[0063] I. Definition

[0064] The terms used herein are used solely to describe specific exemplary configurations and are not intended to be limiting. Where used herein, the singular articles “a,” “an,” and “the” may also include the plural unless otherwise clearly indicated in the context. The terms “comprises,” “comprising,” “including,” and “have” are comprehensive and thus indicate the presence of features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The steps, processes, and operations of the methods described herein should not be construed as necessarily requiring their execution in a specific order described or illustrated unless specifically noted as the order of execution. Additional or alternative steps may be used.

[0065] In this specification, terms such as first, second, third, etc., may be used to describe various elements, components, areas, layers, and / or sections. These elements, components, areas, layers, and / or sections should not be limited by these terms. These terms may be used only to distinguish one element, component, area, layer, or section from another area, layer, or section. Terms such as "first," "second," etc., and other numerical terms do not imply arrangement or order unless explicitly indicated by the context. Thus, the first element, component, area, layer, or section described below may be called the second element, component, area, layer, or section without deviating from the teaching of the illustrated configuration.

[0066] In this specification, when an element is described as “on,” “engaged to,” “connected to,” “attached to,” or “joined to” another element, that element may be directly on, engaged to, connected to, attached to, or joined to the other element, or there may be an intervening element. On the other hand, when an element is described as “directly adjacent to,” “directly engaged to,” “directly connected to,” “directly attached to,” or “directly joined to” another element, it means that there is no intervening element or layer. Other words used to describe the relationship between elements should be interpreted similarly (e.g., “between” and “directly between,” “adjacent” and “directly adjacent,” etc.). As used herein, the term “and / or” includes any combination of one or more of the listed related items.

[0067] As used herein, the term "battery cell" refers to a rechargeable secondary battery. In some embodiments, the battery cell may be a solid lithium-ion battery cell.

[0068] As used herein, the term "anode assembly" refers to an assembly comprising a separator layer and an anode layer.

[0069] As used herein, the term “separator layer” refers to a layer located between the anode and cathode layers in a battery cell, which allows cations (e.g., lithium cations) to flow between the anode and cathode layers. In some embodiments, the separator layer is substantially poreless (e.g., having an apparent porosity of less than 50%, less than 40%, less than 30%, less than 20%, less than 15%, less than 10%, less than 5%, or less than 1%). In some embodiments, the separator layer is also poreless.

[0070] As used herein, the term “anode layer” refers to the negative electrode layer from which electrons flow during the discharge phase of a battery cell. The anode layer is at least partially located on the separator layer and has a first surface facing the separator layer and a second surface facing away from the separator layer. The anode layer comprises a solid electrolyte (SSE) material defining pores adapted to accommodate the anode material. In some embodiments, the absolute pressure P within the pores 細孔 P is the absolute pressure of the environment outside the anode layer. env It is lower than. In other embodiments, when the anode layer is located inside the barrier, P 細孔 This is the absolute pressure P inside the barrier. int It is essentially the same as this.

[0071] As used herein, the term “environment outside the anode layer” means P 細孔This refers to an environment with an absolute pressure greater than that which is separated from the anode layer by one or more barriers that are impermeable to liquids and gases. For example, if the anode layer is located in a seal, the environment outside the anode layer refers to the environment outside the seal. In other embodiments, if the anode layer is located in a housing, the environment outside the anode layer refers to the environment outside the housing. In some embodiments, P env The pressure range is approximately 90,000 Pa to 110,000 Pa.

[0072] As used herein, the term “double layer” refers to an anode layer placed on top of a separator layer.

[0073] As used herein, the term “anode current collector” refers to a current collector coupled to the anode layer. The anode current collector is configured to be electrically coupled to the anode layer during the operation of the battery cell (e.g., during charging and / or discharging of the battery cell). In some embodiments, the anode current collector includes a metal foil. In other embodiments, the anode current collector includes a tab configured to connect to an external circuit.

[0074] As used herein, the term “cathode layer” refers to the positive electrode layer into which electrons flow during the discharge phase of a battery cell.

[0075] As used herein, the term “cathode current collector” refers to a current collector coupled to the cathode layer. The cathode current collector is configured to be electrically coupled to the cathode layer during the operation of the battery cell (e.g., during charging and / or discharging of the battery cell). In some embodiments, the cathode current collector includes a metal foil. In other embodiments, the cathode current collector has a tab configured to connect to an external circuit.

[0076] As used herein, the term “barrier” refers to a component that is arranged around the anode layer and defines its interior and exterior. The anode layer is located inside the barrier. The barrier is impermeable to liquids and gases, thereby preventing the flow of liquids and gases into and from the anode layer. The absolute pressure P inside the barrier. int This is the absolute pressure P outside the barrier. ext It is smaller than. In some embodiments, the barrier is a seal. In other embodiments, the barrier is a housing.

[0077] As used herein, the term “seal” refers to a layer positioned around the anode layer and defining its interior and exterior. The anode layer is located inside the seal. The seal comprises a sealant material. In some embodiments, if the barrier is a seal, the seal is impermeable to liquids and gases, thereby preventing the flow of liquids and gases into or out of the anode layer. In some embodiments, the absolute pressure P inside the seal int This is the absolute pressure P outside the seal. ext It is smaller than that. In other embodiments, the seal is substantially impermeable to liquids and permeable to gases.

[0078] As used herein, the term “apparent porosity” refers to open (or accessible) porosity (i.e., porosity excluding the volume of sealed or closed pores, cells, or voids). Apparent porosity can be expressed as the percentage of the total volume that is occupied by open pores, cells, or voids.

[0079] As used herein, the term “substantial mechanical force-applying component” refers to an anode assembly and / or a component of a battery cell whose primary function is to apply mechanical force to one or more components of the anode assembly and / or battery cell in order to promote uniform plating of the anode material in the pores of the anode layer and / or to prevent the formation of pores in the plated anode material (e.g., lithium metal).

[0080] II. Anode Assembly

[0081] In one embodiment, the present invention provides an anode assembly for a battery cell.

[0082] As shown in Figure 1, the anode assembly 100 comprises a separator layer 102 and an anode layer 104.

[0083] A. Separator layer

[0084] The separator layer may be composed of any suitable material that allows cations (e.g., lithium cations) to flow between the anode and cathode layers during the operation of the battery cell. In some embodiments, the separator layer includes a solid electrolyte (SSE) material. For example, the SSE material of the separator layer may include polymers, sulfides, oxides, chalcogenides, or any combination thereof. For example, the SSE material may include sulfides. In some embodiments, the SSE material includes LSS, LTS, LXPS, LXPSO, LATS, lithium garnet, or any combination thereof, where X is Si, Ge, Sn, As, Al, or any combination thereof, S is S, Si, or any combination thereof, and T is Sn.

[0085] As used herein, “LSS” refers to lithium silicon sulfide which can be described as Li2S-SiS2, Li-SiS2, Li-S-Si, or an SSE material containing Li, S, and Si. In some embodiments, LSS is Li x Si y S zThe formula includes , where 0.33 ≤ x ≤ 0.5, 0.1 ≤ y ≤ 0.2, and 0.4 ≤ z ≤ 0.55. In some embodiments, LSS may contain up to 10 atomic percent oxygen. In other embodiments, LSS may contain an SSE material containing Li, Si, and S. In some embodiments, LSS contains a mixture of Li2S and SiS2. In some embodiments, the molar ratio of Li2S:SiS2 is 90:10, 85:15, 80:20, 75:25, 70:30, 2:1, 65:35, 60:40, 55:45, or 50:50. In some embodiments, LSS is Li x PO y Li x BO y , further comprising doped compounds such as Li4SiO4, Li3MO4, Li3MO3, PS, and / or lithium halides including but not limited to LiI, LiCl, LiF, or LiBr, where 0 <x≦5かつ0<y≦5である。

[0086] As used herein, “LTS” refers to a lithium tin sulfide compound that can be described as Li2S-SnS2, Li2S-SnS, Li-S-Sn, or an SSE material containing Li, S, and Sn. In some embodiments, LTS is Li x Sn y S z It may contain (0.25≦x≦0.65, 0.05≦y≦0.2, and 0.25≦Z≦0.65). In some embodiments, LTS may contain a mixture of Li2S and SnS2 in molar ratios of 80:20, 75:25, 70:30, 2:1, or 1:1 (i.e., Li2S:SnS2). In some embodiments, LTS may contain up to 10 atomic percent oxygen. In other embodiments, LTS may be doped with Bi, Sb, As, P, B, Al, Ge, Ga, In, or any combination thereof. As used herein, "LATS" refers to the LTS used above, further containing arsenic (As).

[0087] As used herein, "LXPS" means Lia MP b S c The term "LSPS" refers to a material characterized by the formula L, where M is Si, Ge, Sn, Al, or any combination thereof, and 2 ≤ a ≤ 8, 0.5 ≤ b ≤ 2.5, and 4 ≤ c ≤ 12. a SiP b S c This refers to electrolyte materials characterized by (2≦a≦8, 0.5≦b≦2.5, 4≦c≦12).

[0088] When M is Sn and Si (i.e., both Sn and Si are present), the LXPS material is called "LSTPS". As used herein, "LSTPSO" refers to an LSTPS that is O-doped, has O, or contains O. In some embodiments, "LSTPSO" is an LSTPS material with an oxygen content of 0.01 to 10 atomic percent. As used herein, "LSPS" refers to an electrolyte material having the chemical components Li, Si, P, and S. As used herein, "LSTPS" refers to an electrolyte material having the chemical components Li, Si, P, Sn, and S. As used herein, "LSPSO" refers to an LSPS that is O-doped, has O, or contains O. In some embodiments, "LSPSO" is an LSPS material with an oxygen content of 0.01 to 10 atomic percent. As used herein, "LATP" refers to an electrolyte material having the chemical components Li, As, Sn, and P. As used herein, "LAGP" refers to an electrolyte material having the chemical components Li, As, Ge, and P. As used herein, "LXPSO" refers to Li a MP b S c O dThis refers to an electrolyte material containing Li2S-P2S5, where M is Si, Ge, Sn, Al, or any combination thereof, and 2≦a≦8, 0.5≦b≦2.5, 4≦c≦12, and d<3. LXPSO refers to the LXPS defined above, having an oxygen doping of 0.1 to about 10 atomic percent. As used herein, "LPS" refers to an electrolyte material containing Li2S-P2S5. As used herein, "LPSO" refers to the LPS as defined herein, further comprising an oxygen doping of 0.1 to about 10 atomic percent.

[0089] In some embodiments, the SSE material of the separator layer includes a polymer. For example, the polymer may include polyolefins, natural rubber, synthetic rubber, polybutadiene, polyisoprene, epoxidized natural rubber, polyisobutylene, polypropylene oxide, polyacrylate, polymethacrylate, polyester, polyvinyl ester, polyurethane, styrene polymers, epoxy resins, epoxy polymers, poly(bisphenol A-co-epichlorohydrin), vinyl polymers, polyvinyl halide, polyvinyl alcohol, polyethyleneimine, poly(maleic anhydride), silicone polymers, siloxane polymers, polyacrylonitrile, polyacrylamide, polychloroprene, polyvinylidene fluoride, polyvinylpyrrolidone, polyepichlorohydrin, mixtures thereof, or copolymers thereof. In some embodiments, the polymer is a polyolefin. In some embodiments, the polymer is natural rubber. In some embodiments, the polymer is synthetic rubber. In some embodiments, the polymer is polybutadiene. In some embodiments, the polymer is polyisoprene. In some embodiments, the polymer is epoxidized natural rubber. In other embodiments, the polymer is polyisobutylene. In some embodiments, the polymer is polypropylene oxide. In some embodiments, the polymer is polyacrylate. In some embodiments, the polymer is polymethacrylate. In some embodiments, the polymer is polyester. In other embodiments, the polymer is polyvinyl ester. In some embodiments, the polymer is polyurethane. In some embodiments, the polymer is styrene polymer. In some embodiments, the polymer is epoxy resin. In some embodiments, the polymer is epoxy polymer. In some embodiments, the polymer is poly(bisphenol A-co-epichlorohydrin). In some embodiments, the polymer is vinyl polymer. In some embodiments, the polymer is polyvinyl halide. In some embodiments, the polymer is polyvinyl alcohol. In some embodiments, the polymer is polyethyleneimine.In other embodiments, the polymer is poly(maleic anhydride). In some embodiments, the polymer is a silicone polymer. In some embodiments, the polymer is a siloxane polymer. In some embodiments, the polymer is polyacrylonitrile. In some embodiments, the polymer is polyacrylamide. In some embodiments, the polymer is polychloroprene. In some embodiments, the polymer is polyvinylidene fluoride. In some embodiments, the polymer is polyvinylpyrrolidone. In some embodiments, the polymer is polyepichlorohydrin. In some embodiments, the molecular weight of the polymer is greater than approximately 50,000 g / mol.

[0090] In some embodiments, the polymer is pre-formed and selected from the group consisting of polypropylene, polyethylene, polybutadiene, polyisoprene, epoxidized natural rubber, poly(butadiene-co-acrylonitrile), polyethyleneimine, polydimethylsiloxane, and poly(ethylene-co-vinyl acetate). In other embodiments, the molecular weight of the polymer is greater than approximately 50,000 g / mol.

[0091] If the SSE material contains a polymer, the SSE material may further contain a metal salt (e.g., a lithium salt (e.g., LiPF6)).

[0092] In some embodiments, the SSE material of the separator layer is lithium perovskite material, Li3N, Li-β-alumina, lithium superionic conductor (LISICON), Li 2.88 PO 3.86 N 0.14 (LiPON), Li9AlSiO8, Li 10 GeP2S 12 This includes lithium garnet SSE material, doped lithium garnet SSE material, lithium garnet composite material, or any combination thereof. In various embodiments, the lithium garnet SSE material is cation-doped Li5La3M 1 20 12 (M 1is Nb, Zr, Ta, or any combination thereof), cation-doped Li6La2BaTa2O 12 cation-doped Li7La3Zr2O 12 and cation-doped Li6BaY2M 1 2O 12 where the chaotic dopant is barium, yttrium, zinc, or any combination thereof, etc. In various other embodiments, the lithium garnet SSE material is Li5La3Nb2O 12 Li5La3Ta2O 12 Li7La3Zr2O 12 Li6La2SrNb2O 12 Li6La2BaNb2O 12 Li^6La^2SrTa^^2O 12 Li6La2BaTa2O 12 Li7Y3Zr2O 12 Li 6.4 Y3Zr 1.4 Ta 0.6 O 12 Li 6.5 La 2.5 Ba 0.5 TaZrO 12 Li6BaY2M 1 2O 12 Li7Y3Zr2O 12 Li 6.75 BaLa2Nb 1.75 Zn 0.25 O 12 Li 6.75 BaLa2Ta 1.75 Zn 0.25 O 12 or any combination thereof.

[0093] In some embodiments, the SSE material of the separator layer and the SSE material of the anode layer are the same (e.g., the SSE material of the separator layer may be any SSE material described herein for the anode layer). In other embodiments, the SSE material of the separator layer and the SSE material of the separator layer are different.

[0094] In some embodiments, the separator layer is substantially poreless (for example, having an apparent porosity of less than 50%, less than 40%, less than 30%, less than 20%, less than 15%, less than 10%, less than 5%, or less than 1%). In some embodiments, the separator layer is also poreless.

[0095] In some embodiments, the separator layer has a thickness of approximately 1 μm to approximately 300 μm. In some embodiments, the separator layer has a thickness of approximately 1 μm to approximately 200 μm. In other embodiments, the separator layer has a thickness of approximately 1 μm to approximately 100 μm. In some embodiments, the separator layer has a thickness of approximately 1 μm to approximately 50 μm. In some embodiments, the separator layer has a thickness of approximately 1 μm to approximately 20 μm. Also, in some embodiments, the separator layer has a thickness of approximately 1 μm to approximately 10 μm.

[0096] Referring again to Figure 1, the separator layer has a front surface 106 facing the anode layer 104, a back surface 108 facing away from the anode layer 104, and an outer surface 110 extending from the front surface 106 to the back surface 108.

[0097] In some embodiments, the separator layers may define recesses 312b and 312c, as shown in Figures 3B and 3C. The recesses 312b and 312c of the separator layers 302d and 302c may be defined on the front, back 308b, and / or outer surface 310c of the separator layers 302d and 302c. For example, the back 308b of the separator layers 302d and 302c may define recesses 312b and 312c, as shown in Figure 3B. In other embodiments, the back 308b and outer surface 310c of the separator layers 302b and 302d define recesses 312b and 312c, as shown in Figure 3C.

[0098] B. Anode layer

[0099] Referring again to Figure 1, the anode layer 104 is at least partially located on the separator layer 102. In some embodiments, the anode layer 104 has a first surface 114 facing the separator layer 104, a second surface 116 facing away from the separator layer 104, and an outer surface 118 extending from the first surface 114 to the second surface 116. The anode layer 104 contains an SSE material defining pores 120 adapted to receive the anode material, as shown in Figure 1.

[0100] Pores in the anode layer, P 細孔 The absolute pressure inside is equal to the absolute pressure P of the environment outside the anode layer. env Smaller than. Where used herein, the term “environment outside the anode layer” means P 細孔 This refers to an environment with an absolute pressure greater than that which is separated from the anode layer by one or more barriers (e.g., seals, housings, etc.) that are impermeable to liquids and gases.

[0101] In some embodiments, P 細孔 It is less than approximately 101,325 Pa. For example, P 細孔 The pressure can range from approximately 1 Pa to approximately 101,324 Pa. In some embodiments, P 細孔 The pressure is approximately 100 Pa to approximately 1,000 Pa. In some embodiments, P 細孔 This is approximately 100 Pa to approximately 200 Pa. In other embodiments, P 細孔 The pressure is approximately 200 Pa to approximately 300 Pa. In some embodiments, P 細孔 It is approximately 300 Pa to approximately 400 Pa. In some embodiments, P 細孔 This is approximately 400 Pa to approximately 500 Pa. In other embodiments, P 細孔 It is approximately 500 Pa to approximately 600 Pa. In some embodiments, P 細孔 This is approximately 600 Pa to approximately 700 Pa. In other embodiments, P 細孔 It is approximately 700 Pa to approximately 800 Pa. In some embodiments, P 細孔 This is approximately 800 Pa to approximately 900 Pa. In some embodiments, P 細孔This is approximately 900 Pa to approximately 1,000 Pa. In some embodiments, P 細孔 The pressure is approximately 100 Pa to approximately 500 Pa. In some embodiments, P 細孔 The pressure is approximately 500 Pa to approximately 1,000 Pa. In some embodiments, P 細孔 The pressure ranges from approximately 250 Pa to approximately 750 Pa.

[0102] In some embodiments, P 細孔 The pressure is approximately 100 Pa to approximately 2,000 Pa. In other embodiments, P 細孔 The pressure is approximately 200 Pa to approximately 1,800 Pa. In some embodiments, P 細孔 The pressure is approximately 300 Pa to approximately 1,700 Pa. In some embodiments, P 細孔 The pressure is approximately 400 Pa to approximately 1,600 Pa. In some embodiments, P 細孔 The pressure is approximately 500 Pa to approximately 1,500 Pa. In other embodiments, P 細孔 The pressure is approximately 600 Pa to approximately 1,400 Pa. In some embodiments, P 細孔 The pressure is approximately 700 Pa to approximately 1,300 Pa. In some embodiments, P 細孔 The pressure is approximately 750 Pa to approximately 1,250 Pa. In other embodiments, P 細孔 The pressure is approximately 800 Pa to approximately 1,200 Pa. In some embodiments, P 細孔 The pressure is approximately 850 Pa to approximately 1,150 Pa. In other embodiments, P 細孔 The pressure is approximately 900 Pa to approximately 1,100 Pa. In addition, in some embodiments, P 細孔 It is approximately 1,000 Pa.

[0103] In some embodiments, P 細孔 The range is approximately 1,000 Pa to approximately 10,000 Pa. For example, P 細孔 The pressure may be approximately 1,000 Pa to approximately 2,000 Pa. In some embodiments, P 細孔 The pressure is approximately 2,000 Pa to approximately 3,000 Pa. In other embodiments, P 細孔 The pressure is approximately 3,000 Pa to approximately 4,000 Pa. In some embodiments, P 細孔The pressure is approximately 4,000 Pa to approximately 5,000 Pa. In some embodiments, P 細孔 The pressure is approximately 5,000 Pa to approximately 6,000 Pa. In other embodiments, P 細孔 The pressure is approximately 6,000 Pa to approximately 7,000 Pa. In some embodiments, P 細孔 The pressure is approximately 7,000 Pa to approximately 8,000 Pa. In some embodiments, P 細孔 The pressure is approximately 8,000 Pa to approximately 9,000 Pa. In other embodiments, P 細孔 The pressure is approximately 9,000 Pa to approximately 10,000 Pa. In some embodiments, P 細孔 The pressure is approximately 1,000 Pa to approximately 5,000 Pa. In some embodiments, P 細孔 The pressure is approximately 5,000 Pa to approximately 10,000 Pa. In addition, in some embodiments, P 細孔 The pressure range is approximately 2,500 Pa to 7,500 Pa.

[0104] In some embodiments, P 細孔 The range is approximately 10,000 Pa to approximately 101,324 Pa. For example, P 細孔 The pressure may be approximately 10,000 Pa to approximately 20,000 Pa. In some embodiments, P 細孔 In other embodiments, P 細孔 The pressure is approximately 30,000 Pa to approximately 40,000 Pa. In some embodiments, P 細孔 The pressure is approximately 40,000 Pa to approximately 50,000 Pa. In some embodiments, P細孔 The pressure is approximately 50,000 Pa to approximately 60,000 Pa. In some embodiments, P 細孔 The pressure is approximately 60,000 Pa to approximately 70,000 Pa. In some embodiments, P 細孔 In other embodiments, P 細孔 The pressure is approximately 80,000 Pa to approximately 90,000 Pa. In some embodiments, P 細孔 The pressure is approximately 90,000 Pa to approximately 100,000 Pa. In some embodiments, P 細孔 The pressure is approximately 10,000 Pa to approximately 50,000 Pa. In some embodiments, P細孔 The pressure is approximately 50,000 Pa to approximately 100,000 Pa. In addition, in some embodiments, P 細孔 The pressure range is approximately 25,000 Pa to 75,000 Pa.

[0105] In some embodiments, P 細孔 The pressure ranges from approximately 0.1 Pa to approximately 100 Pa. For example, P 細孔 The pressure may be approximately 1 Pa to approximately 10 Pa. 細孔 The pressure is approximately 10 Pa to approximately 20 Pa. In other embodiments, P 細孔 The pressure is approximately 20 Pa to approximately 30 Pa. In some embodiments, P 細孔 The pressure is approximately 30 Pa to approximately 40 Pa. In other embodiments, P 細孔 The pressure is approximately 40 Pa to approximately 50 Pa. In some embodiments, P 細孔 The pressure is approximately 50 Pa to approximately 60 Pa. In some embodiments, P 細孔 The pressure is approximately 60 Pa to approximately 70 Pa. In some embodiments, P 細孔 The pressure is approximately 70 Pa to approximately 80 Pa. In other embodiments, P 細孔 The pressure is approximately 80 Pa to approximately 90 Pa. In some embodiments, P 細孔 The pressure is approximately 90 Pa to approximately 100 Pa. In some embodiments, P 細孔 The pressure is approximately 1 Pa to approximately 50 Pa. In other embodiments, P 細孔 The pressure is approximately 50 Pa to approximately 100 Pa. In some embodiments, P 細孔 The pressure is approximately 25 Pa to approximately 75 Pa. In addition, in some embodiments, P 細孔 The pressure is less than approximately 1 Pa.

[0106] In some embodiments, P 細孔 and P env The pressure difference between them is approximately 100 Pa to approximately 100,000 Pa. For example, P 細孔 and P env The pressure difference between them can be approximately 1,000 Pa to approximately 100,000 Pa. In some embodiments, P 細孔 and P envThe pressure difference between them is approximately 10,000 Pa to approximately 100,000 Pa. In some embodiments, P 細孔 and P env The pressure difference between them is greater than approximately 100,000 Pa (for example, approximately 100,000 to approximately 150,000 Pa).

[0107] In some embodiments, P 細孔 and P env The pressure difference between them is approximately 10,000 Pa to approximately 20,000 Pa. In other embodiments, P 細孔 and P env The pressure difference between them is approximately 20,000 Pa to approximately 30,000 Pa. In some embodiments, P 細孔 and P env The pressure difference between them is approximately 30,000 Pa to approximately 40,000 Pa. In other embodiments, P 細孔 and P env The pressure difference between them is approximately 40,000 Pa to approximately 50,000 Pa. In some embodiments, P 細孔 and P env The pressure difference between them is approximately 50,000 Pa to approximately 60,000 Pa. In other embodiments, P 細孔 and P env The pressure difference between them is approximately 60,000 Pa to approximately 70,000 Pa. In some embodiments, P 細孔 and P env The pressure difference between them is approximately 70,000 Pa to approximately 80,000 Pa. In some embodiments, P 細孔 and P env The pressure difference between them is approximately 80,000 Pa to approximately 90,000 Pa. In other embodiments, P 細孔 and P env The pressure difference between them is approximately 90,000 Pa to approximately 100,000 Pa. In some embodiments, P 細孔 and P env The pressure difference between them is approximately 10,000 Pa to approximately 50,000 Pa. In some embodiments, P 細孔 and P env The pressure difference between them is approximately 50,000 Pa to approximately 100,000 Pa. In some embodiments, P 細孔 and P envThe pressure difference between them is approximately 25,000 Pa to approximately 75,000 Pa.

[0108] In some embodiments, the anode layer is located across the entire surface of the separator layer. In other embodiments, the anode layer is located across substantially the entire surface of the separator layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). In yet another embodiment, the anode layer is located across only a portion of the surface of the separator layer.

[0109] In some embodiments, the anode layer has an apparent porosity of about 20% to about 80%. In other embodiments, the anode layer has an apparent porosity of about 35% to about 75%. In some embodiments, the anode layer has an apparent porosity of about 45% to about 65%. In some embodiments, the anode layer has an apparent porosity of about 50% to about 60%. In some embodiments, the anode layer has an apparent porosity of about 60% to about 80%. In some embodiments, the anode layer has an apparent porosity of about 20% to about 95%. Also, in some embodiments, the anode layer has an apparent porosity of about 50% to about 90%.

[0110] In some embodiments, the SSE material of the anode layer and the SSE material of the separator layer are the same. In other embodiments, the SSE material of the anode layer and the SSE material of the separator layer are different. In some embodiments, the SSE material includes a lithium conductor, a sodium conductor, or a magnesium conductor. In some embodiments, the SSE material includes a lithium conductor. In other embodiments, the SSE material includes a sodium conductor. Also, in some embodiments, the SSE material includes a magnesium conductor.

[0111] In some embodiments, the SSE material of the anode layer may include a garnet material. Non-limiting examples of garnet materials include lithium garnet materials, doped lithium garnet materials, lithium garnet composite materials, and combinations thereof. Non-limiting examples of lithium garnet materials include Li3-phase lithium garnet SSE materials (e.g., Li3M 1 Te2O 12 , where M 1 These include lanthanides such as Y, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Zr, Ta, or combinations thereof, and Li 3+x Nd3Te 2-x O 12 Here, x is 0.05 to 1.5, Li5-phase lithium garnet SSE material (e.g., Li5La3M 2 20 12 , here M 2 This includes Nb, Zr, Ta, Sb, or combinations thereof, and cation-substituted Li5La3M. 2 20 12 For example, Li6M 1 La3 M 2 20 12 , here M 1 These are Mg, Ca, Sr, Ba, or combinations thereof, and Li7La3M 2 20 12 , here M 2 (e.g., Zr, Sn, or a combination thereof), Li6-phase lithium garnet SSE material (e.g., Li6M 1 La2 M 2 20 12 , here M 1 M is Mg, Ca, Sr, Ba, or a combination thereof. 2 (is Nb, Ta, or a combination thereof), cation-doped Li6La2BaTa2O 12 , cation-doped Li6BaY2M 2 20 12 , here M 2The dopant is Nb, Ta, or a combination thereof, and the cation dopant is barium, yttrium, zinc, or a combination thereof, Li7-phase lithium garnet SSE material (e.g., cubic Li7La3Zr2O 12 and Li7Y3Zr2O 12 ), cation-doped Li7La3Zr2O 12 Li 5+2x La3, Ta 2-x O2, where x is 0.1~1, Li 6.8 (La 2.95 Ca 0.5 )(Zr 1.75 Nb 0.25 )O 12 (LLCZN), Li 6.4 Y3Zr 1.4 Ta 0.6 O 12 Li 6.5 La 2.5 Ba 0.5 GaZrO 12 Li6BaY2M 1 20 12 Li7Y3Zr2O 12 Li 6.75 BaLa2Nb 1.75 Zn 0.25 O 12 ,or Li 6.75BaLa2Ta 1.75 Zn 0.25 O 12 This includes lithium garnet composite materials (e.g., lithium garnet composites with a conductive carbon matrix or other materials). Other examples of lithium ion conductive SSE materials include 3mol% YSZ-doped Li 7.6 La3Zr 1.94 Y 0.06 O 12 or 8mol% YSZ doped Li 7.16 La3Zr 1.94 Y 0.06 O 12 This includes cubic garnet-type materials such as Li5La3Nb2O. 12 Li5La3Ta2O 12 Li7La3Zr2O 12 Li6La2SrNb2O12 Li6La2BaNb2O 12 Li6La2SrTa2O 12 Li6La2BaTa2O 12 Li7Y3Zr2O 12 Li 6.4 Y3Zr 1.4 Ta 0.6 O 12 Li 6.5 La 2.5 Ba 0.5 GaZrO 12 Li7Y3Zr2O 12 Li 6.75 BaLa2Nb 1.75 Zn 0.25 O 12 , or Li 6.75 BaLa2Ta 1.75 Zn 0.25 O 12 This includes, but is not limited to, the following. In some embodiments, the garnet material is, for example, Li 7-x La 3-y M 1 y Zr 2-Z M 2 Z O 12 Here, x is greater than 0 and less than 2, and M 1 It is selected from Ba, Ca, Y, and combinations thereof, M 2 It is selected from Nb, Ta, and combinations thereof. In some embodiments, the garnet material is Li 6.75 La3Zr 1.75 Ta 0.25 O 12 (LLZT), Li 6.75 La 2.75 Zr 1.75 Ca 0.25 Nb 0.25 O 12 (LLZCN), Li5La3Nb2O 12 (LLZNO), Li7La3Zr2O 12 (LLZ), Li5La3Ta2O 12 Li6La2SrNb2O 12 Li6La2BaNb2O 12 Li6La2SrTa2O12 Li6La2BaTa2O 12 Li7Y3Zr2O 12 Li 6.4 Y3Zr 1.4 Ta 0.6 O 12 Li 6.5 La 2.5 Ba 0.5 GaZrO 12 Li6BaY2M 1 20 12 Li 6.75 BaLa2Nb 1.75 Zn 0.25 O 12 Li 6.75 BaLa2Ta 1.75 Zn 0.25 O 12 , or any combination thereof.

[0112] In some embodiments, the garnet material comprises a composition of formula (I). M1 7-x D1 a M2 3-y D2 b M3 2-z D3 c O 12-w D4 d (I) comprises the composition, During the ceremony, M1 is Li, M2 is La, M3 is Zr, D1 is H, Be, B, Al, Fe, Zn, Ga, Ge, or any combination thereof. D2 is Na, K, Ca, Rb, Sr, Y, Ag, Ba, Bi, Pr, Nd, Pm, Sm, Gd, Tb, Dy, Ho, Er, Tm, Zn, Ce, or any combination thereof. D3 is Mg, Si, Sc, Ti, V, Cr, Mn, Co, Ni, Cu, Ge, As, Se, Nb, Mo, Tc, Ru, Rh, Pd, Cd, In, Sn, Sb, Hf, Ta, W, Ir, Pt, Au, Hg, Tl, Pb, Ce, Eu, Te, Y, Sr, Ca, Ba, Gd, Ge, or any combination thereof, and D4 is F, Cl, Br, I, S, Se, Te, N, P, or any combination thereof. however, 0 ≤ w ≤ 2, -0.5 <x≦3、 0≦y≦3, 0≦z≦2, 0 ≤ a ≤ 2, 0 ≤ b ≤ 3, 0 ≤ c ≤ 2, and, 0 ≤ d ≤ 2, Here, at least one of a, b, c, and d is greater than 0.

[0113] In some embodiments, the anode layer further comprises an anode material disposed in at least a portion of the pores of the anode layer. In some embodiments, the anode material comprises a lithium-containing material, a magnesium-containing material, a sodium-containing material, or any combination thereof. In other embodiments, the anode material comprises a lithium metal, a sodium metal, a magnesium metal, or any combination thereof. In some embodiments, the anode material comprises a lithium metal. In other embodiments, the anode material comprises a sodium metal. Also, in some embodiments, the anode material comprises a magnesium metal.

[0114] In some embodiments, the pores of the anode layer are substantially free of anode material (e.g., the pores contain less than 1%, less than 0.5%, less than 0.25%, less than 0.1%, less than 0.01%, or less than 0.001% of the pore volume). In the context of this disclosure, when it is referred to that the pores of the anode layer are "substantially free" or "absent" of anode material, it will be understood that the pores of the anode layer are substantially free of anode material before the operation of the battery cell, i.e., immediately after the manufacture of the battery cell and before the operation of the battery cell (e.g., charging / discharging the battery cell). In some embodiments, the pores of the anode layer are substantially free of lithium metal, sodium metal, magnesium metal, or any combination thereof. In other embodiments, the pores of the anode layer are substantially free of lithium metal, sodium metal, magnesium metal, or any combination thereof. In some embodiments, the pores of the anode layer are substantially free of lithium metal. Also, in some embodiments, the pores of the anode layer are free of lithium metal.

[0115] As shown in Figure 4A, in some embodiments, the anode layer 404 defines a first porous region 422 and a second porous region 424. The first porous region 422 is defined between the center 426 and the outer surface of the anode layer. The second porous region is defined between the first porous region and the outer surface of the anode layer.

[0116] Referring to Figures 3D and 3E, the anode layer may define recesses 328d, 328e. The recesses 328d, 328e of the anode layer 304d, 304e may be defined on the first surface 314d, 314e, the second surface 316d, and / or the outer surface 318d, 318e of the anode layer. For example, the recess may be cut out around the anode layer defined by the first surface, the second surface, and / or the outer surface, or a portion thereof, as shown in Figures 3D and 3E. In some embodiments, as shown in Figure 3E, the first surface 314e, the second surface 316e, and the outer surface 318e of the anode layer define the recess 328e. In other embodiments, only the outer surface defines the recess. In some embodiments, only the second surface defines the recess. In some embodiments, only the first surface defines the recess. Also, in some embodiments, only the outer surface defines the recess.

[0117] In some embodiments, the anode layer has a thickness of approximately 1 μm to approximately 500 μm. In some embodiments, the anode layer has a thickness of approximately 1 μm to approximately 200 μm. In other embodiments, the anode layer has a thickness of approximately 1 μm to approximately 100 μm. In some embodiments, the anode layer has a thickness of approximately 1 μm to approximately 50 μm. Also, in some embodiments, the anode layer has a thickness of approximately 1 μm to approximately 20 μm.

[0118] C. Anode current collector

[0119] In some embodiments, referring to Figure 2A, the anode assembly 200 further comprises an anode current collector 230, an anode layer 204 (i.e., an anode layer having a first surface 214 facing the separator layer and a second surface 216 away from the separator layer 202), and a separator layer 202 (i.e., a separator layer having a front surface 206 facing the anode layer 204, a back surface 208 away from the anode layer 204, and an outer surface 210 extending from the front surface 206 to the back surface 208). The anode current collector 230 is coupled to the anode layer 204 (i.e., the second surface 216 of the anode layer). In some embodiments, the anode current collector 230 has an internal surface 232 facing the anode layer 204, an external surface 234 with its back to the anode layer 204, and an outer surface 236 extending from the internal surface 232 to the external surface 234.

[0120] In some embodiments, the anode current collector 230 is positioned at least partially on the second surface 216 of the anode layer. In some embodiments, the anode current collector 230 is positioned over the entire second surface 216 of the anode layer. In other embodiments, the anode current collector 230 is positioned over substantially the entire second surface 216 of the anode layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). In yet another embodiment, the anode current collector 230 is positioned over only a portion of the second surface of the anode layer 204.

[0121] In some embodiments, the anode current collector 230 includes a metal foil 238, as shown in Figure 2B. In such embodiments, the metal foil 238 is at least partially placed on the second surface 216 of the anode layer 204. In some embodiments, the metal foil is placed over the entire second surface 216 of the anode layer 204. In other embodiments, the metal foil is placed over substantially the entire second surface of the anode layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). In yet another embodiment, the metal foil is placed over only a portion of the second surface 216 of the anode layer 204.

[0122] In some embodiments, the metal foil 238 has tabs 240 configured to connect to an external circuit, as shown in Figure 2B. In the illustrated embodiment, the tabs are integrated with the metal foil. In other embodiments, the tabs are bonded to the metal foil (e.g., welded).

[0123] In some embodiments, the anode current collector includes a tab configured to connect to an external circuit. In such embodiments, the anode current collector may include only the tab and not a metal foil. For example, the anode current collector includes a tab, which may be coupled to a seal (for example, located within the seal).

[0124] The anode current collector may be made of any suitable material. In some embodiments, the anode current collector (e.g., metal foil and / or tab) includes copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof. In some embodiments, the anode current collector includes copper. In other embodiments, the anode current collector includes a copper alloy. In some embodiments, the anode current collector includes nickel. In other embodiments, the anode current collector includes a nickel alloy. In some embodiments, the anode current collector includes titanium. In some embodiments, the anode current collector includes a titanium alloy. In some embodiments, the anode current collector includes stainless steel. Also, in some embodiments, the anode current collector includes a stainless steel alloy.

[0125] In some embodiments, the anode current collector includes a conductive film. For example, the conductive film may include a polymer material and a conductive material. For example, the conductive material may be a metallic material. In some embodiments, the conductive material includes copper, nickel, titanium, stainless steel, alloys thereof, or any combination thereof. In some embodiments, the polymer includes polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof.

[0126] In some embodiments, a conductive tape is used to couple the anode current collector to the anode layer. During the operation of the battery cell (e.g., during charging and / or discharging), the conductive tape can electrically couple the anode current collector to the anode layer.

[0127] D. Barrier

[0128] In some embodiments, the anode assembly further comprises a barrier. The barrier is located outside the anode layer. The barrier defines the interior and exterior. The anode layer is located inside the barrier. The barrier is impermeable to liquids and gases. Also, the absolute pressure P inside the barrier int This is the absolute pressure P outside the barrier. ext Smaller than. If only a single barrier exists, P 細孔 is the P of the barrier int It will be understood that this is essentially the same thing.

[0129] In some embodiments, the P of the barrier intThe pressure is less than approximately 101,325 Pa. For example, the pressure of the barrier is less than 101,325 Pa. int The pressure can be approximately 1 Pa to approximately 101,324 Pa. In some embodiments, the P of the barrier int The pressure is approximately 100 Pa to approximately 1,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 100 Pa to approximately 200 Pa. In other embodiments, the P of the barrier int The pressure is approximately 200 Pa to approximately 300 Pa. In some embodiments, the P of the barrier int The pressure is approximately 300 Pa to approximately 400 Pa. In some embodiments, the P of the barrier int The pressure is approximately 400 Pa to approximately 500 Pa. In other embodiments, the P of the barrier int The pressure is approximately 500 Pa to approximately 600 Pa. In some embodiments, the P of the barrier int The pressure is approximately 600 Pa to approximately 700 Pa. In other embodiments, the P of the barrier int The pressure is approximately 700 Pa to approximately 800 Pa. In some embodiments, the P of the barrier int The pressure is approximately 800 Pa to approximately 900 Pa. In some embodiments, the P of the barrier int The pressure is approximately 900 Pa to approximately 1,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 100 Pa to approximately 500 Pa. In some embodiments, the P of the barrier int The pressure is approximately 500 Pa to approximately 1,000 Pa. In addition, in some embodiments, the P of the barrier int The pressure range is approximately 250 Pa to 750 Pa.

[0130] In some embodiments, the P of the barrier int The pressure is approximately 100 Pa to approximately 2,000 Pa. In other embodiments, the P of the barrier int The pressure is approximately 200 Pa to approximately 1,800 Pa. In some embodiments, the P of the barrier int The pressure is approximately 300 Pa to approximately 1,700 Pa. In some embodiments, the P of the barrier int The pressure is approximately 400 Pa to approximately 1,600 Pa. In some embodiments, the P of the barrier int The pressure is approximately 500 Pa to approximately 1,500 Pa. In other embodiments, the P of the barrier intThe pressure is approximately 600 Pa to approximately 1,400 Pa. In some embodiments, the P of the barrier int The pressure is approximately 700 Pa to approximately 1,300 Pa. In some embodiments, the P of the barrier int The pressure is approximately 750 Pa to approximately 1,250 Pa. In other embodiments, the P of the barrier int The pressure is approximately 800 Pa to approximately 1,200 Pa. In some embodiments, the P of the barrier int The pressure is approximately 850 Pa to approximately 1,150 Pa. In other embodiments, the P of the barrier intは It is approximately 900 Pa to approximately 1,100 Pa. Also, in some embodiments, the P of the barrier int It is approximately 1,000 Pa.

[0131] In some embodiments, the P of the barrier int The pressure is approximately 1,000 Pa to 10,000 Pa. For example, the pressure of a barrier int The pressure is approximately 1,000 Pa to approximately 2,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 2,000 Pa to approximately 3,000 Pa. In other embodiments, the P of the barrier int The pressure is approximately 3,000 Pa to approximately 4,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 4,000 Pa to approximately 5,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 5,000 Pa to approximately 6,000 Pa. In other embodiments, the P of the barrier int The pressure is approximately 6,000 Pa to approximately 7,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 7,000 Pa to approximately 8,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 8,000 Pa to approximately 9,000 Pa. In other embodiments, the P of the barrier int The pressure is approximately 9,000 Pa to approximately 10,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 1,000 Pa to approximately 5,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 5,000 Pa to approximately 10,000 Pa. In addition, in some embodiments, the P of the barrier intThe pressure range is approximately 2,500 Pa to 7,500 Pa.

[0132] In some embodiments, the P of the barrier int The pressure ranges from approximately 10,000 Pa to approximately 101,324 Pa. For example, the pressure of a barrier int The pressure may be approximately 10,000 Pa to approximately 20,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 20,000 Pa to approximately 30,000 Pa. In other embodiments, the P of the barrier int The pressure is approximately 30,000 Pa to approximately 40,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 40,000 Pa to approximately 50,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 50,000 Pa to approximately 60,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 60,000 Pa to approximately 70,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 70,000 Pa to approximately 80,000 Pa. In other embodiments, the P of the barrier int The pressure is approximately 80,000 Pa to approximately 90,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 90,000 Pa to approximately 100,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 10,000 Pa to approximately 50,000 Pa. In some embodiments, the P of the barrier int The pressure is approximately 50,000 Pa to approximately 100,000 Pa. In addition, in some embodiments, the P of the barrier int The pressure range is approximately 25,000 Pa to 75,000 Pa.

[0133] In some embodiments, the P of the barrier int The pressure ranges from approximately 0.1 Pa to approximately 100 Pa. For example, the pressure of a barrier int The pressure may be approximately 1 Pa to approximately 10 Pa. In some embodiments, the P of the barrier int The pressure is approximately 10 Pa to approximately 20 Pa. In other embodiments, the P of the barrier int The pressure is approximately 20 Pa to approximately 30 Pa. In some embodiments, the P of the barrierint The pressure is approximately 30 Pa to approximately 40 Pa. In other embodiments, the P of the barrier int The pressure is approximately 40 Pa to approximately 50 Pa. In some embodiments, the P of the barrier int The pressure is approximately 50 Pa to approximately 60 Pa. In some embodiments, the P of the barrier int The pressure is approximately 60 Pa to approximately 70 Pa. In some embodiments, the P of the barrier int The pressure is approximately 70 Pa to approximately 80 Pa. In other embodiments, the P of the barrier int The pressure is approximately 80 Pa to approximately 90 Pa. In some embodiments, the P of the barrier int The pressure is approximately 90 Pa to approximately 100 Pa. In some embodiments, the P of the barrier int The pressure is approximately 1 Pa to approximately 50 Pa. In other embodiments, the P of the barrier int The pressure is approximately 50 Pa to approximately 100 Pa. In some embodiments, the P of the barrier int The pressure is approximately 25 Pa to approximately 75 Pa. In addition, in some embodiments, the P of the barrier int The pressure is less than approximately 1 Pa.

[0134] In some embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 100 Pa to approximately 100,000 Pa. For example, the P of the barrier int and P ext The pressure difference between the two may be approximately 1,000 Pa to approximately 100,000 Pa. In some embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 10,000 Pa to approximately 100,000 Pa. In some embodiments, the P of the barrier int and P ext The pressure difference between them is greater than approximately 100,000 Pa (for example, approximately 100,000 to approximately 150,000 Pa).

[0135] In some embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 10,000 Pa to approximately 20,000 Pa. In other embodiments, the P of the barrier int and P extThe pressure difference between them is approximately 20,000 Pa to approximately 30,000 Pa. In some embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 30,000 Pa to approximately 40,000 Pa. In other embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 40,000 Pa to approximately 50,000 Pa. In some embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 50,000 Pa to approximately 60,000 Pa. In other embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 60,000 Pa to approximately 70,000 Pa. In some embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 70,000 Pa to approximately 80,000 Pa. In some embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 80,000 Pa to approximately 90,000 Pa. In other embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 90,000 Pa to approximately 100,000 Pa. In some embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 10,000 Pa to approximately 50,000 Pa. In some embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 50,000 Pa to approximately 100,000 Pa. In some embodiments, the P of the barrier int and P ext The pressure difference between them is approximately 25,000 Pa to approximately 75,000 Pa.

[0136] In some embodiments, the barrier is a seal as described herein. In other embodiments, the barrier is a housing as described herein. When the anode assembly includes both a seal and a housing, it will be understood that at least one of the seal and the housing is impermeable to liquids and gases (i.e., the barrier is at least one of the seal and the housing). For example, in some embodiments, the seal is substantially impermeable to liquids and impermeable to gases, and the housing is impermeable to both liquids and gases (i.e., the barrier is the housing). In other embodiments, the seal is impermeable to both liquids and gases, and the housing is substantially impermeable to liquids and permeable to gases (i.e., the barrier is the seal).

[0137] In some embodiments, the seal and housing are each barriers (i.e., the seal and housing are each impermeable to liquids and gases). In such embodiments, P 細孔 P of the inner barrier (i.e., a barrier placed inside another barrier) int It will be understood that this is substantially the same. Furthermore, in such embodiments, the P of the inner barrier int P of the outer barrier ext It will be understood that it is smaller than. Furthermore, in such embodiments, the P of the inner barrier int P of the outer barrier int It may be less than, equal to, or greater than.

[0138] I don't want to be constrained by theory, but any battery cell including the anode layer must be able to operate before it is blocked by a barrier. Pint However, therefore P 細孔 P ext It is considered certain that the pressure will remain below a certain level. Furthermore, the anode layer is plated with anode material during the operation of the battery cell, which leads to an increase in pressure within the anode layer. The lower initial absolute pressure within the barrier prevents the barrier from failing (e.g., rupturing) as a result of the pressure increase.

[0139] 1. Sticker

[0140] Referring to Figure 2A, in some embodiments, the barrier of the anode assembly 200 is a seal 242. The seal is positioned around the outer surface 218 of the anode layer 204 and, together with the inner surface 232 and front surface 206 of the separator layer 202, defines the internal space 244 and the external space 246. The seal comprises a sealant material known to those skilled in the art. The anode layer is positioned in the internal space 244.

[0141] When the barrier is a seal, the seal is generally impermeable to liquids and gases. However, when the anode assembly includes a seal and the barrier is something other than a seal (e.g., a housing), it will be understood that the seal may be impermeable to liquids but permeable to gases. In some embodiments, the absolute pressure P inside the internal space 244 int This refers to the absolute pressure P outside the seal, such as in space 246. ext Smaller than. If a seal exists and the seal is impermeable to liquids and gases, then P 細孔 P of seal 242 int It will be understood that this is essentially the same thing.

[0142] In some embodiments, the internal space 244 P int It is less than approximately 101,325 Pa. For example, P int The pressure can be approximately 1 Pa to approximately 101,324 Pa. In some embodiments, P int The pressure is approximately 100 Pa to approximately 1,000 Pa. In some embodiments, P int The pressure is approximately 100 Pa to approximately 200 Pa. In other embodiments, P int The pressure is approximately 200 Pa to approximately 300 Pa. In some embodiments, P int The pressure is approximately 300 Pa to approximately 400 Pa. In some embodiments, P int The pressure is approximately 400 Pa to approximately 500 Pa. In other embodiments, P intThe pressure is approximately 500 Pa to approximately 600 Pa. In some embodiments, P int The pressure is approximately 600 Pa to approximately 700 Pa. In other embodiments, P int The pressure is approximately 700 Pa to approximately 800 Pa. In some embodiments, P int The pressure is approximately 800 Pa to approximately 900 Pa. In some embodiments, P int The pressure is approximately 900 Pa to approximately 1,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 100 Pa to approximately 500 Pa. In some embodiments, the P of the seal int The pressure is approximately 500 Pa to approximately 1,000 Pa. In addition, in some embodiments, the P of the seal int The pressure range is approximately 250 Pa to 750 Pa.

[0143] In some embodiments, the seal P int The pressure is approximately 100 Pa to approximately 2,000 Pa. In other embodiments, the P of the seal int The pressure is approximately 200 Pa to approximately 1,800 Pa. In some embodiments, the P of the seal int The pressure is approximately 300 Pa to approximately 1,700 Pa. In some embodiments, the P of the seal int The pressure is approximately 400 Pa to approximately 1,600 Pa. In some embodiments, the P of the seal int The pressure is approximately 500 Pa to approximately 1,500 Pa. In other embodiments, the P of the seal int The pressure is approximately 600 Pa to approximately 1,400 Pa. In some embodiments, the P of the seal int The pressure is approximately 700 Pa to approximately 1,300 Pa. In some embodiments, the P of the seal int The pressure is approximately 750 Pa to approximately 1,250 Pa. In other embodiments, the P of the seal int The pressure is approximately 800 Pa to approximately 1,200 Pa. In some embodiments, the P of the seal int The pressure is approximately 850 Pa to approximately 1,150 Pa. In other embodiments, the P of the seal int The pressure is approximately 900 Pa to approximately 1,100 Pa. In addition, in some embodiments, the P of the seal int It is approximately 1,000 Pa.

[0144] In some embodiments, the seal P int The pressure is approximately 1,000 Pa to 10,000 Pa. For example, the pressure of a seal. int The pressure may be approximately 1,000 Pa to approximately 2,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 2,000 Pa to approximately 3,000 Pa. In other embodiments, the P of the seal int The pressure is approximately 3,000 Pa to approximately 4,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 4,000 Pa to approximately 5,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 5,000 Pa to approximately 6,000 Pa. In other embodiments, the P of the seal int The pressure is approximately 6,000 Pa to approximately 7,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 7,000 Pa to approximately 8,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 8,000 Pa to approximately 9,000 Pa. In other embodiments, the P of the seal int The pressure is approximately 9,000 Pa to approximately 10,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 1,000 Pa to approximately 5,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 5,000 Pa to approximately 10,000 Pa. In addition, in some embodiments, the P of the seal int The pressure range is approximately 2,500 Pa to 7,500 Pa.

[0145] In some embodiments, the seal P int The pressure ranges from approximately 10,000 Pa to approximately 101,324 Pa. For example, the pressure of a seal. int The pressure is approximately 10,000 Pa to approximately 20,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 20,000 Pa to approximately 30,000 Pa. In other embodiments, the P of the seal int The pressure is approximately 30,000 Pa to approximately 40,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 40,000 Pa to approximately 50,000 Pa. In some embodiments, the P of the sealint The pressure is approximately 50,000 Pa to approximately 60,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 60,000 Pa to approximately 70,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 70,000 Pa to approximately 80,000 Pa. In other embodiments, the P of the seal int The pressure is approximately 80,000 Pa to approximately 90,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 90,000 Pa to approximately 100,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 10,000 Pa to approximately 50,000 Pa. In some embodiments, the P of the seal int The pressure is approximately 50,000 Pa to approximately 100,000 Pa. In addition, in some embodiments, the P of the seal int The pressure range is approximately 25,000 Pa to 75,000 Pa.

[0146] In some embodiments, the seal P int The pressure ranges from approximately 0.1 Pa to approximately 100 Pa. For example, the pressure of a seal. int The pressure may be approximately 1 Pa to approximately 10 Pa. In some embodiments, the seal pressure is P int The pressure is approximately 10 Pa to approximately 20 Pa. In other embodiments, the P of the seal int The pressure is approximately 20 Pa to approximately 30 Pa. In some embodiments, the P of the seal int The pressure is approximately 30 Pa to approximately 40 Pa. In other embodiments, the P of the seal int The pressure is approximately 40 Pa to approximately 50 Pa. In some embodiments, the seal P int The pressure is approximately 50 Pa to approximately 60 Pa. In some embodiments, the P of the seal int The pressure is approximately 60 Pa to approximately 70 Pa. In some embodiments, the P of the seal int The pressure is approximately 70 Pa to approximately 80 Pa. In other embodiments, the P of the seal int The pressure is approximately 80 Pa to approximately 90 Pa. In some embodiments, the P of the seal int The pressure is approximately 90 Pa to approximately 100 Pa. In some embodiments, the seal P intThe pressure is approximately 1 Pa to approximately 50 Pa. In other embodiments, the P of the seal int The pressure is approximately 50 Pa to approximately 100 Pa. In some embodiments, the P of the seal int The pressure is approximately 25 Pa to approximately 75 Pa. In addition, in some embodiments, the P of the seal int The pressure is less than approximately 1 Pa.

[0147] In some embodiments, the seal P int and P ext The pressure difference between them is approximately 100 Pa to approximately 100,000 Pa. For example, the P of the seal int and P ext The pressure difference between them may be about 1,000 Pa to about 100,000 Pa. In some embodiments, the seal P int and P ext The pressure difference between them is approximately 10,000 Pa to approximately 100,000 Pa. Also, in some embodiments, the seal P int and P ext The pressure difference between them is greater than approximately 100,000 Pa (for example, approximately 100,000 to approximately 150,000 Pa).

[0148] In some embodiments, the seal P int and P ext The pressure difference between them is approximately 10,000 Pa to approximately 20,000 Pa. In other embodiments, the seal P int and P ext The pressure difference between them is approximately 20,000 Pa to approximately 30,000 Pa. In some embodiments, the seal P int and P ext The pressure difference between them is approximately 30,000 Pa to approximately 40,000 Pa. In other embodiments, the seal P int and P ext The pressure difference between them is approximately 40,000 Pa to approximately 50,000 Pa. In some embodiments, the seal P int and P ext The pressure difference between them is approximately 50,000 Pa to approximately 60,000 Pa. In other embodiments, the seal P int and P extThe pressure difference between them is approximately 60,000 Pa to approximately 70,000 Pa. In some embodiments, the seal P int and P ext The pressure difference between them is approximately 70,000 Pa to approximately 80,000 Pa. In some embodiments, the seal P int and P ext The pressure difference between them is approximately 80,000 Pa to approximately 90,000 Pa. In other embodiments, the seal P int and P ext The pressure difference between them is approximately 90,000 Pa to approximately 100,000 Pa. In some embodiments, the seal P int and P ext The pressure difference between them is approximately 10,000 Pa to approximately 50,000 Pa. In some embodiments, the seal P int and P ext The pressure difference between them is approximately 50,000 Pa to approximately 100,000 Pa. Also, in some embodiments, the seal P int and P ext The pressure difference between them is approximately 25,000 Pa to approximately 75,000 Pa.

[0149] Referring to Figures 3A-3E, in some embodiments, the anode assembly 300 includes an anode current collector 330, an anode layer 304, a separator layer 302, and a seal 342. In some embodiments, the seals 242, 342 are at least partially located on the outer surface of the anode layer 304. In some embodiments, the seals 242, 342 are located on the entire outer surface 218, 318d, 318e of the anode layers 204, 304, 304b, 304c, 304d, 304e, as shown in Figures 2A and 3A-3E. In other embodiments, the seals 242, 342 are located on substantially the entire outer surface 218, 318d, 318e of the anode layers 204, 304, 304b, 304c, 304d, 304e (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). In another embodiment, the seal 542 is positioned only on a portion of the outer surface 518 of the anode layer 504, as shown in Figure 5A.

[0150] In some embodiments, the separator layer 302 is located inside the seal. In other embodiments, the anode current collector is located inside the seal. Also, in some embodiments, both the separator layer and the anode current collector are located inside the seal.

[0151] In some embodiments, when the anode layer defines first and second porous regions, the pores of the first porous region are substantially free of sealant material (for example, the pores contain less than 1%, less than 0.5%, less than 0.25%, less than 0.1%, less than 0.01%, or less than 0.001% of the sealant material relative to the volume of the pores). In other embodiments, the pores of the first porous region are free of sealant material.

[0152] In some embodiments, as shown in Figure 4A, at least a portion of the pores in the second porous region contain a sealant material.

[0153] Referring to Figures 3A-3E, if the anode layers 304b, 304c, 304d, and 304e define recesses, for example, 328d and 328e, the seals 342d and 342e may be positioned within the recesses 328d and 328e, as respectfully shown in Figures 3D and 3E. If the separator layers 302b and 302c define recesses 312b and 312c, the seals 342b and 342c may be positioned within the recesses 312b and 312c, as shown in Figures 3B and 3C. While we do not wish to be constrained by theory, it is conceivable that the recesses 328d and 328e of the anode layers 304d and 304e and / or separator layers 312b and 312c increase the surface area to which the seals 342 bond compared to the bonding surfaces of the anode layers and / or separator layers without recesses.

[0154] In some embodiments, the seals 342, 642, and 742 are at least partially located on the separator layers 302, 602, and 702, as shown in Figures 3A, 6A, and 7A, respectively. In some embodiments, the seals 342, 642, and 742 are at least partially located on the outer surface 314 of the separator layers 302, 602, and 702. In some embodiments, the seals 342, 642, and 742 are located on the entire outer surface of the separator layers 302, 602, and 702, as shown in Figures 6A and 7A. In other embodiments, the seals 302, 602, and 702 are located on substantially the entire outer surface of the separator layers 302, 602, and 702 (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). Also in some embodiments, the seals 342, 642, and 742 are located on only a portion of the outer surface of the separator layers.

[0155] In some embodiments, the seals 342, 642, and 742 are located at least partially on the back surfaces of the separator layers 302, 602, and 702. In other embodiments, the seals 342, 642, and 742 are located on substantially the entire back surface of the separator layers 302, 602, and 702 (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). In yet another embodiment, the seals 342, 642, and 742 are located on only a portion of the back surface of the separator layers 302, 602, and 702, as shown in Figures 3A, 6A, and 7A.

[0156] In some embodiments, seals 342, 642, and 742 are positioned at least partially on the front surface of the separator layers. In other embodiments, seals 342, 642, and 742 are positioned over substantially the entire front surface of the separator layers 302, 602, and 702 (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). In yet another embodiment, seal 342e is positioned over only a portion of the front surface of the separator layers 302, 602, and 702, as shown in Figure 3E.

[0157] In some embodiments, the seals 642 and 742 are located at least partially on the outer and back surfaces of the separator layers 602 and 702, as shown in Figures 6A and 7A. In the illustrated embodiments, the seals 642 and 742 are located only on the entire outer surface and a portion of the back surface of the separator layer. In other embodiments, the seal 342e is located at least partially on the outer surface 318e, front surface, and back surface of the separator layer, as shown in Figure 3E. As shown, the seal 342e is located on the entire outer surface 342e of the separator layer, as well as a portion of the front and back surfaces.

[0158] In other embodiments, as shown in Figures 2A and 2B, for example, there are no seals in the separator layer. In other words, no seals are located on any surface of the separator layer (e.g., the front, back, and / or outer surface).

[0159] In some embodiments, seals 242, 642, and 742 are at least partially located on the anode current collectors 230, 530, and 630, as shown in Figures 2A, 5A, and 6A. In some embodiments, seals 242, 642, and 742 are at least partially located on the outer surfaces of the anode current collectors 230, 530, and 630. In some embodiments, seal 542 is located on the entire outer surface of the anode current collector, as shown in Figure 5A. In other embodiments, the seals are located on substantially the entire outer surface of the anode current collector (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). Also in some embodiments, the seals are located on only a portion of the outer surface of the anode current collector.

[0160] In some embodiments, the seal is located at least partially on the inner surface of the anode current collector. In other embodiments, the seal is located on substantially the entire inner surface of the anode current collector (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). In yet another embodiment, the seals 242, 742 are located on only a portion of the inner surface of the anode current collector, as shown in Figures 2A and 7A.

[0161] In some embodiments, as shown in Figures 8A and 8C, the seals 842, 842' are positioned at least partially on the outer surface 834 of the anode current collector 830. In some embodiments, the seals 842, 842' are positioned over the entire outer surface 834 of the anode current collector. In other embodiments, the seals 842, 842' are positioned over substantially the entire outer surface 834 of the anode current collector 830 (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). In yet another embodiment, the seals 842, 842' are positioned over only a portion of the outer surface of the anode current collector.

[0162] In some embodiments, the seals 842, 842' are positioned at least partially on the outer surface and outer surface 834 of the anode current collector 830, as shown in Figures 8A and 8C. In the illustrated embodiments, the seals 842, 842' are positioned across the entire outer surface 834 and outer surface 836 of the anode current collector 830.

[0163] In other embodiments, as shown in Figure 5A, for example, the anode current collector 530 does not have a seal 542. In other words, the seal 542 is not located on any surface of the anode current collector 530 (e.g., the internal surface, the external surface, and / or the outer surface).

[0164] In some embodiments, as shown in Figure 6A, the seal 642 is at least partially positioned on the outer surface of the anode layer 604, the outer surface of the separator layer 602, and the outer surface of the anode current collector 630. In other embodiments, as shown in Figures 8A and 8C, the seals 842, 842' are at least partially positioned on the outer surface of the anode layer, the outer surface of the separator layer, the outer surface of the anode current collector 830, and the outer surface of the anode current collector 830. Also in some embodiments, the seal 742 is at least partially positioned on the outer surface of the anode layer 704, the outer surface of the separator layer, and the inner surface of the anode current collector 730, as shown in Figure 7A.

[0165] Referring to Figure 4A, the seal 442 may be at least partially located on the outer surface of the anode layer and within the pores of the second porous region of the anode layer. In embodiments where the seal is located within the pores of the anode layer (e.g., a portion of the pores of the second porous region), the seal can also restrict the flow of the anodic active material (e.g., lithium metal) to the outside of the anode layer.

[0166] The sealant material can be any material suitable for restricting the inflow or outflow of liquid and / or gas to the anode pole layer. In some embodiments, the sealant material includes a non-conductive (e.g., non-ionic and non-electron conductor) polymer, a non-conductive (e.g., non-ionic and non-electron conductor) glass, or any combination thereof. In other embodiments, the sealant material includes a non-conductive polymer. In some embodiments, the sealant material includes a non-conductive glass. For example, the sealant material may be a glass with a low coefficient of thermal expansion (CTE). As another example, the sealant material may be a glass ceramic.

[0167] In some embodiments, the sealant material includes polypropylene, polyethylene, polyimide, polyvinyl chloride (PVC), ethylene-vinyl acetate, polyamide, polypropylene, polyurethane, copolymers thereof, or any combination thereof. For example, the sealant material may include polypropylene. In some embodiments, the sealant material includes polyethylene. In other embodiments, the sealant material includes polyimide. In some embodiments, the sealant material includes PVC. In some embodiments, the sealant material includes ethylene-vinyl acetate. In other embodiments, the sealant material includes polyamide. In some embodiments, the sealant material includes polypropylene. Also, in some embodiments, the sealant material includes polyurethane.

[0168] In some embodiments, the sealant material includes polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof. In some embodiments, the sealant material includes polypropylene. In some embodiments, the sealant material includes polyethylene. In other embodiments, the sealant material includes polymethylpentene. In some embodiments, the sealant material includes polybutene-1. In some embodiments, the sealant material includes ethylene-octene copolymer. In some embodiments, the sealant material includes propylene-butane copolymer. In some embodiments, the sealant material includes polyisobutylene. In some embodiments, the sealant material includes poly(α-olefin). In some embodiments, the sealant material comprises ethylene propylene rubber. In other embodiments, the sealant material comprises ethylene propylene diene monomer rubber. In some embodiments, the sealant material comprises ethylene vinyl acetate. In some embodiments, the sealant material comprises ethylene acrylate copolymer. In other embodiments, the sealant material comprises polyamide. In some embodiments, the sealant material comprises polyester. In some embodiments, the sealant material comprises polyurethane. In some embodiments, the sealant material comprises styrene block copolymer. In some embodiments, the sealant material comprises polycaprolactone. In other embodiments, the sealant material comprises polyimide. In some embodiments, the sealant material comprises polyvinyl chloride. In some embodiments, the sealant material comprises polycarbonate. In some embodiments, the sealant material comprises polyacrylate.In some embodiments, the sealant material comprises polymethacrylate. In some embodiments, the sealant material comprises a fluoropolymer. In some embodiments, the sealant material comprises an epoxy resin. In other embodiments, the sealant material comprises an epoxy polymer. Also, in some embodiments, the sealant material comprises silicone rubber.

[0169] In some embodiments, the seal may include a conductive material. For example, the conductive material may be a metallic material. In some embodiments, the conductive material includes copper, aluminum, nickel, titanium, stainless steel, alloys thereof, or any combination thereof.

[0170] In some embodiments, at least a portion of the seal has a thickness of about 1 μm to about 50 μm. In some embodiments, at least a portion of the seal has a thickness of about 1 μm to about 20 μm. In other embodiments, at least a portion of the seal has a thickness of about 1 μm to about 10 μm. Also, in some embodiments, at least a portion of the seal has a thickness of about 1 μm to about 5 μm.

[0171] Naturally, it should be understood that the thickness of an anode assembly includes a dense layer (e.g., separator) with a thickness of 0-50 microns, a porous layer (e.g., anode layer) with a thickness of 0-100 microns, and seal or housing components with a thickness of 0-50 microns.

[0172] If the seal is located on the outer surface of the anode layer, it will be understood that the seal, separator layer, and / or anode current collector can work together to prevent the inflow of liquid and gas into or outflow from the anode layer.

[0173] 2. Housing

[0174] Referring to Figures 5A and 5B, in some embodiments the barrier is a housing 548, 548'. The housing has a plurality of inner walls 550, 550', which together with the housing 548, 548' define the interior 552, 552' and the exterior 553, 533'. Separator layers 502, 502', anode layers 504, 504', anode current collectors 530, 530', and seals 542 are located inside the housing 548, 548'.

[0175] When the barrier is a housing, the housing is impermeable to liquids and gases. However, when the anode assembly includes a housing and the barrier is something other than the housing (e.g., a seal), it will be understood that the housing may be substantially impermeable to liquids and permeable to gases. In some embodiments, the absolute pressure P inside the housing int This is the absolute pressure P on the outside of the housing. ext Smaller than. If a housing exists, and the barrier is in the housing (i.e., the housing is impermeable to liquids and gases), and there is no seal in the anode assembly, then P 細孔 P is housing int It will be understood that this is substantially the same. In other embodiments, when the anode assembly comprises a seal that is substantially impermeable to liquids and impermeable to gases, and the barrier is a housing (i.e., the housing is impermeable to liquids and gases), the P of the seal 細孔 and P int P of the housing int It will be understood that this is essentially the same thing.

[0176] Referring to Figure 5A, the seal 542 is located inside 552 of the housing 548. When the housing is impermeable to liquids and gases, the seal 542 may be substantially impermeable to liquids and precede gases. In such embodiments, P 細孔 P of the housing int It is essentially the same as this.

[0177] In other embodiments, the seal may be impermeable to liquids and impermeable to gases, P 細孔 This is substantially the same as the interior formed by the multiple walls and seals of the housing. In such embodiments, the housing and seals cooperate to form a barrier around the anode layer.

[0178] Referring to Figure 5B, if housing 548' is present, there may be no seal. In this embodiment, housing 548' is impermeable to liquid, and P 細孔 P of the housing int It is essentially the same as this.

[0179] In some embodiments, the P of the housing int The pressure is less than approximately 101,325 Pa. For example, the P of the housing int The pressure can be approximately 1 Pa to approximately 101,324 Pa. In some embodiments, the P of the housing int The pressure is approximately 100 Pa to approximately 1,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 100 Pa to approximately 200 Pa. In other embodiments, the P of the housing int The pressure is approximately 200 Pa to approximately 300 Pa. In some embodiments, the P of the housing int The pressure is approximately 300 Pa to approximately 400 Pa. In some embodiments, the P of the housing int The pressure is approximately 400 Pa to approximately 500 Pa. In other embodiments, the P of the housing int The pressure is approximately 500 Pa to approximately 600 Pa. In some embodiments, the P of the housing int The pressure is approximately 600 Pa to approximately 700 Pa. In other embodiments, the P of the housing int The pressure is approximately 700 Pa to approximately 800 Pa. In some embodiments, the P of the housing int The pressure is approximately 800 Pa to approximately 900 Pa. In some embodiments, the P of the housing int The pressure is approximately 900 Pa to approximately 1,000 Pa. In some embodiments, the P of the housing intThe pressure is approximately 100 Pa to approximately 500 Pa. In some embodiments, the P of the housing of the housing int The pressure is approximately 500 Pa to approximately 1,000 Pa. In addition, in some embodiments, the P of the housing int The pressure range is approximately 250 Pa to 750 Pa.

[0180] In some embodiments, the P of the housing int The pressure is approximately 100 Pa to approximately 2,000 Pa. In other embodiments, the P of the housing int The pressure is approximately 200 Pa to approximately 1,800 Pa. In some embodiments, the P of the housing int The pressure is approximately 300 Pa to approximately 1,700 Pa. In some embodiments, the P of the housing int The pressure is approximately 400 Pa to approximately 1,600 Pa. In some embodiments, the P of the housing int The pressure is approximately 500 Pa to approximately 1,500 Pa. In other embodiments, the P of the housing int The pressure is approximately 600 Pa to approximately 1,400 Pa. In some embodiments, the P of the housing int The pressure is approximately 700 Pa to approximately 1,300 Pa. In some embodiments, the P of the housing int The pressure is approximately 750 Pa to approximately 1,250 Pa. In other embodiments, the P of the housing int The pressure is approximately 800 Pa to approximately 1,200 Pa. In some embodiments, the P of the housing int The pressure is approximately 850 Pa to approximately 1,150 Pa. In other embodiments, the P of the housing int The pressure is approximately 900 Pa to approximately 1,100 Pa. In addition, in some embodiments, the P of the housing int It is approximately 1,000 Pa.

[0181] In some embodiments, the P of the housing int The pressure is approximately 1,000 Pa to 10,000 Pa. For example, the P of the housing int The Pa may be approximately 1,000 Pa to approximately 2,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 2,000 Pa to approximately 3,000 Pa. In other embodiments, the P of the housing intThe pressure is approximately 3,000 Pa to approximately 4,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 4,000 Pa to approximately 5,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 5,000 Pa to approximately 6,000 Pa. In other embodiments, the P of the housing int The pressure is approximately 6,000 Pa to approximately 7,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 7,000 Pa to approximately 8,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 8,000 Pa to approximately 9,000 Pa. In other embodiments, the P of the housing int The pressure is approximately 9,000 Pa to approximately 10,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 1,000 Pa to approximately 5,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 5,000 Pa to approximately 10,000 Pa. In addition, in some embodiments, the P of the housing int The pressure range is approximately 2,500 Pa to 7,500 Pa.

[0182] In some embodiments, the P of the housing int The pressure ranges from approximately 10,000 Pa to approximately 101,324 Pa. For example, the P pressure of the housing... int The pressure is approximately 10,000 Pa to approximately 20,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 20,000 Pa to approximately 30,000 Pa. In other embodiments, the P of the housing int The pressure is approximately 30,000 Pa to approximately 40,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 40,000 Pa to approximately 50,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 50,000 Pa to approximately 60,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 60,000 Pa to approximately 70,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 70,000 Pa to approximately 80,000 Pa. In other embodiments, the P of the housingint The pressure is approximately 80,000 Pa to approximately 90,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 90,000 Pa to approximately 100,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 10,000 Pa to approximately 50,000 Pa. In some embodiments, the P of the housing int The pressure is approximately 50,000 Pa to approximately 100,000 Pa. In addition, in some embodiments, the P of the housing int The pressure range is approximately 25,000 Pa to 75,000 Pa.

[0183] In some embodiments, the P of the housing int The pressure ranges from approximately 0.1 Pa to approximately 100 Pa. For example, the P of the housing int The pressure may be approximately 1 Pa to approximately 10 Pa. In some embodiments, the P of the housing int The pressure is approximately 10 Pa to approximately 20 Pa. In other embodiments, the P of the housing int The pressure is approximately 20 Pa to approximately 30 Pa. In some embodiments, the P of the housing int The pressure is approximately 30 Pa to approximately 40 Pa. In other embodiments, the P of the housing int The pressure is approximately 40 Pa to approximately 50 Pa. In some embodiments, the P of the housing int The pressure is approximately 50 Pa to 60 Pa. In some embodiments, the P of the housing int The pressure is approximately 60 Pa to 70 Pa. In some embodiments, the P of the housing int The pressure is approximately 70 Pa to approximately 80 Pa. In other embodiments, the P of the housing int The pressure is approximately 80 Pa to approximately 90 Pa. In some embodiments, the P of the housing int The pressure is approximately 90 Pa to approximately 100 Pa. In some embodiments, the P of the housing int The pressure is approximately 1 Pa to approximately 50 Pa. In other embodiments, the P of the housing int The pressure is approximately 50 Pa to approximately 100 Pa. In some embodiments, the P of the housing int The pressure is approximately 25 Pa to approximately 75 Pa. In addition, in some embodiments, the P of the housing intThe pressure is less than approximately 1 Pa.

[0184] In some embodiments, the P of the housing int and P ext The pressure difference between them is approximately 100 Pa to approximately 100,000 Pa. For example, the P of the housing int and P ext The pressure difference between the two may be approximately 1,000 Pa to approximately 100,000 Pa. In some embodiments, the P of the housing int and P ext The pressure difference between them is approximately 10,000 Pa to approximately 100,000 Pa. Also, in some embodiments, the P of the housing int and P ext The pressure difference between them is greater than approximately 100,000 Pa (for example, approximately 100,000 to approximately 150,000 Pa).

[0185] In some embodiments, the P of the housing int and P ext The pressure difference between them is approximately 10,000 Pa to approximately 20,000 Pa. In other embodiments, the P of the housing int and P ext The pressure difference between them is approximately 20,000 Pa to approximately 30,000 Pa. In some embodiments, the P of the housing int and P ext The pressure difference between them is approximately 30,000 Pa to approximately 40,000 Pa. In other embodiments, the P of the housing int and P ext The pressure difference between them is approximately 40,000 Pa to approximately 50,000 Pa. In some embodiments, the P of the housing int and P ext The pressure difference between them is approximately 50,000 Pa to approximately 60,000 Pa. In other embodiments, the P of the housing int and P ext The pressure difference between them is approximately 60,000 Pa to approximately 70,000 Pa. In some embodiments, the P of the housing int and P ext The pressure difference between them is approximately 70,000 Pa to approximately 80,000 Pa. In some embodiments, the P of the housing in t and Pext The pressure difference between them is approximately 80,000 Pa to approximately 90,000 Pa. In other embodiments, the P of the housing int and P ext The pressure difference between them is approximately 90,000 Pa to approximately 100,000 Pa. In some embodiments, the P of the housing int and P ext The pressure difference between them is approximately 10,000 Pa to approximately 50,000 Pa. In some embodiments, the P of the housing int and P ext The pressure difference between them is approximately 50,000 Pa to approximately 100,000 Pa. Also, in some embodiments, the P of the housing int and P ext The pressure difference between them is approximately 25,000 Pa to approximately 75,000 Pa.

[0186] The housing may be made of any suitable material. For example, the housing material may include any sealant material described herein. In some embodiments, the housing includes a nonconductive (e.g., nonionic and nonelectronic conductive) polymer, a nonconductive (e.g., nonionic and nonelectronic conductive) glass, or any combination thereof. In other embodiments, the housing includes a nonconductive polymer. In some embodiments, the housing includes nonconductive glass. For example, the housing may be glass having a low coefficient of thermal expansion (CTE). As another example, the housing may be glass ceramic.

[0187] In some embodiments, the housing includes polypropylene, polyethylene, polyimide, polyvinyl chloride (PVC), ethylene-vinyl acetate, polyamide, polypropylene, polyurethane, copolymers thereof, or any combination thereof. For example, the housing may include polypropylene. In some embodiments, the housing includes polyethylene. In other embodiments, the housing includes polyimide. In some embodiments, the housing includes PVC. In some embodiments, the housing includes ethylene-vinyl acetate. In other embodiments, the housing includes polyamide. In some embodiments, the housing includes polypropylene. Also, in some embodiments, the housing includes polyurethane.

[0188] In some embodiments, the housing includes polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof. In some embodiments, the housing includes polypropylene. In some embodiments, the housing includes polyethylene. In other embodiments, the housing includes polymethylpentene. In some embodiments, the housing includes polybutene-1. In some embodiments, the housing includes ethylene-octene copolymer. In some embodiments, the housing includes propylene-butane copolymer. In some embodiments, the housing includes polyisobutylene. In some embodiments, the housing includes poly(α-olefin). In some embodiments, the housing includes ethylene propylene rubber. In other embodiments, the housing comprises ethylene propylene diene monomer rubber. In some embodiments, the housing comprises ethylene vinyl acetate. In some embodiments, the housing comprises ethylene acrylate copolymer. In other embodiments, the housing comprises polyamide. In some embodiments, the housing comprises polyester. In some embodiments, the housing comprises polyurethane. In some embodiments, the housing comprises styrene block copolymer. In some embodiments, the housing comprises polycaprolactone. In other embodiments, the housing comprises polyimide. In some embodiments, the housing comprises polyvinyl chloride. In some embodiments, the housing comprises polycarbonate. In some embodiments, the housing comprises polyacrylate. In some embodiments, the housing comprises polymethacrylate. In some embodiments, the housing comprises a fluoropolymer.In some embodiments, the housing comprises an epoxy resin. In other embodiments, the housing comprises an epoxy polymer. Also, in some embodiments, the housing comprises silicone rubber.

[0189] In some embodiments, the housing may include a conductive material. For example, the conductive material may be a metallic material. In some embodiments, the conductive material includes copper, nickel, aluminum, titanium, stainless steel, alloys thereof, or any combination thereof.

[0190] In some embodiments, the anode assembly does not include any components that apply substantial mechanical force to one or more of the anode layer, separator layer, and anode current collector.

[0191] In another embodiment, the present invention provides an anode assembly for a battery cell. The anode assembly comprises a separator, an anode layer, and a barrier. The anode layer is at least partially disposed on the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer contains a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The barrier is disposed around the outer surface of the anode layer and defines the interior and exterior. The barrier is impermeable to liquids and gases. The anode layer is located inside the barrier. Also, the absolute pressure P inside the barrier int This is the absolute pressure P outside the barrier. ext It is smaller than that.

[0192] In some embodiments, the anode assembly does not include any components that apply substantial mechanical force to one or more of the anode layer, separator layer, and anode current collector.

[0193] In another embodiment, the present invention provides an anode assembly for a battery cell. The anode assembly comprises a separator, an anode layer, and a seal. The anode layer is at least partially disposed on the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The seal is disposed around the outer surface of the anode layer and defines the interior and exterior. The seal comprises a sealant material. The seal is substantially impermeable to liquids and gases. The anode layer is located inside the seal. Also, the absolute pressure P inside the seal int This is the absolute pressure P outside the seal. ext It is smaller than that.

[0194] In a further embodiment, the present invention provides an anode assembly for a battery cell. The anode assembly comprises a housing, a separator, and an anode layer. The housing comprises a plurality of inner walls defining the interior and exterior. The separator layer is located inside the housing. The anode layer is located inside the housing and is at least partially located on the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The housing is impermeable to liquids and gases. Also, the absolute pressure P inside the housing int This is the absolute pressure P outside the housing. ext It is smaller than that.

[0195] In some embodiments, the anode assembly does not include any components that apply substantial mechanical force to one or more of the anode layer, separator layer, and anode current collector.

[0196] In another embodiment, the present invention provides an anode assembly for a battery cell. The anode assembly comprises a separator layer, an anode layer, and an anode current collector. The anode layer is at least partially disposed on the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer contains a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The anode current collector is bonded to the second surface of the anode layer. Also, the absolute pressure P within the pores 細孔 P is the absolute pressure of the environment outside the anode layer. env It is smaller than that.

[0197] In some embodiments, the anode assembly does not include any components that apply substantial mechanical force to one or more of the anode layer, separator layer, and anode current collector.

[0198] In one embodiment, the present invention provides an anode assembly for a battery cell. The anode assembly includes a separator, an anode layer, an anode current collector, and a barrier. The anode layer is at least partially located on the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer contains a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The anode current collector is bonded to the second surface of the anode layer. The barrier is located around the outer surface of the anode layer and defines the interior and exterior. The barrier is impermeable to liquids and gases. The anode layer is located inside the barrier. Also, the absolute pressure P inside the barrier is int This is the absolute pressure P outside the barrier. ext It is smaller than that.

[0199] In yet another embodiment, the present invention provides an anode assembly for a battery cell. The anode assembly comprises a separator, an anode layer, an anode current collector, and a seal. The anode layer is at least partially disposed on the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer contains a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The anode current collector is bonded to the second surface of the anode layer. The seal is disposed around the outer surface of the anode layer and defines the interior and exterior. The seal contains a sealant material. The seal is substantially impermeable to liquids and gases. The anode layer is disposed inside the seal. Also, the absolute pressure P inside the seal int This is the absolute pressure P outside the seal. ext It is smaller than that.

[0200] In some embodiments, the anode assembly does not include any components that apply substantial mechanical force to one or more of the anode layer, separator layer, and anode current collector.

[0201] In a further embodiment, the present invention provides an anode assembly for a battery cell. The anode assembly comprises a housing, a separator, an anode layer, and an anode current collector. The housing comprises a plurality of inner walls defining the interior and exterior. The separator layer is located inside the housing. The anode layer is located inside the housing and is located at least partially on the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer contains a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The anode current collector is located inside the housing and is bonded to the second surface of the anode layer. The housing is impermeable to liquids and gases. Also, the absolute pressure P inside the housing int This is the absolute pressure P outside the housing. ext It is smaller than that.

[0202] In some embodiments, the anode assembly does not include any components that apply substantial mechanical force to one or more of the anode layer, separator layer, and anode current collector.

[0203] In another embodiment, the present invention provides an anode assembly for a battery cell. The anode assembly comprises a housing, a separator, an anode layer, and a seal. The housing comprises a plurality of inner walls defining the interior and exterior. The separator layer is located inside the housing. The anode layer is located inside the housing and is located at least partially on the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The seal is located inside the housing and is positioned around the outer surface of the anode layer. The seal defines the interior and exterior. The seal comprises a sealant material. The seal is substantially impermeable to liquids and gases. The anode layer is located inside the seal. Also, the absolute pressure P inside the seal int This is the absolute pressure P outside the seal. ext It is smaller than that.

[0204] In some embodiments, the anode assembly does not include any components that apply substantial mechanical force to one or more of the anode layer, separator layer, and anode current collector.

[0205] In a further embodiment, the present invention provides an anode assembly for a battery cell. The anode assembly comprises a housing, a separator, an anode layer, and a seal. The housing comprises a plurality of inner walls defining the interior. The separator layer is located inside the housing. The anode layer is located inside the housing and is located at least partially on the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The seal is located inside the housing and is positioned around the outer surface of the anode layer. The seal defines the interior and exterior. The seal comprises a sealant material. The seal is substantially impermeable to liquids but permeable to gases. The anode layer is located inside the seal. The housing is impermeable to liquids and gases. Also, the absolute pressure P inside the housing int This is the absolute pressure P outside the housing. ext It is smaller than that.

[0206] In some embodiments, the anode assembly does not include any components that apply substantial mechanical force to one or more of the anode layer, separator layer, and anode current collector.

[0207] III. Battery Cells

[0208] Another aspect of the present invention provides a battery cell. Referring to Figure 8A, the battery cell 854 comprises a separator layer 802, an anode layer 804, an anode current collector 830, a cathode layer 856, a cathode current collector 858, and a barrier (e.g., a seal 842).

[0209] Exemplary embodiments of the battery cells 854, 854', 954, 954', 1054, and 1054' according to the present invention are provided in Figures 8A-8D, 9A-9D, and 10A-10D.

[0210] In some embodiments, as shown in Figures 8A–8D, the battery cell 854 includes an anode assembly comprising an anode layer 804, a separator layer 802 positioned on the first surface of the anode layer, and an anode current collector 830 having an internal surface 832, an external surface 834, and an outer surface 836 extending from the internal surface 832 to the external surface 834. The battery cell further includes a cathode layer 856 positioned on the back of the separator layer 802 and a cathode current collector 858. In these embodiments, seals 842, 842' are positioned around the external surface of the anode layer 804, the external surface of the separator layer 802, the external surface of the cathode layer 878, and the external surface of the anode current collector 830 (leaving a tab 840 configured to connect to an external circuit exposed), defining the interior and exterior. The seals contain a sealant material. The seals are substantially impermeable to liquids and gases. The anode layer is positioned inside the seals. Also, the absolute pressure P inside the seal int This is the absolute pressure P outside the seal. ext Smaller than. In some of these embodiments, as shown in Figure 8D, the cathode current collector further includes a tab 874 configured to connect to an external circuit. In some embodiments, for example in Figure 8A, a seal 842 is also positioned around the inner surface of the cathode current collector 858, keeping the outer surface (the surface facing away from the inner surface) exposed. In an alternative embodiment, for example in Figure 8D, the seal 842' is positioned around the inner surface of the cathode current collector 858' and at least a portion of the outer surface of the cathode current collector.

[0211] The separator layer 902 may be any separator layer described herein. For example, the separator layer may have a front surface 906, a rear surface 908 spaced apart from the front surface, and an outer surface 902 extending from the front surface 906 to the rear surface 908.

[0212] The anode layer 904 may be any anode layer described herein. For example, the anode layer 904 may be at least partially located on the front surface 906 of the separator layer 902. The anode layer 904 has a first surface facing the separator layer 902, a second surface facing away from the separator layer 902, and an outer surface 902 extending from the first surface to the second surface. The anode layer may also include a porous SSE.

[0213] The anode current collector may be any anode current collector described herein. For example, the anode current collector may be coupled to the second surface of the anode layer.

[0214] A. Cathode layer

[0215] Referring to Figure 9A, the cathode layer is at least partially located on the back surface 908 of the separator layer 902. The cathode layer has a first surface 960 facing the separator layer, a second surface 962 with its back to the separator layer, and an outer surface 964 extending from the first surface to the second surface.

[0216] In some embodiments, the cathode layer is located on the entire back surface of the separator layer. In other embodiments, the cathode layer is located on substantially the entire back surface of the separator layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). Also in some embodiments, the cathode layer is located on only a portion of the back surface of the separator layer.

[0217] The cathode layer may be composed of any suitable material. In some embodiments, the cathode layer includes a lithium-ion conductive material. For example, the lithium-ion conductive material may be LiCoO2, LiNi 1 / 3 Co 1 / 3 Mn 1 / 3 O2, LiLiLi 0.5 Co 0.2 Mn 0.3 Lithium nickel manganese cobalt oxide (NMC, LiNi) such as O2 x Mn y Coz O2 (where x+y+z=1), LiMn2O4, LiNi 0.5 Mn 1.5 The materials may be lithium manganese oxides (LMOs) such as O4, lithium iron phosphates (LFPs) such as LiFePO4, LiMnPO4, and LiCoPO4, and Li2MMn3O8 (where M is selected from Fe, Co, or any combination thereof). In some embodiments, the ion-conducting cathode material is a high-energy ion-conducting cathode material such as Li2MMn3O8, where M is selected from Fe, Co, or any combination thereof.

[0218] In some embodiments, the cathode includes a sodium ion conductive material. For example, the sodium ion conductive material may be Na2V2O5, P2-Na 2 / 3 Fe 1 / 2 Mn 1 / 2 O2, Na3V2(PO4)3, NaMn 1 / 3 Co 1 / 3 Ni 1 / 3 PO4, or any composite material thereof (e.g., composite material with carbon black) (e.g., Na 2 / 3 Fe 1 / 2 Mn 1 / 2 It may be O2 (graphene composite material).

[0219] In some embodiments, the cathode layer includes a magnesium ion conductive material. For example, the magnesium ion conductive material is doped manganese oxide (e.g., Mg x MnO2. y It can be H2O.

[0220] In some embodiments, the cathode layer comprises an organic sulfide or polysulfide. For example, the organic sulfide or polysulfide may be carbine polysulfide and copolymerized sulfur.

[0221] In some embodiments, the cathode layer includes an air electrode. For example, the air electrode may be large surface area carbon particles (e.g., super P (i.e., conductive carbon black)) and catalyst particles (e.g., alpha-MnO2 nanorods) bound together by a mesh (e.g., a polymer binder such as a PVDF binder).

[0222] In some embodiments, the battery cell further includes a catholite (e.g., cathode liquid) placed within the cathode layer. In such embodiments, the seal is substantially impermeable to the cathode layer. The catholite may include any material suitable for promoting liquid-solid contact and / or providing an improved interface for ion transfer. For example, the catholite may include lithium salts, linear carbonates, cyclic carbonates, ionic liquids, or any combination thereof. For example, the catholite may include a mixture of lithium bis(fluorosulfonyl)imide and N-propyl-N-methylpyrrolidinium bis(fluorosulfonyl)imide. In other embodiments, the catholite includes a mixture of lithium hexafluoride phosphate, ethylene carbonate, and ethyl methyl carbonate.

[0223] In some embodiments, the cathode layer has a thickness of about 1 μm to about 500 μm. In some embodiments, the cathode layer has a thickness of about 1 μm to about 200 μm. In other embodiments, the cathode layer has a thickness of about 1 μm to about 100 μm. In some embodiments, the cathode layer has a thickness of about 1 μm to about 50 μm. In some embodiments, the cathode layer has a thickness of about 1 μm to about 20 μm. In some embodiments, the cathode layer has a thickness of about 10 μm to about 150 μm. In other embodiments, the cathode layer has a thickness of about 40 μm to about 100 μm. Also, in some embodiments, the cathode layer has a thickness of about 60 μm to about 80 μm.

[0224] B. Cathode current collector

[0225] The cathode current collector is coupled to the cathode layer. Referring again to Figure 9A, the cathode current collector is coupled to the second surface of the cathode layer. In some embodiments, the cathode current collector has an internal surface 966 facing the cathode layer, an external surface 968 facing away from the cathode layer, and an outer surface 970 extending from the internal surface to the external surface.

[0226] In some embodiments, the cathode current collector is positioned at least partially on the second surface of the cathode layer. In some embodiments, the cathode current collector is positioned over the entire second surface of the cathode layer. In other embodiments, the cathode current collector is positioned over substantially the entire second surface of the cathode layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). In yet another embodiment, the cathode current collector is positioned over only a portion of the second surface of the cathode layer.

[0227] In some embodiments, the cathode current collector includes a metal foil 972, as shown in Figures 9A and 9B. In such embodiments, the metal foil 972 is at least partially placed on the second surface 968 of the cathode layer 956. In some embodiments, the metal foil is placed over the entire second surface of the cathode layer. In other embodiments, the metal foil is placed over substantially the entire second surface of the cathode layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). In yet another embodiment, the metal foil is placed over only a portion of the second surface of the cathode layer.

[0228] In some embodiments, the metal foil has tabs 974 configured to connect to an external circuit, as shown in Figure 9B. In the illustrated embodiment, the tabs are integrated with the metal foil. In other embodiments, the tabs are bonded to (e.g., welded to) the metal foil.

[0229] The cathode current collector may be made of any suitable material. In some embodiments, the cathode current collector (e.g., metal foil and / or tab) includes aluminum, stainless steel, alloys thereof, or any combination thereof. In some embodiments, the cathode current collector includes aluminum. In some embodiments, the cathode current collector includes an aluminum alloy. In other embodiments, the cathode current collector includes stainless steel. Also, in some embodiments, the cathode current collector includes a stainless steel alloy.

[0230] In some embodiments, the cathode current collector includes a conductive film. For example, the conductive film may include a polymer material and a conductive material. For example, the conductive material may be a metallic material. In some embodiments, the conductive material includes aluminum, stainless steel, alloys thereof, or any combination thereof.

[0231] In some embodiments, a conductive tape is used to couple the cathode current collector to the cathode layer. During the operation of the battery cell (e.g., during charging and / or discharging), the conductive tape can electrically couple the cathode current collector to the cathode layer.

[0232] In some embodiments, as shown in Figures 9A and 9B, the cathode current collector 972 defines an opening 976 configured to allow the cathode layer to be filled with catholite. In the illustrated embodiments, the outer surface 968 of the cathode current collector defines an opening configured to allow the cathode layer to be filled with catholite. In other embodiments, as shown in Figures 10C and 10D, the outer surface and outer surface of the cathode current collector define an opening 1076' configured to allow the cathode layer to be filled with catholite. In the embodiments of Figures 9A-D and 10A-D, it will be understood that if the seal is impermeable to liquids and gases (i.e., the barrier is the seal), the anode layer will remain airtightly sealed from the environment outside the cathode current collector.

[0233] In some embodiments, as shown in Figures 8A, 9A, and 10A, the cross-sectional width of the cathode current collector is greater than the cross-sectional width of the cathode layer. In other embodiments, as shown in Figures 8C and 9C, the cross-sectional width of the cathode current collector is substantially the same as the cross-sectional width of the cathode layer.

[0234] C. Barrier

[0235] The barrier is impermeable to liquids and gases. The barrier may be any barrier described herein (e.g., any seal and / or housing described herein).

[0236] In some embodiments, the barrier is located at least partially on the cathode layer. For example, as shown in Figures 9A, 9C, 10A, and 10C, the barrier (e.g., seal) may be located at least partially on the outer surface of the cathode layer. In the illustrated embodiment, the barrier is located on the entire outer surface of the cathode layer. In other embodiments, the barrier is located on substantially the entire outer surface of the cathode layer (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). Also, in some embodiments, the barrier is located on only a portion of the outer surface of the cathode layer.

[0237] In some embodiments, the barrier is positioned at least partially on the cathode current collector. For example, as shown in Figures 9C and 10C, the barrier (e.g., seal) may be positioned at least partially on the outer surface of the cathode current collector. In other embodiments, the barrier is positioned over substantially the entire outer surface of the cathode current collector (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). Also in some embodiments, the barrier is positioned over only a portion of the outer surface of the cathode current collector.

[0238] In some embodiments, as shown in Figures 9A and 10A, the barrier (e.g., seal) is located at least partially on the inner surface of the cathode current collector. In other embodiments, the barrier is located on substantially the entire inner surface of the cathode current collector (e.g., at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%). Also in some embodiments, the barrier is located on only a portion of the inner surface of the cathode current collector, as shown in Figures 9A and 10A.

[0239] In some embodiments, the barrier is located at least partially on the outer surface of the anode layer, the outer surface of the separator layer, and the inner surfaces of the anode and cathode current collectors. For example, as shown in Figures 9A and 10A, the barrier (e.g., seal) may be located only on the entire outer surface of the anode layer, the entire outer surface of the separator layer, and only on a portion of the inner surfaces of the anode and cathode current collectors.

[0240] In some embodiments, as shown in Figure 8A, the barrier (e.g., seal) may be at least partially located on the outer surface of the anode layer, the outer surface of the separator layer, the inner surface of the cathode current collector, and the outer and outer surfaces of the anode current collector. In the illustrated embodiment, the barrier is located on the entire outer surface of the anode layer, the entire outer surface of the separator layer, only a portion of the inner surface of the cathode current collector, and the entire outer and outer surfaces of the anode current collector.

[0241] In some embodiments, the barrier is located at least partially on the outer surface of the anode layer, the outer surface of the separator layer, the outer surface of the cathode layer, and the inner surfaces of the anode and cathode current collectors. For example, as shown in Figures 9A and 10A, the barrier (e.g., seal) may be located only on the entire outer surface of the anode layer, the entire outer surface of the separator layer, the entire outer surface of the cathode layer, and only on a portion of the inner surfaces of the anode and cathode current collectors.

[0242] In some embodiments, the barrier may be at least partially located on the outer surface of the anode layer, the outer surface of the separator layer, the outer surface of the cathode layer, the inner surface of the cathode current collector, and the outer and outer surfaces of the anode current collector. For example, as shown in Figure 8A, the barrier (e.g., seal) may be located on the entire outer surface of the anode layer, the entire outer surface of the separator layer, the entire outer surface of the cathode layer, only a portion of the inner surface of the cathode current collector, and the entire outer and outer surfaces of the anode current collector.

[0243] In some embodiments, as shown in Figure 8C, the barrier (e.g., seal) may be at least partially disposed on the outer surface of the anode layer, the outer surface of the separator layer, the outer surface of the cathode layer, the outer surface of the cathode current collector, and the outer and external surfaces of the anode current collector. In the illustrated embodiment, the barrier is disposed on the entire outer surface of the anode layer, the entire outer surface of the separator layer, the entire outer surface of the cathode layer, the entire outer surface of the cathode current collector, and the outer and external surfaces of the anode current collector.

[0244] In some embodiments, the barrier may be located at least partially on the outer surface of the anode layer, the outer surface of the separator layer, the outer surface of the cathode layer, the outer surface of the cathode current collector, and the inner and outer surfaces of the anode current collector. For example, as shown in Figure 9C, the barrier (e.g., seal) may be located only on the entire outer surface of the anode layer, the entire outer surface of the separator layer, the entire outer surface of the cathode layer, the entire outer surface of the cathode current collector, and only on a portion of the inner surface of the anode current collector.

[0245] In some embodiments, the barrier is at least partially located on the anode layer and the separator layer. In other embodiments, the barrier is at least partially located on the anode layer and the anode current collector. Also in some embodiments, the barrier is at least partially located on the anode layer, the anode current collector, and the separator layer.

[0246] In some embodiments, the battery cell further comprises a housing. The housing may be any housing described herein. In some embodiments, the barrier is the housing. In other embodiments, the housing is substantially impermeable to liquids but permeable to gases. When the housing is present, a separator layer, an anode layer, an anode current collector, a cathode layer, a cathode current collector, and / or a seal may be arranged inside the housing.

[0247] In some embodiments, the battery cell does not include components that apply large mechanical forces to one or more of the anode layer, separator layer, seal, anode current collector, cathode layer, and cathode current collector.

[0248] In one embodiment, the present invention provides a battery cell. The battery cell comprises a separator layer, an anode layer, an anode current collector, a cathode layer, and a cathode current collector. The separator layer has a front surface facing the anode layer, a back surface facing away from the anode layer, and an outer surface extending from the front surface to the back surface. The anode layer is at least partially located on the front surface of the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The anode current collector is bonded to the second surface of the anode layer. The cathode layer is at least partially located on the back surface of the separator layer. The cathode current collector is bonded to the second surface of the cathode layer. Also, the absolute pressure P within the pores 細孔 P is the absolute pressure of the environment outside the anode layer. env It is smaller than that.

[0249] In another embodiment, the present invention provides a battery cell comprising a separator layer, an anode layer, an anode current collector, a cathode layer, a cathode current collector, and a barrier. The separator layer has a front surface facing the anode layer, a back surface facing away from the anode layer, and an outer surface extending from the front surface to the back surface. The anode layer is at least partially located on the front surface of the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The anode current collector is bonded to the second surface of the anode layer. The cathode layer is at least partially located on the back surface of the separator layer. The cathode current collector is bonded to the second surface of the cathode layer. A barrier is located around the outer surface of the anode layer and defines the interior and exterior. The barrier is impermeable to liquids and gases. The anode layer is located inside the barrier. Also, the absolute pressure P inside the barrier int This is the absolute pressure P outside the barrier. ext It is smaller than that.

[0250] In a further embodiment, the present invention provides a battery cell comprising a separator layer, an anode layer, an anode current collector, a cathode layer, a cathode current collector, and a seal. The separator layer has a front surface facing the anode layer, a back surface facing away from the anode layer, and an outer surface extending from the front surface to the back surface. The anode layer is at least partially located on the front surface of the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer contains a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The anode current collector is bonded to the second surface of the anode layer. The cathode layer is at least partially located on the back surface of the separator layer. The cathode current collector is bonded to the second surface of the cathode layer. A seal is located around the outer surface of the anode layer and defines the interior and exterior. The seal contains a sealant material. The seal is impermeable to liquids and gases. The anode layer is located inside the seal. Also, the absolute pressure P inside the seal int This is the absolute pressure P outside the seal. ext It is smaller than that.

[0251] In yet another embodiment, the present invention provides a battery cell comprising a separator layer, an anode layer, an anode current collector, a cathode layer, a cathode current collector, and a housing. The housing comprises a plurality of inner walls defining the interior and exterior. The separator layer is located inside the housing and has a front surface facing the anode layer, a back surface facing away from the anode layer, and an outer surface extending from the front surface to the back surface. The anode layer is located inside the housing and is at least partially located on the front surface of the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The anode current collector is located inside the housing and is coupled to the second surface of the anode layer. The cathode layer is located inside the housing and is at least partially located on the back surface of the separator layer. The cathode current collector is located inside the housing and bonded to the second surface of the cathode layer. The housing is impermeable to liquids and gases. Also, the absolute pressure P inside the housing int This is the absolute pressure P outside the housing. ext It is smaller than that.

[0252] In another embodiment, the present invention provides a battery cell comprising a housing, a separator, an anode layer, an anode current collector, a cathode layer, a cathode current collector, and a seal. The housing comprises a plurality of inner walls defining the interior and exterior. The separator layer is located inside the housing and has a front surface facing the anode layer, a back surface facing away from the anode layer, and an outer surface extending from the front to the back. The anode layer is located inside the housing and is at least partially located on the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The cathode layer is located inside the housing and is at least partially located on the back surface of the separator layer. The cathode current collector is located inside the housing and is coupled to the second surface of the cathode layer. The seal is located inside the housing and is positioned around the outer surface of the anode layer. The seal defines the interior and exterior. The seal contains sealant material. The seal is impermeable to liquids and gases. The anode layer is located inside the seal. Also, the absolute pressure P inside the seal int This is the absolute pressure P outside the seal. ext It is smaller than that.

[0253] In a further embodiment, the present invention provides a battery cell comprising a housing, a separator, an anode layer, an anode current collector, a cathode layer, a cathode current collector, and a seal. The housing comprises a plurality of inner walls defining the interior and exterior. The separator layer is located inside the housing and has a front surface facing the anode layer, a back surface facing away from the anode layer, and an outer surface extending from the front surface to the back surface. The anode layer is located inside the housing and is located at least partially on the separator layer. The anode layer has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material. The cathode layer is located inside the housing and is located at least partially on the back surface of the separator layer. The cathode current collector is located inside the housing and is coupled to the second surface of the cathode layer. The seal is located inside the housing and is positioned around the outer surface of the anode layer. The seal defines the interior and exterior. The seal contains sealant material. The seal is substantially impermeable to liquids but permeable to gases. The anode layer is located inside the seal. The housing is impermeable to liquids and gases. Also, the absolute pressure P inside the housing int This is the absolute pressure P outside the housing. ext It is smaller than that.

[0254] IV. Method for forming an anode assembly

[0255] Another aspect of the present invention provides a method for forming an anode assembly. Referring to Figure 11, a flowchart is provided showing an exemplary embodiment of forming an anode assembly of a battery cell. The method is as follows: (a) Separator layer and an anode layer, at least partially disposed on a separator layer, having a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface, wherein the anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material, (1102) A current collector is provided which is coupled to the second surface of the anode layer, and (b) Arranging the separator layer, anode layer, and anode current collector in the chamber (1104), (c) By reducing the absolute pressure inside the chamber, the pores in the anode layer, P 細孔 To reduce the absolute pressure inside (1106), and (d) After step (c), forming an anode assembly by forming a barrier around the outer surface of the anode layer, wherein the barrier defines the interior and exterior, the anode layer is located inside the interior, and the barrier is substantially impermeable to liquids and gases (1108).

[0256] In some embodiments, step (c) further includes reducing the absolute pressure inside the chamber using a vacuum pump.

[0257] In some embodiments, after step (c), P 細孔 It is less than approximately 101,325 Pa. For example, P 細孔 The pressure after step (c) can be approximately 1 Pa to approximately 101,324 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 100 Pa to approximately 1,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 100 Pa to approximately 200 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 200 Pa to approximately 300 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 300 Pa to approximately 400 Pa. In some embodiments, after step (c), P 細孔The pressure is approximately 400 Pa to approximately 500 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 500 Pa to approximately 600 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 600 Pa to approximately 700 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 700 Pa to approximately 800 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 800 Pa to approximately 900 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 900 Pa to approximately 1,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 100 Pa to approximately 500 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 500 Pa to approximately 1,000 Pa. Also, in some embodiments, after step (c), P 細孔 The pressure range is approximately 250 Pa to 750 Pa.

[0258] In some embodiments, after step (c), P 細孔 The pressure is approximately 100 Pa to approximately 2,000 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 200 Pa to approximately 1,800 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 300 Pa to approximately 1,700 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 400 Pa to approximately 1,600 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 500 Pa to approximately 1,500 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 600 Pa to approximately 1,400 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 700 Pa to approximately 1,300 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 750 Pa to approximately 1,250 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 800 Pa to approximately 1,200 Pa. In some embodiments, after step (c), P 細孔The pressure is approximately 850 Pa to approximately 1,150 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 900 Pa to approximately 1,100 Pa. In addition, in some embodiments, after step (c), P 細孔 It starts from approximately 1,000 Pa.

[0259] In some embodiments, after step (c), P 細孔 The pressure is approximately 1,000 Pa to approximately 10,000 Pa. For example, after step (c), P 細孔 This can be approximately 1,000 Pa to approximately 2,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 2,000 Pa to approximately 3,000 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 3,000 Pa to approximately 4,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 4,000 Pa to approximately 5,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 5,000 Pa to approximately 6,000 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 6,000 Pa to approximately 7,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 7,000 Pa to approximately 8,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 8,000 Pa to approximately 9,000 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 9,000 Pa to approximately 10,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 1,000 Pa to approximately 5,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 5,000 Pa to approximately 10,000 Pa. Also, in some embodiments, after step (c), P 細孔 The pressure range is approximately 2,500 Pa to 7,500 Pa.

[0260] In some embodiments, after step (c), P 細孔The pressure ranges from approximately 10,000 Pa to approximately 101,324 Pa. For example, after step (c), P 細孔 This can be approximately 10,000 Pa to approximately 20,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 20,000 Pa to approximately 30,000 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 30,000 Pa to approximately 40,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 40,000 Pa to approximately 50,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 50,000 Pa to approximately 60,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 60,000 Pa to approximately 70,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 70,000 Pa to approximately 80,000 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 80,000 Pa to approximately 90,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 90,000 Pa to approximately 100,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 10,000 Pa to approximately 50,000 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 50,000 Pa to approximately 100,000 Pa. In addition, in some embodiments, after step (c), P 細孔 The pressure range is approximately 25,000 Pa to 75,000 Pa.

[0261] In some embodiments, after step (c), P 細孔 The pressure ranges from approximately 0.1 Pa to approximately 100 Pa. For example, P 細孔 The pressure after step (c) can be approximately 1 Pa to approximately 10 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 10 Pa to approximately 20 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 20 Pa to approximately 30 Pa. In some embodiments, after step (c), P 細孔The pressure is approximately 30 Pa to approximately 40 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 40 Pa to approximately 50 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 50 Pa to approximately 60 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 60 Pa to approximately 70 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 70 Pa to approximately 80 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 80 Pa to approximately 90 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 90 Pa to approximately 100 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 1 Pa to approximately 50 Pa. In other embodiments, after step (c), P 細孔 The pressure is approximately 50 Pa to approximately 100 Pa. In some embodiments, after step (c), P 細孔 The pressure is approximately 25 Pa to approximately 75 Pa. In addition, in some embodiments, after step (c), P 細孔 The pressure is less than approximately 1 Pa.

[0262] In some embodiments, forming step (d) includes, after step (c), forming a liquid and gas impermeable housing (i.e., the barrier is the housing) around the outer surface of the anode layer. The housing comprises a plurality of inner walls defining the interior and exterior. The separator layer, anode layer, and anode current collector are arranged inside the housing. In some embodiments, step (d) further includes airtight sealing of the plurality of walls to form the housing. For example, a sealant material can be used to airtight seal the plurality of walls. The sealant material may be any sealant material described herein.

[0263] In other embodiments, step (d) includes forming a liquid and gas-impermeable seal (i.e., the barrier is the seal) around the outer surface of the anode layer after step (c) for forming the anode assembly. The seal defines the interior and exterior. The anode layer is positioned inside the seal.

[0264] In some embodiments, forming step (d) includes forming a seal from sealant material by cold pressing, hot pressing, melting, 3D printing, or any combination thereof, at least partially on the outer surface of the anode layer. In some embodiments, forming step (d) includes forming a seal from sealant material by cold pressing at least partially on the outer surface of the anode layer. In other embodiments, forming step (d) includes forming a seal from sealant material by hot pressing at least partially on the outer surface of the anode layer. In some embodiments, forming step (d) includes forming a seal from sealant material by melting at least partially on the outer surface of the anode layer. In some embodiments, forming step (d) also includes forming a seal from sealant material by 3D printing at least partially on the outer surface of the anode layer.

[0265] In some embodiments, forming step (d) includes forming a seal from the sealant material by mechanically applying at least partially the sealant material onto the outer surface of the anode layer. For example, forming step (d) may include forming a seal from the sealant material by applying at least partially the sealant material onto the outer surface of the anode layer using a paintbrush, roller, plastic applicator, metal applicator, molding tool, syringe dispenser, dispenser valve, or any combination thereof. In some embodiments, forming step (d) includes forming a seal from the sealant material by applying at least partially the sealant material onto the outer surface of the anode layer using a paintbrush. In other embodiments, forming step (d) includes forming a seal from the sealant material by applying at least partially the sealant material onto the outer surface of the anode layer using a roller. In some embodiments, forming step (d) includes forming a seal from the sealant material by applying at least partially the sealant material onto the outer surface of the anode layer using a plastic applicator. In some embodiments, forming step (d) includes forming a seal from the sealant material by applying at least partially the sealant material onto the outer surface of the anode layer using a metal applicator. In other embodiments, forming step (d) includes forming a seal from the sealant material by applying at least partially the sealant material onto the outer surface of the anode layer using a molding tool. In some embodiments, forming step (d) includes forming a seal from the sealant material by applying at least partially the sealant material onto the outer surface of the anode layer using a syringe dispenser. In some embodiments, forming step (d) includes forming a seal from the sealant material by applying at least partially the sealant material onto the outer surface of the anode layer using a dispenser valve.

[0266] In some embodiments, forming step (d) includes forming a seal from sealant material by at least partially injection molding, in-line extrusion, spray deposition, 3D printing, wrapping, or any combination thereof onto the outer surface of the anode layer. In some embodiments, forming step (d) includes forming a seal from sealant material by at least partially injection molding the sealant material onto the outer surface of the anode layer. In other embodiments, forming step (d) includes forming a seal from sealant material by at least partially in-line extrusion the sealant material onto the outer surface of the anode layer. In some embodiments, forming step (d) includes forming a seal from sealant material by at least partially spray deposition the sealant material onto the outer surface of the anode layer. In some embodiments, forming step (d) includes forming a seal from sealant material by at least partially 3D printing the sealant material onto the outer surface of the anode layer. In some embodiments, forming step (d) also includes forming a seal from sealant material by at least partially wrapping the sealant material onto the outer surface of the anode layer.

[0267] The temperature and / or application pressure of the sealant material may be selected to provide appropriate sealant flow and coverage without damaging other components of the anode assembly. In embodiments where the sealant material is at least partially placed on the outer surface of the anode layer and within the pores of the second porous region, the temperature and / or application pressure of the sealant material may be sufficient to allow a desired level of penetration into the pores of the second porous region. Similarly, the position of the sealant material, the amount of sealant material, the application rate of the sealant material, and the cooling method of the seal may be adjusted for each particular embodiment of the seal.

[0268] The sealant material may be any sealant material described herein. For example, the sealant material may include polypropylene, polyethylene, polyimide, polyvinyl chloride (PVC), ethylene vinyl acetate, polyamide, polypropylene, polyurethane, copolymers thereof, or any combination thereof. For example, the sealant material may include polypropylene. In some embodiments, the sealant material includes polyethylene. In other embodiments, the sealant material includes polyimide. In some embodiments, the sealant material includes PVC. In some embodiments, the sealant material includes ethylene vinyl acetate. In other embodiments, the sealant material includes polyamide. In some embodiments, the sealant material includes polypropylene. Also, in some embodiments, the sealant material includes polyurethane.

[0269] In some embodiments, the sealant material includes polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof. In some embodiments, the sealant material includes polypropylene. In some embodiments, the sealant material includes polyethylene. In other embodiments, the sealant material includes polymethylpentene. In some embodiments, the sealant material includes polybutene-1. In some embodiments, the sealant material includes ethylene-octene copolymer. In some embodiments, the sealant material includes propylene-butane copolymer. In some embodiments, the sealant material includes polyisobutylene. In some embodiments, the sealant material includes poly(α-olefin). In some embodiments, the sealant material includes ethylene propylene rubber. In other embodiments, the sealant material includes ethylene propylene diene monomer rubber. In some embodiments, the sealant material includes ethylene vinyl acetate. In some embodiments, the sealant material includes ethylene acrylate copolymer. In other embodiments, the sealant material includes polyamide. In some embodiments, the sealant material includes polyester. In some embodiments, the sealant material includes polyurethane. In some embodiments, the sealant material includes styrene block copolymer. In some embodiments, the sealant material includes polycaprolactone. In other embodiments, the sealant material includes polyimide. In some embodiments, the sealant material includes polyvinyl chloride. In some embodiments, the sealant material includes polycarbonate. In some embodiments, the sealant material includes polyacrylate.In some embodiments, the sealant material includes polymethacrylate. In some embodiments, the sealant material includes a fluoropolymer. In some embodiments, the sealant material includes an epoxy resin. In other embodiments, the sealant material includes an epoxy polymer. Also, in some embodiments, the sealant material includes silicone rubber.

[0270] In some embodiments, forming step (d) further includes curing the sealant material. For example, curing the sealant material may include curing the sealant material by exposure to radiation (e.g., ultraviolet (UV) radiation). In some embodiments, curing may be performed by UV radiation from a UV lamp. In other embodiments, curing of the sealant material includes epoxy curing.

[0271] In some embodiments, forming step (d) is performed in a chamber. In other embodiments, the chamber may be further defined as a first chamber, and forming step (d) may be performed in a second chamber. In such embodiments, the absolute pressure in the second chamber is P 細孔 To ensure that this is substantially maintained between steps (c) and (d), it can be substantially the same as the absolute pressure in the first chamber.

[0272] In some embodiments, if step (d) is performed in a chamber, the method further includes (e) removing the anode assembly from the chamber. In other embodiments, if step (d) is performed in a second chamber, the method further includes (e) removing the anode assembly from the second chamber.

[0273] In another embodiment, the present invention provides a method for forming an anode assembly for a battery cell. The method is: (a-1) Separator layer, an anode layer, at least partially disposed on a separator layer, having a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface, wherein the anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material, The anode current collector and, (b-1) Arrange the separator layer, anode layer, and anode current collector in the chamber. (c-1) By reducing the absolute pressure inside the chamber, the absolute pressure inside the pores of the anode layer, P 細孔 To reduce, and (d-1) After step (c), forming a barrier around the outer surface of the anode layer, the barrier defining the interior and exterior, the anode layer being located inside the interior, and the barrier being substantially impermeable to liquids and gases, and (e-1) comprising coupling the anode current collector to the second surface of the anode layer.

[0274] In some embodiments, step (e-1) is performed before step (d-1). In other embodiments, step (d-1) is performed before step (e-1).

[0275] In another embodiment, the present invention provides a method for forming an anode assembly for a battery cell. The method is: (a-2) Separator layer, an anode layer, at least partially disposed on a separator layer, having a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface, wherein the anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material, The anode current collector is provided which is coupled to the second surface of the anode layer, and (b-2) Arrange the separator layer, anode layer, and anode current collector in the chamber. (c-2) By reducing the absolute pressure inside the chamber, the absolute pressure inside the pores of the anode layer, P 細孔 To reduce, and (d-2) After step (c), forming a seal around the outer surface of the anode layer to form an anode assembly, wherein the seal defines the interior and exterior, the anode layer is located inside the interior, and the seal is substantially impermeable to liquids and gases.

[0276] In another embodiment, the present invention provides a method for forming an anode assembly for a battery cell. The method is: (a-3) Separator layer, an anode layer, at least partially disposed on a separator layer, having a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface, wherein the anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material, The anode current collector is provided which is coupled to the second surface of the anode layer, and (b-3) Arrange the separator layer, anode layer, and anode current collector in the chamber. (c-3) By reducing the absolute pressure inside the chamber, the absolute pressure inside the pores of the anode layer, P 細孔 To reduce, and (d-3) After step (c), a seal is formed around the outer surface of the anode layer, the seal defining the interior and exterior, the anode layer being located inside the interior, and the seal being substantially impermeable to liquids and gases. (e-3) comprising coupling the anode current collector to the second surface of the anode layer.

[0277] In some embodiments, step (e-3) is performed before step (d-3). In other embodiments, step (d-3) is performed before step (e-3).

[0278] V. Examples

[0279] Examples are provided below to allow for a more complete understanding of the inventions described herein. The examples described in this application are provided to illustrate the methods and anode assemblies provided herein and should not be construed as limiting their scope in any way.

[0280] Example 1: Anode Assembly

[0281] A separator layer and an anode layer at least partially disposed on the separator layer are provided. The anode layer contains a solid electrolyte (SSE) material defining pores adapted to receive the anode material. An anode current collector is also provided. The double layer (i.e., the separator layer and the anode layer) and the anode current collector are placed inside a glove box. The absolute pressure inside the glove box (e.g., an MBraun glove box) is set based on a desired absolute pressure in the pores of the anode layer (e.g., less than about 101,324 Pa).

[0282] When the absolute pressure within the pores of the anode layer becomes substantially the same as the absolute pressure inside the glove box, the anode current collector is bonded to the surface of the anode layer opposite the separator layer with an adhesive (e.g., a conductive adhesive material (e.g., conductive tape)). Next, a sealant material that is impermeable to liquids and gases is applied to the outer surface of the anode layer (i.e., the surface extending between the surface bonded to the anode current collector and the surface located on the separator layer) to form a seal. The seal, in conjunction with the separator layer and the anode current collector, is likely to ensure that the absolute pressure within the pores of the anode layer remains substantially the same as the absolute pressure inside the glove box after the anode assembly is removed from the glove box. Equivalents and Scope

[0283] In the claims, articles such as “a,” “an,” and “the” may mean one or more unless otherwise indicated or made clear from the context. Claims or descriptions that include “or” between one or more elements of a group are considered satisfied unless otherwise indicated or made clear from the context if one, two or more, or all of the elements of the group are present, used, or otherwise related to a given product or process. The present invention includes embodiments in which exactly one element of the group is present, used, or otherwise related to a given product or process. The present invention includes embodiments in which two or more, or all, of the elements of the group are present, used, or otherwise related to a given product or process.

[0284] Furthermore, the present invention encompasses all variations, combinations, and substitutions in which one or more limitations, elements, clauses, and descriptive terms from one or more of the enumerated claims are introduced into another claim. For example, any claim dependent on another claim may be modified to include one or more limitations found in any other claim dependent on the same basic claim. Where elements are presented as a list, for example in Markush group form, each subgroup of elements is also disclosed, and any element(s) may be removed from this group. Naturally, generally, where the present invention or an aspect of the present invention is referred to as including certain elements and / or features, certain particular embodiments or aspects of the present invention consist of, or essentially consist of, such elements and / or features. For simplicity, these embodiments are not specifically described verbatim in this specification. It should also be noted that the terms “including” and “containing” are intended to be open and may also allow for the inclusion of additional elements or steps. Where a scope is given, it includes the endpoints. Furthermore, unless otherwise indicated, or unless it is clearly understood from the context and the understanding of those skilled in the art, any value expressed as a range may be considered any specific value or subrange within the defined range of different embodiments of the present invention, up to one-tenth of the lower limit unit of the range, unless it is clearly understood from the context.

[0285] This application references various issued patents, published patent applications, journal articles, and other publications, all of which are incorporated herein by reference. In the event of any conflict between any of the referenced documents and this application, this specification shall prevail. Furthermore, any particular embodiment of the Invention within the scope of the prior art may be expressly excluded from any one or more of the claims. Such embodiments may be excluded even if not explicitly stated herein, as they are considered to be known to those skilled in the art. Any particular embodiment of the Invention may be excluded from any claim for any reason, whether or not relating to the existence of the prior art.

[0286] Those skilled in the art will be able to recognize or confirm many equivalents to the specific embodiments described herein using only routine experiments. The scope of the embodiments described herein is not intended to be limited to the above specification, but is as set out in the appended claims. Those skilled in the art will understand that various changes and modifications can be made to this specification without departing from the spirit or scope of the invention as defined in the following claims.

Claims

1. an anode assembly for a battery cell, Separator layer, An anode layer, at least partially disposed on the separator layer, having a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface, wherein the anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material, and an absolute pressure P within the pores 細孔 This is the absolute pressure P of the environment outside the anode layer. ｅｎｖ The anode assembly, comprising the anode layer which is smaller than the anode layer.

2. P 細孔 The anode assembly according to claim 1, wherein the pressure is less than approximately 101,325 Pa.

3. P 細孔 The anode assembly according to claim 1, wherein the pressure is approximately 1 Pa to approximately 101,324 Pa.

4. P 細孔が The anode assembly according to claim 3, wherein the current is approximately 100 Pa to approximately 1,000 Pa.

5. P 細孔が The anode assembly according to claim 3, wherein the current is approximately 1,000 Pa to approximately 10,000 Pa.

6. P 細孔 The anode assembly according to claim 3, wherein the current is approximately 10,000 Pa to approximately 101,324 Pa.

7. P 細孔 The anode assembly according to claim 3, wherein the current is approximately 100 Pa to approximately 2,000 Pa.

8. P 細孔 The anode assembly according to claim 3, wherein P is from about 500 Pa to about 1,500 Pa.

9. P 細孔 The anode assembly according to claim 3, wherein the current is approximately 750 Pa to approximately 1,250 Pa.

10. P 細孔 and P ｅｎｖ The anode assembly according to claim 1, wherein the pressure difference between the two is approximately 100 Pa to approximately 100,000 Pa.

11. The aforementioned P 細孔 and P ｅｎｖ The anode assembly according to claim 10, wherein the pressure difference between the two is approximately 1,000 Pa to approximately 100,000 Pa.

12. The aforementioned P 細孔 and P ｅｎｖ The anode assembly according to claim 10, wherein the pressure difference between the two is approximately 10,000 Pa to approximately 100,000 Pa.

13. The anode assembly according to any one of claims 1 to 12, wherein the separator layer is substantially free of pores.

14. The anode assembly according to any one of claims 1 to 13, wherein the separator layer comprises an SSE material.

15. The anode assembly according to claim 14, wherein the SSE material of the separator layer comprises a polymer, a sulfide, an oxide, a chalcogenide, or any combination thereof.

16. The anode assembly according to any one of claims 1 to 15, wherein the separator layer has a thickness of about 1 μm to about 300 μm.

17. The anode assembly according to any one of claims 1 to 16, further comprising an anode material disposed in at least a portion of the pores of the anode layer.

18. The anode assembly according to claim 17, wherein the anode material includes lithium metal, sodium metal, magnesium metal, or any combination thereof.

19. The anode assembly according to any one of claims 1 to 18, wherein the anode layer comprises a garnet material.

20. The anode assembly according to any one of claims 1 to 19, wherein the anode layer has a thickness of about 1 μm to about 500 μm.

21. The anode assembly according to claim 20, further comprising an anode current collector bonded to the second surface of the anode layer.

22. The anode assembly according to claim 21, wherein the anode current collector includes a metal foil.

23. The anode assembly according to claim 22, wherein the metal foil comprises copper, nickel, titanium, stainless steel, an alloy thereof, or any combination thereof.

24. The anode assembly according to claim 22 or 23, wherein the metal foil has tabs configured to connect to an external circuit.

25. an anode assembly for a battery cell, Separator layer, An anode layer, at least partially disposed on the separator layer, having a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface, wherein the anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material, A barrier is disposed around the outer surface of the anode layer, defining the interior and exterior, wherein the barrier is impermeable to liquids and gases, and the anode layer is disposed inside the barrier, with the absolute pressure P inside ｉｎｔ This is the absolute pressure P of the external environment. ｅｘｔ The anode assembly, comprising the barrier, which is smaller than the barrier.

26. P ｉｎｔ The anode assembly according to claim 25, wherein the pressure is less than approximately 101,325 Pa.

27. P ｉｎｔ The anode assembly according to claim 25, wherein the pressure is approximately 1 Pa to approximately 101,324 Pa.

28. P ｉｎｔ The anode assembly according to claim 27, wherein the current is approximately 100 Pa to approximately 1,000 Pa.

29. P ｉｎｔ The anode assembly according to claim 27, wherein the current is approximately 1,000 Pa to approximately 10,000 Pa.

30. P ｉｎｔ The anode assembly according to claim 27, wherein the pressure is approximately 10,000 Pa to approximately 101,324 Pa.

31. P ｉｎｔ The anode assembly according to claim 27, wherein the current is approximately 100 Pa to approximately 2,000 Pa.

32. P ｉｎｔ The anode assembly according to claim 27, wherein the current is approximately 500 Pa to approximately 1,500 Pa.

33. P ｉｎｔ The anode assembly according to claim 27, wherein the current is approximately 750 Pa to approximately 1,250 Pa.

34. P ｉｎｔ and P ｅｘｔ The anode assembly according to claim 25, wherein the pressure difference between the two is approximately 100 Pa to approximately 100,000 Pa.

35. The aforementioned P ｉｎｔ and P ｅｘｔ The anode assembly according to claim 34, wherein the pressure difference between the two is approximately 1,000 Pa to approximately 100,000 Pa.

36. The aforementioned P ｉｎｔ and P ｅｘｔ The anode assembly according to claim 34, wherein the pressure difference between the two is approximately 10,000 Pa to approximately 100,000 Pa.

37. The anode assembly according to any one of claims 25 to 36, wherein the separator layer is disposed inside the barrier.

38. The anode assembly according to any one of claims 25 to 37, wherein the separator layer is substantially free of pores.

39. The anode assembly according to any one of claims 25 to 38, wherein the separator layer comprises an SSE material.

40. The anode assembly according to claim 39, wherein the SSE material of the separator layer comprises a polymer, a sulfide, an oxide, a chalcogenide, or any combination thereof.

41. The anode assembly according to any one of claims 25 to 40, wherein the separator layer has a thickness of about 1 μm to about 300 μm.

42. The anode assembly according to any one of claims 25 to 41, further comprising an anode material disposed in at least a portion of the pores of the anode layer.

43. The anode assembly according to claim 42, wherein the anode material includes lithium metal, sodium metal, magnesium metal, or any combination thereof.

44. The anode assembly according to any one of claims 25 to 43, wherein the anode layer comprises a garnet material.

45. The anode assembly according to any one of claims 25 to 44, wherein the anode layer has a thickness of about 1 μm to about 500 μm.

46. The anode assembly according to any one of claims 25 to 45, further comprising an anode current collector bonded to the second surface of the anode layer.

47. The anode assembly according to claim 46, wherein the anode current collector is disposed inside the barrier.

48. The anode assembly according to claim 46 or 47, wherein the anode current collector includes a metal foil.

49. The anode assembly according to claim 48, wherein the metal foil comprises copper, nickel, titanium, stainless steel, an alloy thereof, or any combination thereof.

50. The anode assembly according to claim 48 or 49, wherein the metal foil has tabs configured to connect to an external circuit.

51. The anode assembly according to any one of claims 25 to 50, wherein the barrier is a seal and the seal comprises a sealant material.

52. The anode assembly according to claim 51, wherein the seal is at least partially disposed on the anode current collector.

53. The anode assembly according to claim 51 or claim 52, wherein the seal is at least partially disposed on the outer surface of the anode layer.

54. The anode assembly according to any one of claims 51 to 53, wherein the seal is at least partially disposed on the separator layer.

55. The anode assembly according to claims 51 to 54, wherein the separator layer has a front surface facing the anode layer, a back surface facing away from the anode layer, and an outer surface extending from the front surface to the back surface.

56. The anode assembly according to claim 55, wherein the seal is at least partially disposed on the outer surface of the separator layer.

57. The anode assembly according to any one of claims 51 to 56, wherein the separator layer defines a recess and the seal is disposed within the recess of the separator layer.

58. The anode assembly according to any one of claims 51 to 57, wherein the anode layer defines a first porous region between the center of the anode layer and the outer surface of the anode layer, and defines a second porous region between the first porous region and the outer surface of the anode layer.

59. The anode assembly according to claim 58, wherein the sealant material is substantially absent in the pores of the first porous region.

60. The anode assembly according to claim 58 or claim 59, wherein at least a portion of the pores in the second porous region contains the sealant material.

61. The anode current collector further includes an anode current collector coupled to the second surface of the anode layer, The separator layer has a front surface facing the anode layer, a back surface facing away from the anode layer, and an outer surface extending from the front surface to the back surface, and the anode current collector has an inner surface facing the anode layer, an outer surface facing away from the anode layer, and an outer surface extending from the inner surface to the outer surface, The anode assembly according to claim 51, wherein the seal is at least partially disposed on the outer surface of the anode layer, the outer surface of the separator layer, and the outer surface of the anode current collector.

62. The anode assembly according to any one of claims 51 to 61, wherein the sealant material comprises a non-conductive polymer, a non-conductive glass, or any combination thereof.

63. The anode assembly according to any one of claims 51 to 61, wherein the sealant material comprises polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof.

64. The anode assembly according to any one of claims 51 to 63, wherein at least a portion of the seal has a thickness of about 1 μm to about 50 μm.

65. It is a battery cell, an anode assembly according to claim 1 or 25, an anode current collector bonded to the second surface of the anode layer, A cathode layer is disposed at least partially on the separator layer and has a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface. The battery cell comprising a cathode current collector bonded to the second surface of the cathode layer.

66. The battery cell according to claim 65, further comprising a housing having a plurality of inner walls defining the interior, wherein the anode assembly, anode current collector, cathode layer, and cathode current collector are disposed inside the housing.

67. The battery cell according to claim 65 or claim 66, further comprising a cassolite disposed in the cathode layer.

68. A method for forming an anode assembly, (a) Separator layer and An anode layer, at least partially disposed on the separator layer, having a first surface facing the separator layer, a second surface facing away from the separator layer, and an outer surface extending from the first surface to the second surface, wherein the anode layer comprises a solid electrolyte (SSE) material defining pores adapted to receive the anode material, The anode current collector is provided which is bonded to the second surface of the anode layer. (b) Arranging the separator layer, anode layer, and anode current collector in the chamber, (c) By reducing the absolute pressure in the chamber, the absolute pressure in the pores of the anode layer, P 細孔 To reduce, and (d) The method comprising, after step (c), forming a barrier around the outer surface of the anode layer to form the anode assembly, wherein the barrier defines an interior and an exterior, the anode layer is located inside the barrier, and the barrier is impermeable to liquids and gases.

69. After step (c), P 細孔 The method according to claim 68, wherein the pressure is less than approximately 101,325 Pa.

70. After step (c), P 細孔 The method according to claim 68, wherein the pressure is approximately 1 Pa to approximately 101,324 Pa.

71. After step (c), P 細孔 The method according to claim 70, wherein the current is approximately 100 Pa to approximately 1,000 Pa.

72. After step (c), P 細孔 The method according to claim 70, wherein the current is approximately 1,000 Pa to approximately 10,000 Pa.

73. After step (c), P 細孔 The method according to claim 70, wherein the current is approximately 10,000 Pa to approximately 101,324 Pa.

74. After step (c), P 細孔 The method according to claim 70, wherein the current is approximately 100 Pa to approximately 2,000 Pa.

75. After step (c), P 細孔 The method according to claim 70, wherein the current is approximately 500 Pa to approximately 1,500 Pa.

76. After step (c), P 細孔 The method according to claim 70, wherein the current is approximately 750 Pa to approximately 1,250 Pa.

77. The method according to any one of claims 68 to 76, wherein the barrier is a seal, and the forming of step (d) comprises forming the seal from the sealant material by cold pressing, hot pressing, melting, 3D printing, or any combination thereof, at least partially on the outer surface of the anode layer.

78. The method according to any one of claims 68 to 76, wherein the barrier is a seal, and step (d) forming the seal is formed from the sealant material by applying the sealant material at least partially to the outer surface of the anode layer using a paintbrush, roller, plastic applicator, metal applicator, molding tool, syringe dispenser, dispenser valve, or any combination thereof.

79. The method according to any one of claims 68 to 76, wherein the barrier is a seal, and the forming of step (d) includes forming the seal from the sealant material by immersion coating at least a portion of the outer surface of the anode layer with the sealant material.

80. The method according to any one of claims 68 to 76, wherein the barrier is a seal, and the forming of step (d) comprises forming the seal from the sealant material by at least partially injecting, in-line extrusion, spray deposition, 3D printing, wrapping, or any combination thereof onto the outer surface of the anode layer.

81. The method according to any one of claims 77 to 80, wherein the sealant material is a polymer, and the polymer includes polypropylene, polyethylene, polymethylpentene, polybutene-1, ethylene-octene copolymer, propylene-butane copolymer, polyisobutylene, poly(α-olefin), ethylene propylene rubber, ethylene propylene diene monomer rubber, ethylene vinyl acetate, ethylene acrylate copolymer, polyamide, polyester, polyurethane, styrene block copolymer, polycaprolactone, polyimide, polyvinyl chloride, polycarbonate, polyacrylate, polymethacrylate, fluoropolymer, epoxy resin, epoxy polymer, silicone rubber, or any combination thereof.

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