Single pouch battery cell and method for manufacturing the same

Abstract

To cope with a problem of defect propagation during manufacturing or operation of a battery, a problem of fire hazard induced by a large amount of electrolyte in each battery cell, and a problem of metal contamination caused during welding processes.SOLUTION: An electrochemical cell includes a first current collector coupled to a first portion of a pouch, the first current collector having a first electrode material disposed thereon, a second current collector coupled to a second portion of the pouch, the second current collector having a second electrode material disposed thereon, and a separator disposed between the first electrode material and the second electrode material. The first portion of the pouch is coupled to the second portion of the pouch to enclose the electrochemical cell.SELECTED DRAWING: Figure 1B

Description

Technical Field

[0001] Cross - Reference to Related Applications

[1001] This application claims the priority and benefit of U.S. Provisional Patent Application No. 62 / 181,385, filed on June 18, 2015, entitled "Single Pouch Battery Cells and Methods of Manufacture", the entire disclosed content of which is incorporated herein by reference.

[0002]

[1002] The embodiments described herein generally relate to the manufacture of battery cells, and more particularly, to systems and methods for manufacturing and using single pouch battery cells of a battery module.

Background Art

[0003]

[1003] Lithium - ion electrochemical (battery) cells typically include alternating anode layers and cathode layers separated by a separator. A combination of one anode, one cathode, and one separator separating them may be referred to as one stack. Multiple stacks are typically connected in parallel and inserted into a pouch to form a battery cell. The number of stacks within a battery cell (and thus within the pouch) is usually relatively large (e.g., more than 20) to increase the capacity. The pouch also contains an electrolyte (e.g., an organic solvent and dissolved lithium salts), and the electrolyte is typically introduced in a tightly controlled environment and serves as a medium for lithium - ion transport. The amount of electrolyte within the pouch is proportional to the number of stacks within the pouch, i.e., more electrolyte can be added when there are more stacks.

[0004]

[1004] In manufacturing, battery cells can be constructed by alternately stacking electrode layers (typical high-performance rectangular cells) or by winding a long electrode strip into a "jelly roll" shape (typical cylindrical cells). The stack or roll of electrodes can be inserted into a rigid case sealed with a gasket (most commercially available cylindrical cells), inserted into a laser-welded rigid case, or enclosed in a foil pouch with a heat-sealed seam (commonly referred to as a lithium-ion polymer cell).

[0005]

[1005] One promising application of lithium-ion battery cells is in automotive battery packs, which typically contain multiple battery cells to meet the required output and capacity, and sometimes hundreds or even thousands of battery cells. Each battery cell can further include a plurality of stacks (i.e., anode, cathode, and separator) and electrode leads (i.e., tabs). Usually, several cells are connected via battery tabs and busbars (i.e., interconnecting units) to form one module. A typical battery pack can contain dozens of such modules. As a result, a significant amount of joining, such as welding, is usually required to output the desired amount of power and capacity from one battery pack.

SUMMARY OF THE INVENTION

[0006]

[1006] The devices, systems, and methods described herein relate to the manufacture and use of single-pouch battery cells. In some embodiments, an electrochemical cell comprises a first current collector coupled to a first portion of the pouch, the first current collector having a first electrode material disposed thereon; a second current collector coupled to a second portion of the pouch, the second current collector having a second electrode material disposed thereon; and a separator disposed between the first electrode material and the second electrode material. The first portion of the pouch is coupled to the second portion of the pouch to enclose the electrochemical cell.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]

Figure 1A

[1007] Schematic diagram showing a battery cell according to one embodiment.

Figure 1B

[1008] Schematic diagram showing another type of battery cell according to some embodiments.

Figure 1C

[1009] Top view of the battery cell shown in FIG. 1B.

Figure 1D

[1010] Top view showing another battery cell according to some embodiments.

Figure 1E

[1011] Schematic diagram showing a type of battery cell created using the concept of self - fusing according to some embodiments.

Figure 1F

[1012] Photo of the edge of the battery cell shown in FIG. 1E.

Figure 2

[1013] Schematic diagram showing a battery module including a plurality of single - pouch battery cells according to some embodiments.

Figure 3

[1014] Schematic diagram showing a battery pack including a plurality of battery modules shown in FIG. 2 according to one embodiment.

Figure 4A

[1015] Schematic diagram showing the relative dimensions of each component of a single - pouch battery cell according to some embodiments.

Figure 4B

[1016] Enlarged view showing the corner of the single - pouch battery cell shown in FIG. 4A.

Figure 5

[1017] Schematic diagram showing a battery module including a single - pouch battery cell enclosed in a metal case according to some embodiments.

Figure 6A

[1018] Side view showing a battery module (with the lid open) including a single - pouch battery cell enclosed in a metal case according to some embodiments.

Figure 6B

[1019] Side view showing the battery module shown in FIG. 6A after the lid is closed.

Figure 7A

[1020] Top view showing a battery module including a plurality of single pouch battery cells encapsulated within a plastic frame, according to some embodiments.

Figure 7B

[1021] Side view of the battery module shown in FIG. 7A, showing the upper and bottom covers.

Figure 8A

[1022] Diagram showing a tab design utilized in a battery module including a plurality of single pouch battery cells, according to some embodiments.

Figure 8B

[1023] Diagram showing a spacer of a tab design including a tab connection region of the battery module shown in FIG. 8A.

Figure 8C

[1024] Diagram showing the connector portion of the battery module shown in FIG. 8A.

Figure 9

[1025] Flowchart showing a method of manufacturing single pouch battery cells and modules, according to some embodiments.

Figure 10A

[1026] Diagram showing the layout of an anode assembly including a plurality of anodes disposed on a pouch film, according to some embodiments.

Figure 10B

[1027] Cross-sectional view of the anode assembly shown in FIG. 10A.

Figure 11A

[1028] Diagram showing the layout of a cathode assembly including a plurality of cathodes disposed on a pouch film, according to some embodiments.

Figure 11B

[1029] Cross-sectional view of the cathode assembly shown in FIG. 11A.

Figure 12

[1030] Top view showing an electrode assembly including a cathode assembly and an anode assembly, according to some embodiments.

Figure 13A

[1031] Diagram showing the layout of a unit cell assembly including a plurality of unit cells, according to some embodiments.

Figure 13B

[1032] Cross-sectional view of the unit cell assembly shown in FIG. 13A.

Figure 14

[1033] Figure showing a method for manufacturing unit cells within individual pouches, according to some embodiments.

Figure 15A

[1034] Figure showing a method for manufacturing a unit cell stack, according to some embodiments.

Figure 15B

Figure 16A

[1035] Top view of a unit cell stack prepared by the method shown in FIGS. 15A - 15B.

Figure 16B

Figure 17A

[1036] Figure showing a pouch cell having additional parts for gas venting, resealing, and removal during the manufacture of a single pouch battery cell, according to some embodiments.

Figure 17B

Figure 18

[1037] Figure showing an exemplary tab configuration of a single pouch battery cell, according to some embodiments.

Figure 19A

[1038] Figure showing an exemplary manufacturing method for preparing a single pouch battery cell, according to some embodiments.

Figure 19B

Figure 19C

[1039] Figure showing an exemplary manufacturing method for manufacturing a battery cell with a cylindrical configuration, according to some embodiments.

Figure 19D

Figure 19E

[1040] Figure showing an exemplary manufacturing method for preparing a battery cell with a square configuration, according to some embodiments.

Figure 19F

Figure 19G

Figure 20

[1041] A diagram showing a single pouch battery cell according to some embodiments.

Figure 21

[1042] A diagram showing the capacity retention curve of a battery cell manufactured using the method described above.

Figure 22

[1043] A schematic diagram showing a battery module including an array of single pouch battery cells according to some embodiments.

Figure 23A

[1044] An exploded view of a battery module including a plurality of single pouch battery modules enclosed in a metal case according to some embodiments.

Figure 23B

Figure 24A

[1045] An exploded view of a battery module including a plurality of single pouch battery modules enclosed in a plastic case according to some embodiments.

Figure 24B

Figure 25

[1046] A diagram showing a battery pack including a two-dimensional array of battery modules according to some embodiments.

Figure 26

[1047] A diagram showing a battery pack including a one-dimensional array of battery modules according to some embodiments.

Figure 27A

[1048] A schematic diagram of a battery pack showing the stacking and connection characteristics of battery modules according to some embodiments.

Figure 27B

Figure 27C

Figure 28A

[1049] A completed view of a battery rack including a plurality of single pouch battery modules arranged in a rack configuration according to some embodiments.

Figure 28B

DETAILED DESCRIPTION OF THE INVENTION

[0008]

[1050] The embodiments described herein generally relate to single pouch battery cells, and more particularly to systems and methods for manufacturing and using single pouch battery cells in battery modules or battery packs. In some embodiments, a single pouch battery cell includes an anode, a cathode, a separator disposed therebetween, and a pouch that houses the anode, cathode, and separator to form the single pouch battery cell. In some embodiments, the anode and / or cathode includes a semi-solid electrode material.

[0009]

[1051] By reducing the amount of non-electrochemically active material within a battery cell, the energy density of a given battery cell can be increased. The thickness of the current collector is typically selected to be more easily handled than taking into account the current density and / or to provide mechanical support for the electrode. In other words, the current collector is generally thicker than the thickness required to handle the high current density generated by the electrochemical reaction within the battery, but if the current collector becomes thinner (i.e., optimized for current density), it can become very brittle and may easily break during the manufacturing process. For example, a current collector with a thickness of 20 μm currently used in some conventional batteries can easily handle the amount of current generated by a conventional battery, but only a few μm of the current collector is required to shuttle its electrons.

[0010]

[1052] As described herein, a single pouch cell can be made to use a thinner current collector while improving other aspects of the battery cell structure. For example, the current collector can be coupled to the pouch so that the pouch provides physical support for the current collector and can improve handling, allowing a thinner current collector to be used for electrical conduction while using the pouch. Some additional advantages of this approach include, but are not limited to, (i) reducing or eliminating defect propagation from one battery cell to one or more adjacent battery cells, (ii) reducing the fire hazard or other thermal hazards caused by the large amount of flammable electrolyte in conventional batteries, (iii) reducing or eliminating metal contamination that can occur during the welding process in the manufacture of conventional batteries and can impair battery performance by causing an internal short circuit within the battery, (iv) facilitating handling of individual pouches when stacking multiple single pouch battery cells into a battery module or battery pack, (v) improving manufacturing yield (by capacity, thickness, impedance, weight, etc.) due to the convenience of sorting and eliminating individual pouches during the manufacture of multi-pouch or multi-stack batteries, (vi) providing means for supporting the semi-solid electrode material during the manufacture of the battery or electrode, thereby achieving a uniform distribution of the electrode material (e.g., uniform thickness) and avoiding leakage of the electrode material from the battery cell, and (vii) reducing or eliminating the fire hazard of wet electrodes in a welding process where welding sparks can ignite the usually flammable electrolyte. The single pouch battery cell approach can prevent welding sparks from reaching and igniting the electrolyte since all welding processes can be performed after the individual battery cells are housed within the pouch, thus reducing or eliminating such a fire hazard. As used herein, the term "semi-solid" refers to a material in which a liquid phase and a solid phase are mixed, such as a particle suspension, a colloidal suspension, an emulsion, a gel, or a micelle.

[0011]

[1053] As used herein, the term "single pouch battery cell" refers to a battery cell (also referred to herein as an electrochemical cell) that includes a pouch that typically houses a single unit cell assembly including one anode, one cathode, and one separator. In some cases, as explicitly stated herein, a single pouch battery cell can also include two unit cell assemblies.

[0012]

[1054] As used herein, the terms "about" and "approximately" generally include plus or minus 10% of the stated value. For example, "about 5" would include from 4.5 to 5.5, "approximately 10" would include from 9 to 11, and "about 100" would include from 90 to 110.

[0013]

[1055] In conventional battery manufacturing, a number of complex and costly processes need to be performed in sequence, each of which results in a yield loss, incurs capital expenses for equipment, and involves energy consumption and operating expenses for consumable materials. The battery manufacturing process first includes preparing separate anode mixtures / cathode mixtures (also referred to as "slurries"), which are typically mixtures of electrochemically active ion storage compounds, conductive additives, and polymeric binders. The surface of a flexible metal foil is then coated with this mixture to form electrodes (anodes and cathodes). The formed electrodes are then typically compressed under high pressure to increase density and adjust thickness. These compressed electrode / foil composites are then cut to a size and / or shape suitable for the particular form factor of the battery being manufactured.

[0014]

[1056] One anode, one cathode, and one separator can be stacked to form a unit cell assembly. Each unit cell assembly typically also includes a conductive tab (also called a lead) that couples the electrodes to an external circuit. A plurality of unit cell assemblies are then stacked or arranged to form a battery cell. The number of unit cell assemblies within one battery cell can vary, for example, depending on the desired capacity and / or thickness of the resulting battery cell. These stacked unit cell assemblies are electrically in parallel, and the tabs of each unit cell assembly are typically welded together by a welding process such as resistance welding, laser welding, ultrasonic welding, seam welding, and electron beam welding. A vacuum pouch sealing process can then be performed to form the battery cell. During vacuum pouch sealing, an electrolyte is typically injected into the stacked unit cell assemblies, and the unit cell assemblies and the electrolyte are sealed within the pouch.

[0015]

[1057] The sealed battery cell is then subjected to a formation process. In this process, an initial charge operation can be performed to passivate the electrode / electrolyte interface and create a stable solid electrolyte interface (SEI) that can prevent side reactions. Further, typically several charge and discharge cycles of the battery are also performed to ensure that the capacity of the battery meets the required specifications. Typically, a degassing process is performed to release gases introduced during the initial charge stage, called the precharge process, or during the electrochemical reactions in the battery formation process. The presence of gas trapped in the electrodes generally reduces the conductivity and density of the electrodes, limits the amount of active electrochemical material that can be placed in the battery cell, and further can cause lithium dendrites to form, which degrade the performance of the battery, such as cycle life and overall safety performance. After releasing the trapped gas, a resealing process can be performed to reseal the battery cell.

[0016]

[1058] The above manufacturing process and the battery obtained thereby have several problems. The first problem is defect propagation during battery manufacturing or operation. More specifically, during manufacturing, if there is a problem with one unit cell assembly, usually multiple unit cell assemblies within the entire cell, including the assembly, may be in a defective state. Therefore, a defect in one unit cell assembly may propagate, resulting in the rejection of multiple unit cell assemblies within the same battery cell, which may affect the manufacturing yield. Furthermore, during battery operation, there is also a risk that a defect may propagate from one unit cell assembly to one or more adjacent unit cell assemblies. For example, a typical defect in a battery is thermal runaway. During thermal runaway, the increase in temperature causes more active electrochemical reactions, which may further increase the temperature, resulting in a positive feedback loop and, in some cases, cycle destruction. If a thermal runaway reaction occurs in one unit cell assembly within a battery cell, it is highly likely to cause thermal runaway in adjacent unit cell assemblies through various heat transfer mechanisms such as direct contact between cases, collision of hot ventilation gases, or collision of burning ventilation gases. A chain reaction may occur, and there is a risk that the pack may be destroyed within seconds or within a few hours of using each cell.

[0017]

[1059] A second problem in conventional battery manufacturing is the fire hazard posed by the large amount of electrolyte within each battery cell. In lithium-ion batteries, the electrolyte is generally hydrocarbon-based and is usually flammable. The fact that the electrolyte in a lithium-ion cell is hydrocarbon-based means that in the event of a fire, these cells may behave differently from lead-acid, NiMH, or NiCd cells containing aqueous electrolytes. More specifically, there is a risk that flammable vapors will be released due to leakage or ventilation of the lithium-ion cell. When a cell containing an aqueous electrolyte is exposed to fire, the water within the cell absorbs heat, reducing the total heat released by the fire and mitigating the danger. In contrast, when a lithium-ion cell is exposed to fire, it causes the release of flammable electrolyte, thereby increasing the total heat released by the fire and exacerbating the fire hazard. The amount of electrolyte within a battery cell is approximately proportional to the amount of electrode material within the same battery cell. Conventional battery cells containing multiple unit cell assemblies (i.e., multiple anode / cathode stacks) typically contain a corresponding large amount of electrolyte. Therefore, the large amount of electrolyte within each battery cell can pose an increased fire hazard.

[0018]

[1060] A third problem in conventional battery manufacturing is metal contamination that occurs during the welding process. Welding is typically performed before sealing the entire battery cell, which contains multiple electrode stacks, within a pouch, so the electrodes are exposed to metal particles that spatter from the welding area. If these metal particles adhere near the welding area, there is a possibility of an electrical short circuit. Additionally, these metal particles can disperse within the electrode material during welding, potentially causing an internal short circuit. The contaminated metal within this cell can form metal dendrites, which can cause a short circuit. For example, copper contaminants during welding to the cathode region can electrochemically deposit on the anode side during battery cycling, which can potentially cause an internal short circuit because copper is unstable at most voltages of the cathode material. Copper dendrites are more robust than lithium dendrites because they have a higher melting point.

[0019] Single Pouch Battery Cell and Battery Module

[1061] Figure 1A is a schematic diagram showing a battery cell that can at least partially address the aforementioned problems of conventional battery manufacturing. The battery cell 100 includes an anode 110 including an anode material 111 disposed on an anode current collector 150 (also referred to herein as "ACC150"), a cathode 120 including a cathode material 121 disposed on a cathode current collector 160 (also referred to herein as "CCC160"), and a separator 130 disposed between the anode 110 and the cathode 120. The assembly of the anode 110, the cathode 120, and the separator 130 is substantially housed within a pouch 140, and the pouch 140 can reduce defect propagation (e.g., fire hazard) by separating the battery cell 100 from one or more adjacent cells in a battery module or pack, thereby limiting unintentional electrochemical reactions within individual cells. Optionally, the ACC150 and the CCC160 can also be disposed inside the pouch 140 before assembling the anode 110, the cathode 120, or the battery cell 100. By using the pouch, the pouch 140 protects the electrodes (i.e., the anode 110 and the cathode 120) from metal particles or any other substances that could short-circuit the battery cell, so that metal contamination at the electrodes during the welding process during the construction of the battery module / pack can also be reduced or eliminated. Optionally, in some embodiments, at least one of the ACC150 and the CCC160 can also include a tab or tab connection (not shown) that acts as an electrical lead (or connection point) for connecting to one or more external electrical circuits.

[0020]

[1062] In some embodiments, the ACC150 and CCC160 (collectively referred to herein as the "current collector") can be in the form of a substrate, sheet, or foil, or in any other shape factor, and can include a conductive material. In some embodiments, the current collector can include aluminum, copper, lithium, nickel, stainless steel, tantalum, titanium, tungsten, vanadium, or a mixture, combination, or alloy thereof. In other embodiments, the current collector can also include non-metallic materials such as carbon, carbon nanotubes, or metal oxides (such as TiN, TiB2, MoSi2, n-BaTiO3, Ti2O3, ReO3, RuO2, IrO2, etc.). In some embodiments, the current collector can include a conductive coating disposed on any of the aforementioned metallic and non-metallic materials. In some embodiments, the conductive coating can include carbon-based materials, conductive metals, and / or non-metallic materials such as composites or layer materials.

[0021]

[1063] In some embodiments, the current collector includes a base substrate having one or more surface coatings to improve the mechanical, thermal, chemical, or electrical properties of the current collector. In one example, one or more coatings of the current collector can be configured to reduce corrosion and modify adhesion properties (e.g., a hydrophilic coating or a hydrophobic coating, respectively). In another example, one or more coatings of the current collector can include a material having high conductivity to improve the overall charge transport of the base substrate. In yet another example, the coating can include a material having high thermal conductivity to promote heat dissipation of the base substrate and protect the battery from overheating. In yet another example, the coating can include a heat-resistant or flame-retardant material to prevent the fire hazard of the battery. In yet another example, the coating can be configured to be rough so as to increase the surface area and / or enhance the adhesion to electrode materials (such as anode material 111 and cathode material 121). In yet another example, the coating can include a material having good adhesion or pasting properties to the electrode materials.

[0022]

[1064] In some embodiments, the current collector includes a conductive substrate, sheet, or foil having a roughened surface to improve mechanical, electrical, and thermal contact between the electrode material and the current collector. The roughened surface of the current collector can enhance the adhesion of the electrode material to the current collector by increasing the physical contact area between the electrode material and the current collector. By increasing the physical contact area in this way, the electrical and thermal contact between the current collector and the electrode material can also be improved (e.g., reducing electrical resistance and thermal resistance).

[0023]

[1065] In some embodiments, the current collector includes a porous current collector such as a wire mesh. A wire mesh (also referred to herein as a mesh) can include any number of filament wires that can be assembled into various configurations using suitable processes, such as a regular pattern or structure made by weaving, braiding, knitting, etc., or a more random pattern or structure made by randomly distributing wires and connecting them by welding, adhesion, or other suitable techniques. Further, the wires including the mesh can be made of any suitable material. For example, in some embodiments, the wire is a metal such as steel, aluminum, copper, titanium, or any other suitable metal. Other embodiments In this case, the wire can be made of a conductive non-metallic material, such as, for example, carbon nanofibers or any other suitable material. In some embodiments, the wire can include a coating. For example, the coating can be configured to reduce corrosion and improve or reduce adhesion properties (e.g., a hydrophilic coating or a hydrophobic coating, respectively). Examples of porous current collectors are described in U.S. Patent Publication No. US2013 / 0065122, entitled "Semi-Solid Electrode Cell Having A Porous Current Collector and Methods of Manufacture", and U.S. Patent Application No. US15 / 097838, entitled "Semi-Solid Electrodes with Porous Current Collectors and Methods of Manufacture", the disclosures of which are hereby incorporated by reference in their entireties.

[0024]

[1066] In some embodiments, the current collector can be made by any of coating or deposition techniques such as, but not limited to, chemical vapor deposition (CVD) (initiated CVD, hot wire CVD, plasma enhanced CVD, and other portable CVDs, etc.), physical vapor deposition, sputter deposition, magnetron sputtering, high frequency sputtering ring, atomic layer deposition, pulsed laser deposition, plating, electroplating, dip coating, brushing, spray coating, sol-gel method (by dip coating, brushing or spray coating), electrostatic spray coating, 3D printing, spin coating, electrodeposition, powder coating, sintering, self-assembly method, and any combination of these techniques.

[0025]

[1067] In some embodiments, the properties of the current collector formed by deposition or coating can be optimized by varying the deposition parameters during deposition. For example, physical properties such as the texture of the coating, the thickness of the coating, the uniformity of the thickness, and surface morphology such as surface roughness, porosity, and general mechanical properties such as fracture toughness, ductility, and tensile strength can be optimized by fine-tuning the deposition parameters. Similarly, chemical properties such as chemical resistance and corrosion resistance to electrolytes and salts, as well as special reactivity, adhesiveness, and affinity can be optimized by changing the deposition parameters to produce a functional current collector. In some embodiments, the various physical and chemical properties of the current collector formed by deposition or coating can be further improved or modified after deposition by subsequent surface treatment or temperature treatment such as annealing or rapid thermal (flash) annealing, or electrochemical polishing, or using any combination of these techniques.

[0026]

[1068] In some embodiments, the anode current collector 150 can have a thickness in the range of about 1 μm to about 20 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 1 μm to about 18 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 1 μm to about 17 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 1 μm to about 16 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 1 μm to about 15 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 1 μm to about 14 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 1 μm to about 13 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 1 μm to about 12 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 2 μm to about 11 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 3 μm to about 10 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 4 μm to about 9 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 5 μm to about 8 μm. In some embodiments, the ACC 150 can have a thickness in the range of about 6 μm to about 7 μm. In some embodiments, the ACC 150 can have a thickness less than about 1 μm, less than about 2 μm, less than about 3 μm, less than about 4 μm, less than about 5 μm, less than about 6 μm, less than about 7 μm, less than about 8 μm, less than about 9 μm, less than about 10 μm, less than about 11 μm, less than about 12 μm, less than about 13 μm, less than about 14 μm, less than about 15 μm, less than about 16 μm, less than about 17 μm, less than about 18 μm, less than about 19 μm, and less than about 20 μm, including all thicknesses between the following values.

[0027]

[1069] The anode material 111 can be selected from various materials. In some embodiments, the anode material 111 includes carbon-based materials such as, but not limited to, hard carbon, carbon nanotubes, carbon nanofibers, porous carbon, and graphene. In some embodiments, the anode material 111 includes, but is not limited to, spinel Li4Ti5O 12 (LTO), titanium-based oxides such as titanium dioxide (TiO2, titani um a). In some embodiments, the anode material 111 includes alloy or dealloy materials such as, but not limited to, silicon, silicon monoxide (SiO), germanium, tin oxide (SnO2). In some embodiments, the anode material 111 includes transition metal compounds (such as oxides, phosphides, sulfides, nitrides, etc.). The general formula of the transition compound can be written as M x N y , where M can be selected from iron (Fe), cobalt (Co), copper (Cu), manganese (Mn), and nickel (Ni), and N can be selected from oxygen (O), phosphorus (P), sulfur (S), and nitrogen (N).

[0028]

[1070] In some embodiments, the anode material 111 is amorphous carbon, disordered carbon, graphite-like carbon, or carbon coated or decorated with metal, graphite, non-graphite-like carbon, mesocarbon microbeads, boron-carbon alloy, hard or disordered carbon, lithium titanium spinel, or a solid metal or metal alloy or metalloid or metalloid alloy that reacts with lithium to form an electron compound, such as Si, Ge, Sn, Bi, Zn, Ag, Al, any other suitable metal alloy, or a combination thereof, or LiAl, Li9Al4, Li3Al, LiZn, LiAg, Li 10 Ag3, Li5B4, Li7B6, Li 12 Si7, Li 21 Si8, Li 13 Si4, Li 21 Si5, Li5Sn2, Li 13 Sn5, Li7Sn2, Li 22It can include a solid selected from a group consisting of lithiated metals or metal alloys such as compounds like Sn5, Li2Sb, Li3Sb, LiBi, or Li3Bi, or lithiated or non-lithiated compositions, any other materials or their alloys, amorphous metal alloys, or any other combinations thereof.

[0029]

[1071] In some embodiments, the anode material 111 includes an electron compound. The electron compound can be based on the chemical formula MM', where M is one metal element and M' is a different metal element. The electron compound can also include more than two metal elements. The M atoms of the electron compound can be, for example, Cu, Li, and Mn, and the M' element of the electron compound can be, for example, Sb. Exemplary electron compounds are, in particular, Cu2Sb, Li2CuSb, and Li3Sb. In one example, the electron compound of the anode material 111 can have a completely disordered structure in which the M or M' atoms are randomly arranged. In another example, the electron compound of the anode material 111 has a partially disordered structure in which the M or M' atoms in the crystal lattice are arranged non-disorderly.

[0030]

[1072] In some embodiments, the anode material 111 can be made porous so as to increase the surface area and enhance the lithium intercalation rate of the resulting electrode. In one example, the anode material 111 includes porous Mn2O3 that can be prepared, for example, by thermal decomposition of MnCO3 spheres. In another example, the anode material 111 includes porous carbon fibers that are prepared, for example, by electrospinning a mixed solution of polyacrylonitrile and poly(1-lactide) followed by carbonization. In some embodiments, the porosity of the anode material 111 can be realized or enhanced by using a porous current collector. For example, the anode material 111 can include Cu2Sb conformally deposited on a porous foam structure so as to have a specific porosity.

[0031]

[1073] In some embodiments, the thickness of the anode material 111 can be in the range of about 250 μm to about 2000 μm, including all thicknesses between the following values, in the range of about 300 μm to about 2000 μm, in the range of about 350 μm to about 2000 μm, in the range of about 400 μm to about 2000 μm, in the range of about 450 μm to about 2000 μm, in the range of about 500 μm to about 2000 μm, in the range of about 250 μm to about 1500 μm, in the range of about 300 μm to about 1500 μm, in the range of about 350 μm to about 1500 μm, in the range of about 400 μm to about 1500 μm, in the range of about 450 μm to about 1500 μm, in the range of about 500 μm to about 1500 μm, in the range of about 250 μm to about 1000 μm, in the range of about 300 μm to about 1000 μm, in the range of about 350 μm to about 1000 μm, in the range of about 400 μm to about 1000 μm, in the range of about 450 μm to about 1000 μm, in the range of about 500 μm to about 1000 μm, in the range of about 250 μm to about 750 μm, in the range of about 300 μm to about 750 μm, in the range of about 350 μm to about 750 μm, in the range of about 400 μm to about 750 μm, in the range of about 450 μm to about 750 μm, in the range of about 500 μm to about 750 μm, in the range of about 250 μm to about 700 μm, in the range of about 300 μm to about 700 μm, in the range of about 350 μm to about 700 μm, in the range of about 400 μm to about 700 μm, in the range of about 450 μm to about 700 μm, in the range of about 500 μm to about 700 μm, in the range of about 250 μm to about 650 μm, in the range of about 300 μm to about 650 μm, in the range of about 350 μm to about 650 μm, in the range of about 400 μm to about 650 μm, in the range of about 450 μm to about 650 μm, in the range of about 500 μm to about 650 μm, in the range of about 250 μm to about 600 μm, in the range of about 300 μm to about 600 μm, in the range of about 350 μm to about 600 μm, in the range of about 400 μm to about 600 μm, in the range of about 450 μm to about 600 μm, in the range of about 500 μm to about 600 μm, in the range of about 250 μm to about 550 μm, in the range of about 300 μm to about 550 μm, in the range of about 350 μm to about 550 μm, in the range of about 400 μm to about 550 μm, in the range of about 450 μm to about 550 μm, or in the range of about 500 μm to about 550 μm.

[0032]

[1074] In some embodiments, the cathode 120 includes a cathode current collector 160 and a cathode material 121. The cathode current collector 160 of the cathode 120 is substantially the same as the anode current collector 150 of the anode 110 described above. Thus, the same techniques described in relation to the deposition and / or coating techniques of the anode current collector 150 may also be applicable to the fabrication of the cathode current collector 160. In some embodiments, the cathode current collector 160 can have a thickness in the range of about 1 μm to about 40 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 38 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 36 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 34 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 32 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 30 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 28 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 26 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 24 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 22 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 20 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 2 μm to about 18 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 3 μm to about 16 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 4 μm to about 14 μm. In some embodiments, the CCC 160 can have a thickness in the range of about 5 μm to about 12 μm and It is possible. In some embodiments, CCC160 can have a thickness in the range of about 6 μm to about 10 μm. In some embodiments, CCC160 can have a thickness in the range of about 7 μm to about 8 μm. In some embodiments, CCC160 can have a thickness of less than about 1 μm, less than about 2 μm, less than about 3 μm, less than about 4 μm, less than about 5 μm, less than about 6 μm, less than about 7 μm, less than about 8 μm, less than about 9 μm, less than about 10 μm, less than about 11 μm, less than about 12 μm, less than about 13 μm, less than about 14 μm, less than about 15 μm, less than about 16 μm, less than about 17 μm, less than about 18 μm, less than about 19 μm, less than about 20 μm, less than about 21 μm, less than about 22 μm, less than about 23 μm, less than about 24 μm, less than about 25 μm, less than about 26 μm, less than about 27 μm, less than about 28 μm, less than about 29 μm, less than about 30 μm, less than about 31 μm, less than about 32 μm, less than about 33 μm, less than about 34 μm, less than about 35 μm, less than about 36 μm, less than about 37 μm, less than about 38 μm, less than about 39 μm, and less than about 40 μm, including all thicknesses between the following values.

[0033]

[1075] The cathode material 121 of the cathode 120 can be, for example, nickel cobalt aluminum (NCA), core shell gradient (CSG), spinel type lithium ion (LMO), lithium iron phosphate (LFP), cobalt based lithium ion (LCO), and nickel cobalt manganese (NCM). In some embodiments, the cathode material 121 is nickel It can include solid compounds known to those skilled in the art, such as those used in nickel-metal hydride (NiMH) batteries and nickel-cadmium (NiCd) batteries. In some embodiments, the cathode material 121 can include the general family of ordered rock salt compounds LiMO2, such as D-NaFeO2 (so-called "layered compounds") or those having an orthorhombic LiMnO2 structure type, or their derivatives having different crystal symmetries, atomic orderings, or partial substitutions of metals or oxygen. M includes at least one Group 1 transition metal, but may also include non-transition metals such as Al, Ca, Mg, or Zr, among others. Examples of such compounds are LiCoO2, Mg-doped LiCoO2, LiNiO2, Li(Ni, Co, Al)O2 (referred to as "NCA"), and Li(Ni, Mn, Co)O2 (referred to as "NMC" or "NCM"). Exemplary cathode materials 121 of other families include those having a spinel structure such as LiMn2O4 and its derivatives, so-called "layered spinel nanocomposites" that include nanoscopic regions having an ordered rock salt and spinel order, olivine LiMPO4 (M includes one or more of Mn, Fe, Co, or Ni) and its derivatives, partially fluorinated compounds such as LiVPO4F, other "polyanion" compounds described below, and vanadium oxides V 11 such as V2O5 and V6O x O y .

[0034]

[1076] In some embodiments, the cathode material 121 includes a transition metal polyanion compound as described, for example, in U.S. Patent No. 7,338,734. In some embodiments, the cathode material 121 includes an alkali metal transition metal oxide or phosphate. For example, this compound is A x (M’ 1-a M” a ) y (XD4) z , A x (M’ 1-a M” a ) y (DXD4) z or A x(M’ 1-a M” a ) y (X2D7) z having the composition such that x + y(1 - a)×(one or more formal valences of M’) + ya×(one or more formal valences of M”) has a value equal to z×(the formal valence of the XD4, X2D7 or DXD4 group), or this compound is (A 1-a M” a ) x M’ y (XD4) z 、(A 1-a M” a ) x M’ y (DXD4) z or (A 1-a M” a ) x M’ y (X2D7) z having the composition such that (1 - a)x + (amount ax)×(one or more formal valences of M”) + y×(one or more formal valences of M’) has a value equal to z×(the formal valence of the XD4, X2D7 or DXD4 group). In this compound, A is at least one of an alkali metal and hydrogen, M’ is a Group 1 transition metal, X is at least one of phosphorus, sulfur, arsenic, molybdenum and tungsten, M” is any one of the metals of Group IIA, IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB, IIIB, IVB, VB, and VIB, and D is at least one of oxygen, nitrogen, carbon or halogen. The cathode material 121 can be a olivine structure compound LiMPO4, where M is one or more of V, Cr, Mn, Fe, Co and Ni, and this compound is optionally doped at the positions of Li, M or O. Defects at the Li position are compensated by the addition of a metal or metalloid, and defects at the O position are compensated by the addition of a halogen. In some embodiments, the cathode material 121 has an olivine structure and the chemical formula (Li 1-x Z x)It contains a thermally stable transition metal-doped lithium transition metal phosphate having MPO4. Here, M is one or more of V, Cr, Mn, Fe, Co, and Ni, Z is a non-alkali metal dopant such as one or more of Ti, Zr, Nb, Al, or Mg, and x ranges from 0.005 to 0.05.

[0035]

[1077] In other embodiments, the lithium transition metal phosphate material is Li 1-x-z M 1+z has an overall composition of MPO4, where M is at least one first-row transition metal selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, and Ni, x ranges from 0 to 1, and z can be positive or negative. M contains Fe and z is between about 0.15 and 0.15. This material can exhibit a solid solution in the composition range of 0 < x < 0.15, or can exhibit a stable solid solution in the composition range of x from 0 to at least about 0.05, or can exhibit a stable solid solution in the composition range of x from 0 to at least 0.07 at room temperature (22 - 25 °C). This material may also exhibit a solid solution in a regime poor in lithium, for example, x ≥ 0.8, or x ≥ 0.9, or x ≥ 0.95.

[0036]

[1078] In some embodiments, the cathode material 121 includes a metal salt that stores alkali ions by undergoing a substitution or conversion reaction. Examples of such compounds include metal oxides such as CoO, Co3O4, NiO, CuO, and MnO, which react with Li to undergo a substitution or conversion reaction to form a mixture of Li2O and a metal component in a more reduced oxide form or the form of the metal itself, and are usually used as an inert electrode in a lithium battery. Other examples include metal fluorides such as CuF2, FeF2, FeF3, BiF3, CoF2, and NiF2, which undergo a substitution or conversion reaction to form LiF and a reduced metal component. Such fluorides can be used as a positive electrode in a lithium battery. In other embodiments, the cathode material 121 includes carbon monofluoride or a derivative thereof. In some embodiments, the cathode material 121 that undergoes a substitution or conversion reaction is in the form of particles having an average dimension of 100 nanometers or less. In some embodiments, the cathode material 121 that undergoes a substitution or conversion reaction includes a nanocomposite of the cathode material 121 mixed with an inert host such as, but not limited to, carbon, or a conductive and relatively ductile compound such as a metal or a metal sulfide. FeS2 and FeF3 can also be used as inexpensive conductive cathode materials 121 in non-aqueous or aqueous lithium systems. In some embodiments, CF x An electrode, an FeS2 electrode, or an MnO2 electrode is a positive cathode material used with a negative electrode of lithium metal to fabricate a lithium battery. In some embodiments, such a battery is a primary battery. In some embodiments, such a battery is a storage battery.

[0037]

[1079] In some embodiments, the operating ions acting in the cathode material 121 are Li + , Na + , H + , Mg 2+ , Al 3+ , or Ca 2+ selected from a group consisting of. In some embodiments, the operating ions are Li + or Na +It is selected from a group consisting of. In some embodiments, the cathode material 121 includes a solid such as an ion storage compound. In some embodiments, this ion is a proton or a hydroxyl ion, and the cathode material 121 includes those ions used in nickel-cadmium batteries or nickel-metal hydride batteries. In some embodiments, this ion is lithium, and the cathode material 121 is selected from a group consisting of metal fluorides such as CuF2, FeF2, FeF3, BiF3, CoF2, and NiF2.

[0038]

[1080] In some embodiments, this ion is lithium, and the cathode material 121 is selected from a group consisting of metal oxides such as CoO, Co3O4, NiO, CuO, and MnO.

[0039]

[1081] In some embodiments, this ion is lithium, and the cathode material 121 includes an intercalation compound selected from compounds having the chemical formula (Li 1-x Z x )MPO4. Here, M is one or more of V, Cr, Mn, Fe, Co, and Ni, Z is a non-alkali metal dopant such as one or more of Ti, Zr, Nb, Al, or Mg, and x is in the range of 0.005 to 0.05.

[0040]

[1082] In some embodiments, the ion is lithium, and the cathode material 121 includes an intercalation compound selected from compounds having the chemical formula LiMPO4. Here, M is one or more of V, Cr, Mn, Fe, Co, and Ni, and this compound is optionally doped at the positions of Li, M, or O.

[0041]

[1083] In some embodiments, the ion is lithium, and the cathode material 121 is A x (M’ 1-a M” a ) y (XD4) z 、A x(M’ 1-a M” a ) y (DXD4) z 、and A x (M’ 1-a M” a ) y (X2D7) z comprises an intercalation compound selected from the group consisting of. Here, x + y(1 - a)×(one or more formal valences of M’) + ya×(one or more formal valences of M”) is equal to z×(formal valence of the XD4, X2D7, or DXD4 group), A is at least one of an alkali metal and hydrogen, M’ is a Group 1 transition metal, X is at least one of phosphorus, sulfur, arsenic, molybdenum, and tungsten, M” is any one of the metals of Group IIA, IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB, IIIB, IVB, VB, and VIB, and D is at least one of oxygen, nitrogen, carbon, or halogen.

[0042]

[1084] In some embodiments, this ion is lithium, and the cathode material 121 is (A 1-a M” a ) x M’ y (XD4) z , (A 1-a M” a ) x M’ y (DXD4) z and (A 1-a M” a ) x M’ y (X2D7) zIt contains an intercalation compound selected from a group consisting of. Here, (1 - a)x + (amount ax) × (one or more formal valences of M”) + y × (one or more formal valences of M’) is equal to z × (formal valence of the XD4, X2D7 or DXD4 group), A is at least one of an alkali metal and hydrogen, M’ is a Group 1 transition metal, X is at least one of phosphorus, sulfur, arsenic, molybdenum and tungsten, M” is any of the metals in Group IIA, IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB, IIIB, IVB, VB, and VIB, and D is at least one of oxygen, nitrogen, carbon or halogen.

[0043]

[1085] In some embodiments, this ion is lithium, and the cathode material 121 contains an intercalation compound selected from a group consisting of ordered rock salt compounds LiMO2 such as α-NaFeO2 and those having an orthorhombic LiMnO2 structure type, or their derivatives having different crystal symmetries, atomic orders or partial substitutions of metals or oxygen. Here, M contains at least one Group 1 transition metal, but may also contain non-transition metals such as Al, Ca, Mg or Zr although not limited thereto.

[0044]

[1086] In some embodiments, the cathode material 121 contains a solid such as amorphous carbon, disordered carbon, graphite-like carbon, or carbon coated or decorated with a metal.

[0045]

[1087] In some embodiments, the cathode material 121 can contain a solid containing nanostructures such as, for example, nanowires, nanorods and nanotetrapods.

[0046]

[1088] In some embodiments, the cathode material 121 contains a solid such as an organic redox compound.

[0047]

[1089] In some embodiments, the cathode material 121 comprises a solid selected from the group consisting of ordered rock-salt compounds LiMO2, such as those having α-NaFeO2 and orthorhombic LiMnO2 structure types, or derivatives thereof having different crystal symmetries, atomic orders, or partial substitutions of metal or oxygen, where M includes at least one first row transition metal, but may also include non-transition metals, such as, but not limited to, Al, Ca, Mg, or Zr.

[0048]

[1090] In some embodiments, the cathode material 121 is A x (M' 1-a M” a ) y (XD4) z , A x (M' 1-a M” a ) y (DXD4) z , and A x (M' 1-a M” a ) y (X2D7) z where x+y(1-a)×(formal valence(s) of M′)+ya×(formal valence(s) of M″) is equal to z×(formal valence(s) of Group XD4, X2D7 or DXD4), A is at least one of an alkali metal and hydrogen, M′ is a first row transition metal, X is at least one of phosphorus, sulfur, arsenic, molybdenum and tungsten, M″ is any of Group IIA, IIIA, IVA, VA, VIA, VIIA, VIIIA, IB, IIB, IIIB, IVB, VB, and VIB metals, and D is at least one of oxygen, nitrogen, carbon, or halogen.

[0049]

[1091] In some embodiments, the cathode material 121 is LiMn2O4 and its derivatives, layered spinel nanocomposites whose structures include nanoscopic domains with ordered rocksalt and spinel order, including but not limited to LiNi 0.5 Mn1.5 So-called "high-voltage spinels" having a potential exceeding 4.3 V (vs. Li / Li+), such as O4, olivine LiMPO4 (M includes one or more of Mn, Fe, Co, or Ni), and its derivatives, partially fluorinated compounds such as LiVPO4F, other "polyoxyanion" compounds, and V2O5 and V 11 such as vanadium oxides V x O y can include compounds selected from a group consisting of.

[0050]

[1092] In some embodiments, the thickness of the cathode material 121 is within the range of about 250 μm to about 2000 μm, within the range of about 300 μm to about 2000 μm, within the range of about 350 μm to about 2000 μm, within the range of about 400 μm to about 2000 μm, within the range of about 450 μm to about 2000 μm, within the range of about 500 μm to about 2000 μm, within the range of about 250 μm to about 1500 μm, within the range of about 300 μm to about 1500 μm, within the range of about 350 μm to about 1500 μm, within the range of about 400 μm to about 1500 μm, within the range of about 450 μm to about 1500 μm, within the range of about 500 μm to about 1500 μm, within the range of about 250 μm to about 1000 μm, within the range of about 300 μm to about 1000 μm, within the range of about 350 μm to about 1000 μm, within the range of about 400 μm to about 1000 μm, within the range of about 450 μm to about 1000 μm, within the range of about 500 μm to about 1000 μm, within the range of about 250 μm to about 750 μm, within the range of about 300 μm to about 750 μm, within the range of about 350 μm to about 750 μm, within the range of about 400 μm to about 750 μm, within the range of about 450 μm to about 750 μm, within the range of about 500 μm to about 750 μm, within the range of about 250 μm to about 700 μm, within the range of about 300 μm to about 700 μm, within the range of about 350 μm to about 700 μm, within the range of about 400 μm to about 700 μm, within the range of about 450 μm to about 700 μm, within the range of about 500 μm to about 700 μm, within the range of about 250 μm to about 650 μm, within the range of about 300 μm to about 650 μm, within the range of about 350 μm to about 650 μm, within the range of about 400 μm to about It can be within the range of 650 μm, within the range of about 450 μm to about 650 μm, within the range of about 500 μm to about 650 μm, within the range of about 250 μm to about 600 μm, within the range of about 300 μm to about 600 μm, within the range of about 350 μm to about 600 μm, within the range of about 400 μm to about 600 μm, within the range of about 450 μm to about 600 μm, within the range of about 500 μm to about 600 μm, within the range of about 250 μm to about 550 μm, within the range of about 300 μm to about 550 μm, within the range of about 350 μm to about 550 μm, within the range of about 400 μm to about 550 μm, within the range of about 450 μm to about 550 μm, or within the range of about 500 μm to about 550 μm.

[0051]

[1093] In some embodiments, at least one of the anode material or the cathode material includes a semi-solid or a concentrated ion storage liquid reactant. "Semi-solid" means that the material is a mixture of a liquid phase and a solid phase, such as, for example, a semi-solid particle suspension, a colloidal suspension, an emulsion, a gel, or a micelle. "Concentrated ion storage liquid" or "concentrated liquid" means that the liquid is not merely a solvent as in the case of the cathode liquid or anode liquid of an aqueous flow cell, but that the liquid itself has redox activity. Such liquid forms can be diluted or mixed with another non-redox active liquid that is a diluent or a solvent, for example, mixed with such a diluent to form a lower melting point liquid phase, emulsion, or micelle such as an ion storage liquid. The cathode or anode material can be a fluid semi-solid or a concentrated liquid composition. The fluid semi-solid of the anode (referred to herein as "anode liquid") and / or the fluid semi-solid of the cathode ("cathode liquid") are composed of electrochemically active agents (anode particles and / or cathode particles) and optionally conductive particles suspended in an electrolyte. The cathode particles and the conductive particles are suspended together in the electrolyte to produce the semi-solid of the cathode liquid. The anode particles and the conductive particles are suspended together in the electrolyte to produce the semi-solid of the anode liquid. These semi-solids can flow by an applied pressure, gravity, or other field exerting a force on the semi-solid, and optionally with the aid of mechanical vibration. Examples of battery architectures that utilize semi-solid suspensions are described in International Patent Publication WO2012 / 024499 entitled "Stationary, Fluid Redox Electrode" and International Patent Publication WO2012 / 088442 entitled "Semi-Solid Filled Battery and Method of Manufacture", the disclosures of which are hereby incorporated by reference in their entireties.

[0052]

[1094] In some embodiments, the separator 130 can be a thin microporous membrane that electrically isolates the cathode 120 from the anode 110, but allows ions to pass through pores between the two electrodes during discharge and charging. In some embodiments, the separator 130 includes thermoplastic polymers such as, but not limited to, polyolefins, polyvinyl chloride, nylon, fluorocarbons, and polystyrene. In some embodiments, the separator 130 includes polyolefin materials including, for example, polyethylene, ultra-high molecular weight polyethylene, polypropylene, polybutene, polymethylpentene, polyisoprene, copolymers thereof, and combinations thereof. Exemplary combinations can include, but are not limited to, mixtures including two or more of polyethylene, ultra-high molecular weight polyethylene, and polypropylene, and mixtures with copolymers such as ethylene-butene copolymers and ethylene-hexene copolymers as described above.

[0053]

[1095] In some embodiments, the battery 100 further includes an electrolyte (not shown in FIG. 1A) substantially contained within the pouch 140. The electrolyte can include a non-aqueous electrolyte such as a lithium salt (in the case of a lithium-ion battery) or a sodium salt (in the case of a sodium-ion battery) in a solvent. Exemplary lithium salts can include, but are not limited to, LiPF6, LiBF4, and LiClO4. Exemplary sodium salts include NaClO4, NaPF6, and sodium bis(trifluoromethanesulfonyl)imide (Na-TFSI). Exemplary solvents include propylene carbonate (PC), ethylene carbonate (EC), dimethyl carbonate (DMC), dimetho xyethane (DME), diethyl carbonate (DEC), tetrahydrofuran (THF), and triethy lene glycol dimethyl ether (Triglyme).

[0054]

[1096] The pouch 140 of the battery cell 100 shown in FIG. 1A substantially houses the anode 110, the cathode 120, the separator 130, and an electrolyte (not shown). The pouch 140 can physically separate the battery cell 100 from adjacent cells to reduce or eliminate defect propagation and facilitate the handling of the battery cell 100 during battery manufacturing. The pouch 140 can also reduce the likelihood of ignition of a flammable electrolyte during a welding process that may occur in battery manufacturing where sparks can be generated.

[0055]

[1097] In some embodiments, the anode 110, the cathode 120, the separator 130, and the electrolyte (not shown) are completely sealed within the pouch 140 (e.g., by vacuum sealing). In some embodiments, the pouch 140 may be only partially sealed or not sealed at all. In some embodiments, the perimeter of the pouch 140 can be sealed to enclose the anode 110, the cathode 120, the separator 130, and the electrolyte. In some embodiments, the seal of the pouch 140 can substantially enclose the anode 110, the cathode 120, the separator 130, and the electrolyte. In some embodiments, the seal of the pouch 140 has a sealed region that includes all widths and width ranges between the following values, in the range of about 10 μm to about 10 mm, about 10 μm to about 9 mm, about 10 μm to about 8 mm, about 10 μm to about 7 mm, about 10 μm to about 6 mm, about 10 μm to about 5 mm, about 10 μm to about 4 mm, about 10 μm to about 3 mm, about 10 μm to about 2 mm, about 10 μm to about 1 mm, about 10 μm to about 900 μm, about 10 μm to about 800 μm, about 10 μm to about 700 μm, about 10 μm to about 600 μm, about 10 μm to about 500 μm, about 10 μm to about 400 μm, about 10 μm to about 300 μm, about 10 μm to about 200 μm, about 10 μm to about 100 μm, and about 10 μm to about 50 μm.

[0056]

[1098] In some embodiments, the sealed area of the pouch 140 is at a specific distance from the outer edge of the pouch 140. In some embodiments, the distance between the sealed area and the outer edge can be about 10 μm to about 20 mm, about 10 μm to about 15 mm, about 10 μm to about 10 mm, about 10 μm to about 5 mm, about 10 μm to about 4 mm, about 10 μm to about 3 mm, about 10 μm to about 2 mm, about 10 μm to about 1 mm, about 10 μm to about 900 μm, about 10 μm to about 800 μm, about 10 μm to about 700 μm, about 10 μm to about 600 μm, about 10 μm to about 500 μm, about 10 μm to about 400 μm, about 10 μm to about 300 μm, about 10 μm to about 200 μm, about 10 μm to about 100 μm, and about 10 μm to about 50 μm, including all distances and distance ranges between the following values.

[0057]

[1099] In some embodiments, the sealed area of the pouch 140 is at a specific distance from the outermost edge of at least one of the anode 110 and the cathode 120. In some embodiments, the distance between the sealed area and the outermost edge of at least one of the anode 110 and the cathode 120 can be about 1 μm to about 10 mm, about 1 μm to about 9 mm, about 1 μm to about 8 mm, about 1 μm to about 7 mm, about 1 μm to about 6 mm, about 1 μm to about 5 mm, about 1 μm to about 4 mm, about 1 μm to about 3 mm, about 1 μm to about 2 mm, about 1 μm to about 1 mm, about 1 μm to about 900 μm, about 1 μm to about 800 μm, about 1 μm to about 700 μm, about 1 μm to about 600 μm, about 1 μm to about 500 μm, about 1 μm to about 400 μm, about 1 μm to about 300 μm, about 1 μm to about 200 μm, about 1 μm to about 100 μm, and about 1 μm to about 50 μm, including all distances and distance ranges between the following values.

[0058]

[1100] In some embodiments, the separator 130 is larger than at least one of the anode 110 and the cathode 120. In some embodiments, the separator 130 is larger than at least one of the anode current collector 150 and the cathode current collector 160. In some embodiments, the separator 130 is larger than at least one of the anode material 111 and the cathode material 121. In some embodiments, the separator 130 extends beyond at least one of the anode 110, the cathode 120, the anode material 111, the cathode material 121, the ACC 150, and the CCC 160, and can thus be sealed inside the sealed region in the pouch 140. In other words, the separator 130 extends into the sealed region of the pouch 140 and effectively separates the anode 110 and the cathode 120. In some embodiments, the separator 130 extends into the sealed region of the pouch 140 and completely separates the anode 110 and the cathode 120. In some embodiments, the separator 130 partially extends into the sealed region of the pouch 140 and partially separates the anode 110 and the cathode 120. In some embodiments, the separator 130 extends to multiple positions in the sealed region of the pouch 140 and effectively separates the anode 110 and the cathode 120 at those positions. For example, if at least one of the anode 110 and the cathode 120 has a tab connection for making an external electrical connection, the separator 130 may not extend to the positions and regions around the tab connection portion of the pouch 140. In some embodiments, one or more of the positions and regions reached by the separator 130 extending into the sealed region of the pouch 140 can be used to form one or more structures for functional purposes in the single-pouch battery cell 100. For example, the functional purpose may be in the form of pressure relief or pressure reduction during overcharge, gas generation, or pressure generation due to some form of electrochemical malfunction. Similarly, in some embodiments, one or more of the positions or regions in the sealed region of the pouch 140 that the separator 130 does not reach can be used to form one or more structures for functional purposes within the single-pouch battery cell 100.

[0059]

[1101] In these embodiments, the pouch 140 can still reduce or eliminate the possibility of being exposed to sparks that may ignite the electrolyte (e.g., by a welding process). After the welding process, a final sealing step can be performed to seal one or more single pouch battery cells within an outer pouch or package, where the outer pouch or package can perform a moisture control function. In some embodiments, the pouch 140 is mechanically attached to the cathode 120 and / or the anode 110. In some embodiments, the pouch 140 is attached to the current collector of the cathode 120 and / or the current collector of the anode 110 by, for example, heat sealing, gluing, or any other method known to those skilled in the art.

[0060]

[1102] In some embodiments, the pouch 140 includes a three-layer structure, i.e., an intermediate layer sandwiched between an outer layer and an inner layer, and the inner layer is in contact with the electrodes and the electrolyte. For example, the outer layer can include a nylon-based polymer film. The inner layer can include a polypropylene (PP) polymer film that can be corrosion-resistant to acids or other electrolytes and insoluble in electrolyte solvents. The intermediate layer can include an aluminum (Al) foil. With this structure, the pouch can have both high mechanical flexibility and strength.

[0061]

[1103] In some embodiments, the outer layer of the pouch 140 includes polymer materials such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), nylon, high-density polyethylene (HDPE), oriented polypropylene (o-PP), polyvinyl chloride (PVC), polyimide (PI), polysulfone (PSU), and any combination thereof.

[0062]

[1104] ​In some embodiments, the intermediate layer of the pouch 140 is composed of a metal layer (such as foil, substrate, film, etc.) made of aluminum (Al), copper (Cu), stainless steel (SUS), and their alloys, or any combination thereof.

[0063]

[1105] In some embodiments, the inner layer of the pouch 140 includes materials such as cast polypropylene (c-PP), polyethylene (PE), ethylene vinyl acetate (EVA), PET, polyvinyl acetate (PVA), polyamide (PA), acrylic adhesive, ultraviolet (UV) / electron beam (EB) / infrared (IR) curable resin, and any combination thereof.

[0064]

[1106] In some embodiments, the pouch 140 can include non-flammable materials such as polyetheretherketone (PEEK), polyethylene naphthalate (PEN), polyethersulfone (PES), PI, polyphenylene sulfide (PPS), polyphenylene oxide (PPO), and any combination thereof. In some embodiments, the pouch 140 can include a coating or film of a flame-retardant additive material such as flame-retardant PET.

[0065]

[1107] In some embodiments, the pouch 140 includes a two-layer structure, that is, an outer layer and an inner layer. In some embodiments, the outer layer can include the above-mentioned PET, PBT or other materials. In some embodiments, the inner layer can include the above-mentioned PP, PE or other materials.

[0066]

[1108] In some embodiments, the pouch 140 can include a water barrier layer and / or a gas barrier layer. In some embodiments, the barrier layer can include a metal layer and / or an oxide layer. In some embodiments, the oxide layer tends to be insulating and can prevent short circuits in the battery, so it may be advantageous to include an oxide layer.

[0067] ​

[1109] In some embodiments, there may be only one (or two) unit cell assemblies within the pouch 140, and the pouch 140 can be made substantially thinner than the pouches commonly used for multi-stack battery cells. For example, the pouch 140 can have a thickness of less than 200 μm, less than 150 μm, less than 100 μm, less than 50 μm, less than 45 μm, less than 40 μm, less than 35 μm, less than 30 μm, less than 25 μm, less than 20 μm, less than 18 μm, less than 16 μm, less than 14 μm, less than 12 μm, less than 10 μm, less than 9 μm, less than 8 μm, less than 7 μm, less than 6 μm, less than 5 μm, less than 4 μm, less than 3 μm, less than 2 μm, or less than 1 μm. In some embodiments, the thickness of the pouch 140 may be determined by at least two sides. On one side, it may be desirable to achieve a high energy density in the resulting cell, in which case a thinner pouch may be useful as it can secure a larger portion of the space within the battery cell for the electrode material. On another side, it may be desirable to maintain or improve the safety advantages of the pouch 140. In this case, a thicker pouch and / or a non-flammable pouch may be useful, for example, to reduce the fire hazard. In some embodiments, the thickness of the pouch can be quantified as the ratio of the volume occupied by the pouch material to the total volume of the battery cell.

[0068]

[1110] In some embodiments, the ratio of the electrode material (e.g., anode material 111 and / or cathode material 121) to the current collector and / or non-electrode materials such as pouch 140 can be defined by the ratio of their thicknesses. In some embodiments, the ratio of the electrode material to the current collector can be any thickness ratio between the following values, including all thickness ratios between: about 12:1, about 14:1, about 16:1, about 18:1, about 20:1, about 22:1, about 24:1, about 26:1, about 28:1, about 30:1, about 32:1, about 34:1, about 36:1, about 38:1, about 40:1, about 42:1, about 44:1, about 46:1, about 48:1, about 50:1, about 52:1, about 54:1, about 56:1, about 58:1, about 60:1, about 62:1, about 64:1, about 66:1, about 68:1, about 70:1, about 72:1, about 74:1, about 76:1, about 78:1, about 80:1, about 82:1, about 84:1, about 86:1, about 88:1, about 90:1, about 92:1, about 94:1, about 96:1, about 98:1, about 100:1, about 110:1, about 112:1, about 114:1, about 116 :1, about 118:1, about 120:1, about 122:1, about 124:1, about 126:1, about 128:1, about 130:1, about 132:1, about 134:1, about 136:1, about 138:1, about 140:1, about 142:1, about 144:1, about 146:1, about 148:1, about 150:1, about 152:1, about 154:1, about 156:1, about 158:1, about 160:1, about 162:1, about 164:1, about 166:1, about 168:1, about 170:1, about 172:1, about 174:1, about 176:1, about 178:1, about 180:1, about 182:1, about 184:1, about 186:1, about 188:1, about 190:1, about 192:1, about 194:1, about 196:1, about 198:1, about 200:1, about 300:1, about 400:1, about 500:1, about 600:1, about 700:1, about 800:1, about 900:1, about 1000:1, and greater than about 2000:1.

[0069]

[1111] In some embodiments, the current collector can cover the pouch 140 to form a bonding thickness. In these embodiments, the ratio between the electrode material and the bonding thickness of the current collector and the pouch 140 can be any value between the following ratios, including ratios for all thicknesses between them: about 12:1, about 14:1, about 16:1, about 18:1, about 20:1, about 22:1, about 24:1, about 26:1, about 28:1, about 30:1, about 32:1, about 34:1, about 36:1, about 38:1, about 40:1, about 42:1, about 44:1, about 46:1, about 48:1, about 50:1, about 52:1, about 54:1, about 56:1, about 58:1, about 60:1, about 62:1, about 64:1, about 66:1, about 68:1, about 70:1, about 72:1, about 74:1, about 76:1, about 78:1, about 80:1, about 82:1, about 84:1, about 86:1, about 88:1, about 90:1, about 92:1, about 94:1, about 96:1, about 98:1, about 100:1, about 110:1, about 112:1, about 114:1, about 116:1, about 118:1, about 120:1, about 122:1, about 124:1, about 126:1, about 128:1, about 130:1, about 132:1, about 134:1, about 136:1, about 138:1, about 140:1, about 142:1, about 144:1, about 146:1, about 148:1, about 150:1, about 152:1, about 154:1, about 156:1, about 158:1, about 160:1, about 162:1, about 164:1, about 166:1, about 168:1, about 170:1, about 172:1, about 174:1, about 176:1, about 178:1, about 180:1, about 182:1, about 184:1, about 186:1, about 188:1, about 190:1, about 192:1, about 194:1, about 196:1, about 198:1, about 200:1, about 300:1, about 400:1, about 500:1, about 600:1, about 700:1, about 800:1, about 900:1, about 1000:1, and about 2000:1.

[0070]

[1112] In some embodiments, the pouch 140 includes one layer of a thinner and lower-cost material. For example, these materials can be polypropylene or a combination of multiple polyolefins that can be sealed together using heat or pressure (such as heat melting or vacuum sealing).

[0071]

[1113] In some embodiments, the pouch 140 includes a layer of flame retardant material to prevent the propagation of fire hazards from one single pouch battery cell to another. In some embodiments, the pouch 140 includes an airtight material that prevents the propagation of gases released from one single pouch battery cell to another single pouch battery cell, thereby reducing defect propagation.

[0072]

[1114] In practice, the battery 100 can have several advantages. For example, this single pouch battery cell approach (also called the individual package cell approach) is convenient because it can be integrated into the manufacture of batteries that include semi-solid electrodes. Using individual package cells facilitates the handling and processing of individual stacks. It also provides a way to protect individual stacks from deformations that may occur when packaging the electrode stacks.

[0073]

[1115] Another advantage of using one pouch per stack is that metal contamination of the electrode material or electrolyte is avoided. The pouch of each single pouch battery cell can prevent metal contaminants (or other types of contaminants) from entering the electrode material and electrolyte.

[0074]

[1116] In some embodiments, one pouch can have an energy capacity, which is also referred to herein as "package size". In some embodiments, the package size includes an energy capacity from about 0.1 Ah to about 40 Ah. In some embodiments, the package size includes an energy capacity from about 0.5 Ah to about 35 Ah. In some embodiments, the package size includes an energy capacity from about 1 Ah to about 30 Ah. In some embodiments, the package size includes an energy capacity from about 1.5 Ah to about 25 Ah. In some embodiments, the package size includes an energy capacity from about 2 Ah to about 20 Ah. In some embodiments, the package size includes an energy capacity from about 2.5 Ah to about 15 Ah. In some embodiments, the package size includes an energy capacity from about 3 Ah to about 10 Ah. In some embodiments, the package size includes an energy capacity from about 3 Ah to about 8 Ah. In some embodiments, the package size includes an energy capacity from about 3 Ah to about 6 Ah. In some embodiments, the package size includes an energy capacity from about 3 Ah to about 5 Ah. In some embodiments, the package size includes an energy capacity from about 0.1 Ah to about 5 Ah. In some embodiments, the package size includes an energy capacity from about 0.1 Ah to about 4 Ah. In some embodiments, the package size includes an energy capacity from about 0.1 Ah to about 3 Ah. In some embodiments, the package size includes an energy capacity from about 0.1 Ah to about 2 Ah. In some embodiments, the package size includes an energy capacity from about 0.1 Ah to about 1 Ah.In some embodiments, the package size includes energy capacities and capacity ranges between the following values, including about 0.1 Ah, about 0.2 Ah, about 0.3 Ah, about 0.4 Ah, about 0.5 Ah, about 0.6 Ah, about 0.7 Ah, about 0.8 Ah, about 0.9 Ah, about 1 Ah, about 1.2 Ah, about 1.4 Ah, about 1.6 Ah, about 1.8 Ah, about 2 Ah, about 2.2 Ah, about 2.4 Ah, about 2.6 Ah, about 2.8 Ah, about 3 Ah, about 3.2 Ah, about 3.4 Ah, about 3.6 Ah, about 3.8 Ah, about 4 Ah, about 4.2 Ah, about 4.4 Ah, about 4.6 Ah, about 4.8 Ah, about 5 Ah, about 5.5 Ah, about 6 Ah, about 6.5 Ah, about 7 Ah, about 7.5 Ah, about 8 Ah, about 8.5 Ah, about 9 Ah, about 9.5 Ah, about 10 Ah, about 11 Ah, about 12 Ah, about 13 Ah, about 14 Ah, about 15 Ah, about 16 Ah, about 17 Ah, about 18 Ah, about 19 Ah, about 20 Ah, about 22 Ah, about 24 Ah, about 26 Ah, about 28 Ah, about 30 Ah, about 32 Ah, about 34 Ah, about 36 Ah, about 38 Ah, and about 40 Ah.

[0075]

[1117] Further, by using a simple single-pouch material to seal one stack, the strict requirements for the pouch material and sealing method in conventional battery manufacturing can be relaxed. Each pouch usually contains only one or two unit cell assemblies, and thus contains less electrode material and electrolyte compared to conventional multi-stack battery cells. Therefore, the pouch material can have more options, such as being a single-layer polymer layer instead of a multi-layer structure. The thickness of the pouch can be made even smaller (e.g., <100 μm), and the sealing method can also be made flexible (e.g., pressure sealing, heat sealing, and / or UV sealing, etc.).

[0076]

[1118] In some embodiments, the separator 130 can be sized to be placed with the pouch 140 and sealed. In some embodiments, the pouch 140 can include a laminated sheet that can include a peripheral portion that extends beyond the perimeter of the separator 130 so that the pouch can be joined to form a seal. In some embodiments, the inner layers of the pouch can each be formed of a material that is thermally bondable to itself such that when two laminated sheets are joined, the two inner layers are joined at their perimeters and thermally bonded to each other to form an airtight seal. Further examples are described in International Patent Publication WO2013 / 173689 entitled "Electrochemical Cells and Methods of Manufacturing the Same", which is hereby incorporated by reference in its entirety. formed such that when two laminated sheets are joined, the two inner layers are joined at their perimeters and thermally bonded to each other to form an airtight seal. Further examples are described in International Patent Publication WO2013 / 173689 entitled "Electrochemical Cells and Methods of Manufacturing the Same", which is hereby incorporated by reference in its entirety.

[0077]

[1119] In some embodiments, the tab (electrical lead) can be sized such that when the pouch is sealed, the tab is exposed outside the pouch and can be used to electrically connect the battery cell. For example, the first tab of the ACC150 and the second tab of the CCC160 can be used to connect to at least one of the negative and positive terminals of an external circuit. In some embodiments, the tab can be sealed within the pouch, in which case holes can be made in the pouch to enable an electrical connection between at least one of the ACC150 and the CCC160 and an external contact or electrical circuit. One or more holes can be placed at any location in the pouch, although locations adjacent to the ACC150 and the CCC160 respectively are preferred.

[0078]

[1120] Figure 1B is a schematic diagram showing a battery cell 101 according to various other embodiments of the present invention, sometimes referred to as a "bicell". In the battery cell 101, the anode current collector 151 includes two anode materials 111a and 111b (collectively referred to as "anode material 111") It is sandwiched between them. On each of the anode materials 111a and 111b, separators 131a and 131b (collectively referred to as "separator 131") are disposed. A pair of cathode materials 121a and 121b (collectively referred to as "cathode material 121") are disposed on the separators 131a and 131b, respectively. On each of the cathode materials 121a and 121b, corresponding cathode current collectors 161a and 161b (collectively referred to as "cathode current collector 161" ") are disposed. The anode material 111, the anode current collector 151, the cathode material 121, the cathode current collector 161, and the separator 131 can be substantially the same as those described above in relation to FIG. 1A. In one example, the anode current collector 151 and the cathode current collector 161 include substantially the same material. In another example, the anode current collector 151 includes a first metal material (e.g., copper), and the cathode current collector 161 includes a second metal material (e.g., aluminum). The battery cell 101 is substantially sealed in a pouch (not shown) to form a single pouch battery cell.

[0079]

[1121] FIG. 1B shows a cross-sectional view of an exemplary embodiment of a bicell including a double-sided anode (including the anode current collector 151 and the pair of anode materials 111a and 111b) and two single-sided cathodes disposed on each side of the double-sided anode (including the first cathode material 121a disposed on the first cathode current collector 161a and the second cathode material 121b disposed on the second cathode current collector 161b). In some other embodiments, the battery 101 can also include a double-sided cathode and two single-sided anodes disposed on each side of the cathode. As described herein, the battery cell 101 can be packaged alone in a pouch or, alternatively, packaged in a pouch together with a plurality of "bicells".

[0080]

[1122] FIG. 1C is a top view showing the battery cell 101 shown in FIG. 1B. From this top view, it can be seen that the cathode current collectors 161a and 161b are misaligned or staggered within the bicell. In some embodiments, the anode current collector 151 and the cathode current collector 161 are located on different sides of the battery cell 101. In some embodiments, the anode current collector 151 and the cathode current collector 161 are located on opposite sides of the battery cell 101. In some embodiments, the anode current collector 151 and the cathode current collector 161 are located on the same side of the battery cell 101.

[0081]

[1123] FIG. 1D is a view showing another embodiment of the battery cell 102. In this embodiment, the battery cell 102 includes two bicells each including two double-sided anodes. In some embodiments, the battery cell 102 can also include two bicells each including two double-sided cathodes. As shown in this figure, it can be seen that the cathode current collectors 161c, 161d, 161e, and 161f (collectively referred to herein as "cathode current collector 161x") are misaligned or staggered within the battery cell 102. Similarly, it can be seen that the anode current collectors 151a and 151b (collectively referred to herein as "anode current collector 151x") are also misaligned or staggered within the battery cell 102. In some embodiments, the anode current collector 151x and the cathode current collector 161x are located on different sides of the battery cell 102. In some embodiments, the anode current collector 151x and the cathode current collector 161x are located on opposite sides of the battery cell 102. In some embodiments, the anode current collector 151x and the cathode current collector 161x are located on the same side of the battery cell 102.

[0082]

[1124] In some embodiments, the misalignment or staggering of the current collectors enables various interconnections of the current collectors within a single pouch cell. In some embodiments, for example, by using an extension tab to connect desired current collectors, one extension tab can be used to extend into the sealed region of the single pouch cell for external electrical connection. This can prevent contamination of the electrodes or battery by welding electrical contacts outside the single pouch cell.

[0083]

[1125] FIG. 1E is a schematic diagram showing a single pouch battery cell using the concept of self-fusion. Only one electrode (anode or cathode) is shown in FIG. 1E, and the separator and other electrodes within the battery cell can be added according to the embodiments shown in any of FIGS. 1A, 1B, 1C, or 1D. The battery cell 103 includes a tab 112 for coupling the battery cell 103 to other battery cells or external electrical contacts, a foil 122 including a plurality of slurry pockets 142 for accommodating electrode materials, a plurality of foil bridges 152 for electrically coupling the plurality of slurry pockets 142 to each other, and an epoxy portion 132 filling the portions of the foil not covered by the slurry pockets 142 and the foil bridges 152. FIG. 1F is a photograph of a portion of the battery cell 103.

[0084]

[1126] FIG. 2 is a diagram showing a battery module 200 including a plurality of single pouch battery cells according to some embodiments. As shown, the battery module 200 includes a plurality of single pouch battery cells 201, 202, and 203 enclosed in a module case 260. The battery module also includes a tab connection portion 250 that couples the tabs of each single pouch battery cell 201 - 203 to an external tab 252, and this external tab 252 then electrically connects the battery module 200 to an external circuit.

[0085]

[1127] In some embodiments, the tabs of each single pouch battery module 201-203 can be part of the respective current collector. For example, each current collector of the single pouch battery cells 201-203 can have a lead portion that extends outside the electrode portion (i.e., the portion disposed with the electrode material) as a tab. In some embodiments, the tabs of each single pouch battery cell 201-203 can be additional independent components electrically coupled to the respective current collector or electrode material. For example, each tab can also be a metal strip attached to the current collector by soldering, welding, gluing, or other means known in the art.

[0086]

[1128] In some embodiments, the connection between the tab connection portion 250 and the external tab 252 can be realized by, for example, a weld point, a rivet, a screw, or other means known in the art. Note that when welding is used to couple the tab connection portion 250 and the external tab 252 it is possible to perform the welding after sealing each single pouch battery cell 201-203 in each pouch that can prevent metal particles from reaching the electrode material, so that substantial metal contamination of the electrode material can still be avoided.

[0087]

[1129] In some embodiments, the module case 260 can apply a force to the stack of single pouch battery cells 201-203 to apply a stack pressure to the battery module 200. In some embodiments, the module case 260 includes a metal material such as stainless steel. In some embodiments, the module case 260 includes a plastic or polymer material. In some embodiments, the module case 260 includes substantially the same material as that constituting the pouches within each single pouch battery cell 201-203. In these embodiments, the module case 260 can be regarded as an additional pouch that can further reduce defect propagation, fire hazard, and metal contamination.

[0088]

[1130] In some embodiments, the single pouch battery cells 201-203 can be stacked and adhered by gluing, applying an adhesive, or heat caulking. For example, the application of heat or an adhesive can be performed by applying glue one by one in sequence, or by applying glue to all the single pouch battery cells simultaneously. In some embodiments, the stacking process can include a non-contact heating technique. For example, a layer or portion of a material that can act as an adhesive when mechanical or electrical fluctuations such as heat, light such as UV or IR, or ultrasonic or sound waves, radio frequency or microwave, or any combination thereof are applied when activated can cover each single pouch battery cell.

[0089]

[1131] The battery module 200 shown in FIG. 2 includes three single pouch battery cells 201-203. However, in practice, the number of single pouch battery cells in the module may be more or less than three depending on the desired output capacity, thickness requirements, or other specifications.

[0090]

[1132] FIG. 3 is a schematic diagram showing a battery pack including a plurality of battery modules according to some embodiments. The battery pack 300 includes a first battery module 310, a second battery module 320, and a third battery module 330. Each battery module of the plurality of battery modules 310-330 can be substantially the same as the battery module 200 shown in FIG. 2. Each battery module of the plurality of battery modules 310-330 includes external tabs 312, 322, and 332, respectively, which are coupled to an external bus bar 352. The coupling between the external tabs 312-332 and the external bus bar 352 can be achieved by, for example, welding, soldering, riveting, screwing, or other means known in the art.

[0091]

[1133] Due to the modular design of each battery module among the plurality of battery modules 310-330, a battery that can meet the actual demand during application can be conveniently constructed. In some embodiments, the plurality of battery modules 310-330 can be connected in series as shown in FIG. 3 to obtain a higher output voltage. In some embodiments, the plurality of battery modules 310-330 can be connected in parallel to obtain a higher output current. In some embodiments, the plurality of battery modules 310-330 can be stacked vertically as shown in FIG. 3 to meet the requirements of a specific thickness or shape. In some embodiments, the plurality of battery modules 310-330 can be dispersed horizontally to obtain a specific shape factor (for example, when a battery pack sheet with a special specification thickness is desired).

[0092]

[1134] The battery pack 300 shown in FIG. 3 includes three battery modules 310-330. However, in reality, the number of battery modules in the battery pack may be more or less than three according to the desired output capacity, thickness requirements, or other specifications.

[0093] Tab Connection of Single Pouch Battery Cells and Modules

[1135] FIGS. 4A-4B are perspective views showing a single pouch battery including a conductive tab that couples a battery cell to an external circuit, an adjacent battery cell, or other electrical components in an application field. The single pouch battery cell 400 shown in FIG. 4A includes an anode 410, a separator 430, and a cathode 420 (behind the separator 430 and shown in FIG. 4B), which are stacked on top of each other as described above. The pouch 440 substantially houses a stack of the anode 410, the cathode 420, and the separator 430. The anode 410 has an anode lead portion 412 that extends outside an electrode portion (i.e., a portion covered with anode material) of a current collector (not shown) as a tab. Similarly, the cathode also has a cathode lead portion 422 that extends outside an electrode portion (i.e., a portion covered with cathode material) of the current collector as a tab. In some embodiments, the lead portions 412 and 422 shown in FIG. 4A are metal strips. In some embodiments, the current collectors used for the anode 410 and the cathode 420 can be mesh current collectors, and the corresponding lead portions 412 and 422 can be, for example, a metal wire, a bundle of metal wires, a braid of metal wires, or an array of metal wires. In some embodiments, the metal wire can be substantially the same as the wire constituting the mesh current collector. In some embodiments, the metal wire can include a conductive material different from the metal material used in the mesh current collector.

[0094]

[1136] FIG. 4A also shows an example of the relative dimensions of each component of the single pouch battery cell. As shown in FIG. 4A, both the anode 410 and the cathode 420 are smaller than the separator 430, and the anode 410 and the cathode 420 are not in electrical contact with each other. The pouch 440 is larger than the electrode portions of the anode 410 and the cathode 420 and the separator 430, and is configured to seal the battery cell and / or avoid leakage of the electrode material and the electrolyte. The two tabs 412 and 422 extend outside the pouch 440 and are configured to electrically couple the battery cell 400 to external elements such as other battery cells.

[0095]

[1137] Figure 4B is an enlarged view of a corner of the single pouch battery cell 400 that more clearly shows the relative dimensions of the above-described elements. In Figure 4B, the cathode 420 is slightly smaller than the anode 410, and thus the cathode 420 is "hidden" in this figure by the anode 410. In some embodiments, at least a portion of the separator 430 is heat-sealed within the pouch 440 to prevent any contact between the anode 410 and the cathode 420. In some embodiments, the cathode 420 can be substantially the same size as the anode 410.

[0096]

[1138] The relatively large size of the pouch 440 provides a means for supporting the electrode materials, particularly the semi-solid electrode materials, during battery manufacturing. That is, the pouch 440 can hold the anode material and the cathode material. The pouch 440 can also prevent the electrodes from deforming, which may occur when packaging the electrode stack, particularly at the edges of the electrodes.

[0097]

[1139] Exemplary dimensions of the elements of the single pouch battery cell 400 can be as follows. That is, the anode 410 and the cathode 420 can have dimensions of 202 mm × 150 mm, the separator 430 can be 3 mm larger in each direction, that is, 205 mm × 153 mm, and the pouch 440 can be 12 mm larger in each direction than the anode 410 and the cathode 420, with dimensions of 214 mm × 162 mm. The thickness of each electrode (anode 410 and cathode 420) can be, for example, greater than 150 μm, greater than 200 μm, or greater than 300 μm. The overall thickness of the single pouch battery can be, for example, greater than 600 μm, greater than 800 μm, or greater than 1 mm.

[0098]

[1140] FIG. 5 is a top view showing a battery module including a plurality of single pouch battery cells enclosed in a metal case. The battery module 500 includes a metal case 560 that substantially encloses a plurality of single pouch battery cells (only one single pouch battery cell is shown in FIG. 5). Each single pouch battery cell includes an anode 510, a separator 530, and a cathode (located behind the separator 530 and not shown in FIG. 5), all of which are housed and sealed within a pouch 540. The anode 510 has a current collector having a lead portion 512 that extends outside the electrode portion as an anode tab. Similarly, the cathode also has a current collector having a lead portion 522 that extends outside the electrode portion as a cathode tab. The plurality of anode tabs 512 and cathode tabs 522 are coupled to each other, and the coupled tabs 521 and 522 are further coupled to external electrical connectors 514 and 524. More specifically, the anode tab 512 is coupled to the anode connector 514 of the battery module 500, and the cathode tab 522 is coupled to the cathode connector 524 of the battery module 500.

[0099]

[1141] The anode connector 514 includes a conductive element 515 that is coupled at one end to the anode tab 512 and at the other end to an external element such as another battery or utility. The conductive element 515 is disposed through the wall of the metal case 560 and is electrically isolated from the wall of the metal case 560 by the anode connector coupler 516, which also substantially holds the conductive element 515 and prevents its sliding. Similarly, the cathode connector 524 includes a conductive element 525 that is coupled at one end to the cathode tab 522 and at the other end to an external element. The cathode connector coupler 526 is configured to electrically insulate the conductive element 525 from the wall of the metal case 560 and to substantially hold the conductive element 525. In some embodiments, one of the conductive elements 515 or 525 can be directly connected to the metal case 560 without insulation. In these embodiments, the metal case 560 can have the same polarity as the conductive element (i.e., 515 or 525) directly connected to the metal case 560.

[0100]

[1142] In some embodiments, the anode connector coupler 516 and / or the cathode connector coupler 526 can be a pair of fasteners (e.g., screws or bolts) and nuts, which are made of a non-conductive material or coated with a non-conductive material and are mechanically coupled to each other and to the wall of the metal case 560. In some embodiments, the anode connector coupler 516 and / or the cathode connector coupler 526 can be a pair of magnetic couplers that are coupled to each other by magnetic force. In some embodiments, the anode connector coupler 516 and / or the cathode connector coupler 526 can be glued together to the wall of the metal case 560 and disposed therethrough.

[0101]

[1143] In some embodiments, the metal case 560 is substantially rigid to protect the battery cells within the metal case 560. In some embodiments, the metal case 560 has a specific mechanical flexibility to have higher impact resistance. In some embodiments, the metal case 560 includes materials such as stainless steel, copper, aluminum, or combinations or alloys thereof. In some embodiments, the metal case 560 has a thickness of about 0.2 mm to 2 mm, or 0.5 mm to 1.5 mm, or 0.8 mm to 1 mm. In some embodiments, the metal case 560 can be slightly larger than the pouch 540. In one example, the pouch 540 has dimensions of 214 mm × 162 mm, and the metal case 560 has dimensions of 232 mm × 165 mm. Therefore, the single pouch battery cell is expected to be substantially fixed within the metal case without moving freely.

[0102]

[1144] In some embodiments, the battery module 500 functions as an independent battery that provides power via the anode connector 514 and the cathode connector 524. In some embodiments, the battery module 500 can be coupled to other battery modules of the same or different types to form a battery pack having specific specifications (e.g., capacity, voltage, current, size, shape, etc.).

[0103]

[1145] FIGS. 6A-6B are side views showing a battery module including a single pouch battery cell enclosed within a metal case. FIG. 6 is a view showing a battery module 600 including a metal can 660 and a lid 662 that cooperate to form a metal case and accommodate a plurality of single pouch battery cells 601. This battery module also includes an electrode connector 614 that can be either an anode connector or a cathode connector. Although only one electrode connector is shown in FIG. 6A, other electrode connectors may be behind the illustrated connector and thus may not be visible.

[0104]

[1146] In practice, a plurality of single pouch battery cells can be disposed within the metal can 660, and then, the lid 662 can be disposed on top of the metal can 660 and sealed to form the battery module 600. The completed battery module 600 is shown in FIG. 6B.

[0105]

[1147] In some embodiments, the lid 662 and the metal can 660 can comprise substantially the same material, such as stainless steel, copper, and aluminum, in particular. In some embodiments, the lid 662 comprises a material different from that of the metal can 660. For example, the metal can 660 is made of stainless steel, and the lid 662 comprises an aluminum foil or a tin foil that can be easily welded by the metal can 660. In some embodiments, the lid 662 can be attached to the metal can 660 by mechanical methods such as laser welding, seam welding, crimping, or any other method known in the art.

[0106]

[1148] FIG. 7A is a top view showing a battery module including a plurality of single pouch battery cells encapsulated in a plastic frame. The battery module 700 includes a plastic frame 760 that substantially houses the perimeter (sides) of a plurality of single pouch battery cells (only one single pouch battery cell is shown in FIG. 7A). Each single pouch battery cell includes an anode 710, a separator 730, and a cathode (behind the separator 730 and not shown in FIG. 7), all of which are housed and sealed within the pouch 740. The anode 710 has a current collector including a lead portion 712 that extends outside the electrode portion as an anode tab. Similarly, the cathode also has a current collector including a lead portion 722 that extends outside the electrode portion as a cathode tab. The plurality of anode tabs 712 and cathode tabs 722 are coupled to each other, and these coupled tabs are further coupled to an external electrical connector. More specifically, the anode tab 712 is coupled to the anode connector 714 of the battery module 700, and the cathode tab 722 is coupled to the cathode connector 724 of the battery module 700.

[0107]

[1149] In some embodiments, the anode connector 714 and the cathode connector 724 are in direct contact with the wall surface of the plastic frame 760 since the plastic frame 760 is insulating. In some embodiments, additional couplers such as couplers 516 and 526 shown in FIG. 5 can be utilized to mechanically hold the anode connector 714 and the cathode connector 724.

[0108]

[1150] In some embodiments, the plastic frame 760 can have a thickness of about 2 mm to about 10 mm to achieve sufficient rigidity and protect the single pouch battery within the plastic frame 760. In some embodiments, the thickness of the plastic frame 760 can be about 3 mm to about 7 mm, or about 4 mm to about 6 mm. In some embodiments, the plastic frame 760 comprises materials such as nylon, acrylic resin, polyvinyl chloride (PVC), uPVC, polytene, polypropylene, polycarbonate, bakelite, epoxy resin, and melamine. In some embodiments, the plastic frame 760 can include a thin metal plate or foil on the outer surface, inner upper surface, or within the plastic frame 760 to prevent the penetration of gas or water. In some embodiments, the plastic frame 760 can include a surface coating. In some embodiments, the surface coating can reduce the penetration of water and gas. In some embodiments, the plastic frame 760 comprises materials such as nylon, acrylic resin, polyvinyl chloride (PVC), uPVC, polytene, polypropylene, polycarbonate, bakelite, epoxy resin, and melamine. In some embodiments, the plastic frame 760 can include a thin metal plate or foil on the outer surface, inner upper surface, or within the plastic frame 760 to prevent the penetration of gas or water. In some embodiments, the plastic frame 760 can include a surface coating. In some embodiments, the surface coating can reduce the penetration of water and gas.

[0109]

[1151] FIG. 7B is a side view showing the battery module 700 shown in FIG. 7A. As can be seen from FIG. 7B, the battery module 700 also includes a pair of lids 762a and 762b disposed on respective sides (upper and bottom) of the plastic frame 760, forming an entire container that substantially houses the single pouch battery cells. In some embodiments, the lids 762a and 762b include a polymer foil that can be heat-sealed to the plastic frame 760. In some embodiments, the lids 762a and 762b include a polymer or other plastic foil that can be vacuum-sealed to the plastic frame 760. In some embodiments, the lids 762a and 762b include a foil that can be glued to the plastic frame 760. In some embodiments, one or both of the lids 762a and 762b include a plate that can be made of plastic or metal. In some embodiments, this plastic plate can include a metal foil disposed on the outer surface or the inner surface. In some embodiments, this plate can have a surface coating.

[0110]

[1152] FIGS. 8A-8C are diagrams showing the tab design and corresponding tab connection regions of a battery module including a plurality of single pouch battery cells enclosed in a metal case. FIG. 8A is a side view showing a battery module 800 including a metal case 860 (only a part of the whole case is shown in FIG. 8A) substantially housing a plurality of single pouch battery cells 801, and each single pouch battery cell 801 has a tab 812 that couples the single pouch battery cell to the remaining battery cells in the battery module 800 via a plurality of spacers 871. A spacer coupler 872 electrically couples the spacer 871 and the tab 812 to an end piece 876, and the end piece 876 is electrically coupled to an electrode connector 814 (anode connector or cathode connector). The electrode connector 814 further includes a conductive part piece 815 that penetrates the wall of the metal case 860 and a connector coupler 816 that electrically insulates the conductive part piece 815 from the wall of the metal case 860. The battery module 800 can provide power to a utility through the electrode connector 814. In some embodiments, the conductive part piece 815 is a coaxial connector. In some embodiments, the conductive part piece 815 is a snap connector. In some embodiments, the conductive part piece 815 is a pin connector, or any other electrical connector known in the art.

[0111]

[1153] FIG. 8B is a side view showing one of the spacers 871 shown in FIG. 8A. The spacer 871 includes a bridge portion 874 and an end portion 875. The bridge portion 874 of each spacer 871 is pressed against the tab 812 of the single pouch battery cell 801. Thus, these multiple tabs can be electrically coupled to multiple spacers, and those spacers mechanically hold those tabs in place. The end portion 875 has a hole for receiving the spacer coupler 872. In some embodiments, the spacer coupler 872 is a rivet, screw, bolt, or any other conductive part piece.

[0112]

[1154] FIG. 8C is a diagram showing a connector portion 870 of a battery module 800 in the vicinity of tabs 812 and electrode connectors 814 for explaining the design of the tabs. When a spacer coupler 872 (e.g., a rivet) is fixed, each tab 812 can physically and electrically contact a bridge portion 874 of a spacer 871. The bridge portion 874 is further electrically coupled to an end portion 875, and the end portion 875 is electrically coupled to an end piece 876 via the spacer coupler 872. The electrode connector 814 is connected to the end piece 876 to provide power to an external utility or receive power from an external power source (e.g., charge a battery). In some embodiments, both the bridge portion 874 and the end portion 875 of the spacer 871 can be made conductive to form a conductive path from the single pouch battery cell 801 to the electrode connector 814. In some embodiments, only a portion of the bridge portion 874 (e.g., the portion in contact with the tab 812) is conductive.

[0113]

[1155] In some embodiments, the spacer 871 includes a metallic material (e.g., stainless steel, copper, aluminum, silver, etc.). In some embodiments, the spacer 871 includes a non-conductive substrate (e.g., plastic) coated with a conductive material (e.g., metal, carbon, conductive metal oxide, etc.) so as to reduce the weight or cost of the battery module 800. In some embodiments, some of the tabs 812 can be connected together to an extension tab instead of the spacer 871, in which case some of the extension tabs are connected to the end portion 876. In some embodiments, all of the tabs are connected together to the end piece 876 at once.

[0114]

[1156] In some embodiments, the metal case 860 and / or the battery module 800 can include silicone oil or any liquid that promotes battery safety. Such liquids and silicone oil can help maintain the pressure (e.g., stack pressure) within the metal case 860. In some embodiments, using such liquids can also help prevent water penetration into the metal case 860 and / or the battery module 800.

[0115] Method for manufacturing single pouch battery cells and modules

[1157] FIG. 9 is a flowchart showing a method for manufacturing single pouch battery cells and modules according to some embodiments. This method 900 begins with electrode slurry preparation in step 910, where anode slurry and cathode slurry can be prepared separately.

[0116]

[1158] In some embodiments, the electrode slurry includes a mixture of an electrochemically active ion storage compound, a conductive additive, and a polymeric binder.

[0117]

[1159] In some embodiments, at least one of the anode slurry and the cathode slurry includes a semi-solid electrode material that includes a suspension of an active material and a conductive material in a non-aqueous liquid electrolyte. Examples of semi-solid electrode materials are described in U.S. Patent Publication No. US2013 / 0065122A1, entitled "Semi-solid Electrode Cell Having A Porous Current Collector and Methods of Manufacture", which is hereby incorporated by reference in its entirety.

[0118]

[1160] Next, in step 920, the prepared electrode slurry is disposed (e.g., coated or covered) on a current collector (e.g., foil, mesh, porous conductive foam) to form an electrode. An additional compression step of compressing the current collector coated with the electrode slurry at high pressure is performed to increase the density and thickness The sa can be controlled.

[0119]

[1161] In some embodiments, the slurry preparation step 910 and the electrode formation step 920 can be combined into one step called the mixing and formation of the slurry electrode, which generally includes (i) the conveyance and / or supply of raw materials, (ii) mixing, (iii) the conveyance of the mixed slurry, (iv) formulation and / or extrusion, and (v) formation. In some embodiments, multiple steps in this process can be performed simultaneously and / or using the same equipment. For example, the mixing and conveyance of the slurry can also be performed simultaneously using an extruder. Each step in this process can include one or more possible embodiments. For example, each step of this process can be performed manually or by various process equipment. Each step may include one or more sub-processes and optionally may also include an inspection step to monitor the quality of the process.

[0120]

[1162] The conveyance and / or supply of raw materials includes batch manual weighing of materials by natural supply (e.g., enabling the mixer to receive the materials without external force and make a mixture), batch manual weighing of materials by forced supply using a piston mechanism or a screw-type "side stuffer", gravimetric screw solid feeder by natural supply (e.g., the mixer supplies materials at a rate at which it can naturally receive the materials), gravimetric screw solid feeder by forced supply (e.g., a device manufactured by Brabender combined with a piston mechanism or a screw-type "side stuffer") and / or any other suitable conveyance and / or supply method and / or any suitable combination thereof.

[0121]

[1163] In some embodiments, the slurry can be mixed using a Banburry (registered trademark) type batch mixer, the mixing section of a twin-screw extruder, a centrifugal planetary mixer, and / or a planetary mixer. In some embodiments, the slurry can be sampled and / or monitored after mixing to measure and / or evaluate homogeneity, rheology, conductivity, viscosity, and / or density.

[0122]

[1164] In some embodiments, for example after mixing, the slurry can be conveyed and / or pressurized using, for example, a piston pump, a peristaltic pump, a gear / lobe pump, a single-screw pump, a single-screw extruder, the mixing section of a twin-screw extruder, and / or any other suitable conveying device. In some embodiments, the torque and / or output of the conveying device, the pressure, flow rate, and / or temperature at the outlet of the conveying device can be measured, monitored, and / or controlled during conveying and / or pressurization.

[0123]

[1165] In some embodiments, for example after conveying and / or pressurizing, the slurry can be formulated and / or extruded. The slurry can be formulated and / or extruded using, for example, a "hanger die" sheet extrusion die, a "winter manifold" sheet extrusion die, a profile style sheet extrusion die, any nozzle operable to apply a continuous flow of material to a substrate, injection into a mold of the correct size and shape (e.g., filling a pocket with material), and / or any other suitable formulating device.

[0124]

[1166] In some embodiments, after formulation, the slurry can be formed into the final electrode. For example, the slurry can be calendared, punched and / or pressed, vibration set, and / or cut into individual parts. Further, in some embodiments, unwanted portions of the material can be removed (e.g., masking and washing) and optionally recycled into the slurry manufacturing process.

[0125]

[1167] After forming the electrodes (anode and cathode), in step 930, the unit cells can be assembled. In some embodiments, each unit cell assembly can include, for example, as described above and shown in FIG. 1A, an anode, a cathode, and a separator disposed between the anode and the cathode to electrically insulate them. In some embodiments, each unit cell assembly can include, as described above and shown in FIG. 1B, a double-sided anode, two single-sided cathodes, and two separators.

[0126]

[1168] In step 940, each assembled unit cell is sealed within a pouch. In some embodiments, the pouch includes a three-layer structure, for example, an outer layer including a nylon-based polymer film, an inner layer including a polypropylene (PP) polymer film, and an intermediate layer including an aluminum (Al) foil. This type of pouch can be sealed, for example, by heat sealing using an MTI MSK-140 compact heat sealer. The seal temperature can be, for example, 50° to 200°, and the seal pressure can be, for example, 0 to 0.7 MPa. In some embodiments, the pouch can include one layer of a thinner and lower-cost material. For example, these materials can be polypropylene, resin, or a combination of multiple polyolefins that can be sealed to each other using heat or pressure. In some embodiments, a pre-charging process can be performed on the unit cell before individually sealing each pouch. The pre-charging process can generate gas before pouch sealing, thus eliminating the need for the gas venting process that was performed after conventional battery formation.

[0127]

[1169] In some embodiments, the electrode slurry is a semi-solid electrode material, and the prepared electrode and subsequent unit cell assembly already contain an electrolyte in the electrode material. In this case, the pouch can be sealed immediately after preparing the unit cell assembly. In some embodiments, another electrolyte (i.e., a liquid electrolyte) is introduced into the pouch before sealing.

[0128]

[1170] After sealing the pouch, at step 950, tabs are prepared for each unit cell assembly to facilitate the construction of battery modules, battery packs, or other applications. In some embodiments, the tab can be part of the current collector. For example, the current collector can have a lead portion that extends outside the electrode portion (e.g., 412 and 422 shown in FIG. 4A). In some embodiments, the tab can be a separate element (e.g., a metal strip or wire) electrically coupled to the electrode. This coupling can be to the current collector or to the electrode material (i.e., the electrode slurry) and can be achieved by welding, gluing, stapling, or other means known in the art.

[0129]

[1171] Following the preparation of each unit cell assembly, in step 960, a plurality of unit cell assemblies are coupled to each other to form a basic battery module. In this step, the plurality of unit cell assemblies may be stacked vertically, arranged horizontally, or both, depending on the actual application field. Also, in this step, typically, all the cathode tabs are combined together to form one connection point that can be further coupled to a cathode connector. Similarly, typically, all the anode tabs are combined together to form one connection point that can be further coupled to an anode connector. In some embodiments, these tabs (anode tabs or cathode tabs or both) are joined by welding, soldering, or gluing. In some embodiments, these tabs are joined by using spacers and rivets (as shown, for example, in FIGS. 8A - 8C). In some embodiments, these tabs are joined by screws.

[0130]

[1172] In step 970, the basic battery module is encapsulated within a case. In some embodiments, this case is metallic (as shown, for example, in FIG. 5). In these embodiments, the basic battery module is first placed within a metal can, and then each single pouch The tabs of the battery cells can be coupled to the anode and cathode connectors. Then, a metal lid can be placed over the metal can to form a completed housing for the basic battery module. The metal lid can be coupled to the metal can by, for example, welding, soldering, or mechanical means. In some embodiments, the case includes a plastic frame on the side and two foils on the top and bottom (as shown, for example, in FIGS. 7A - 7B). In these embodiments, the basic module can be coupled to the plastic frame by first connecting the tabs to the anode and cathode connectors, and then the two foils can be coupled to the plastic frame by, for example, heat sealing or pressure sealing.

[0131]

[1173] Next, in step 980, the encapsulated battery module is subjected to a forming process and an initial charge operation is performed to passivate the electrode / electrolyte interface and prevent side reactions, thereby creating a stable solid electrolyte interface (SEI). Further, usually, charging and discharging for several cycles of the battery are also performed to ensure that the capacity of the battery meets the required specifications. The charging and discharging for several cycles of the battery are also performed to ensure that the capacity of the battery meets the required specifications.

[0132]

[1174] FIGS. 10A and 10B are a top view and a side view, respectively, showing an anode assembly layout including a plurality of anodes according to several embodiments. FIG. 10A shows an anode assembly 1000 including a pouch film 1040 (e.g., a PE / PP film) that can form a pouch for accommodating a resulting battery cell on which anodes 1001a, 1001b, 1001c, and 1001d are disposed. For example, the first anode 1001a includes an anode material 1010a further disposed on an anode current collector 1020a disposed on the pouch film 1040. The first anode 1001a further includes an anode tab 1022a electrically coupled to the anode current collector 1020a such that the first anode 1001a is coupled to an external circuit. Similarly, the second anode 1001b includes a tab 1022b and an anode material 1010b disposed on an anode current collector 1020b. Each anode (1001a - 1001d) is electrically insulated from another anode within the anode assembly 1000 (e.g., by physical separation).

[0133]

[1175] The tabs (such as 1022a, 1022b, etc.) are arranged such that their positions with respect to their respective current collectors are alternating. More specifically, when one tab (e.g., 1022a) is disposed on the right side of the associated current collector (1020a), the adjacent tab (e.g., 1022b) is disposed on the left side of the associated current collector (1020b). Also, vice versa. By configuring the tabs in this alternating manner, it becomes possible to conveniently assemble the unit cells in subsequent steps in the manufacture of a single pouch cell.

[0134]

[1176] The anode assembly 1000 shown in FIG. 10A includes four anodes 1001a to 1001d, which is for illustrative purposes only. In practice, the number of anodes disposed on the pouch film 1040 may be more or less than four.

[0135]

[1177] FIG. 10B is a cross-sectional view (a cross-section taken along 10B-10B shown in FIG. 10A) showing the anode assembly 1000 including the anode material 1010, the anode current collector 1020, and the pouch film 1040 from top to bottom. As can be seen from FIGS. 10A to 10B, the anode material 1010 is smaller in size compared to the anode current collector 1020, and the anode current collector 1020 is even smaller in size compared to the pouch film 1040. This pyramid structure actually enables the anode to be conveniently handled during manufacturing. More specifically, due to the relatively large size of the pouch film 1040, a means for supporting the electrode material, particularly the semi-solid electrode material, can be obtained during battery manufacturing. That is, the pouch film can hold the electrode material. The pouch film 1040 can also protect the electrodes so as not to cause deformation that may occur during the packaging of the electrode stack, particularly at the edges of the electrodes. Further, the pouch film 1040 can prevent leakage of the electrode material and contamination of other components that may occur during battery manufacturing by accommodating the electrode material within the space defined by the pouch film 1040. It can also protect the electrodes so as not to cause deformation that may occur at the edges of the electrodes, especially during the packaging of the electrode stack. Further, the pouch film 1040 can prevent leakage of the electrode material and contamination of other components that may occur during battery manufacturing by accommodating the electrode material within the space defined by the pouch film 1040.

[0136]

[1178] The method of preparing the anode assembly 1000 shown in FIGS. 10A-10B can start from a pouch film. Next, a plurality of anode current collectors can be laminated on the pouch film (e.g., using an adhesive) such that the tabs are configured alternately as described above. The plurality of anode current collectors can be arranged in a periodic structure to facilitate the subsequent assembly of unit battery cells. In some embodiments, the anode current collectors are arranged in a one-dimensional array (e.g., as shown in FIG. 10A). In some embodiments, the anode current collectors can be arranged in a two-dimensional array. After adhering the pouch film and the anode current collectors to each other, an anode material can be disposed on each anode current collector to form the anode assembly 1000.

[0137]

[1179] In some embodiments, the plurality of anode current collectors can be deposited on the pouch by any of coating or deposition techniques such as, but not limited to, chemical vapor deposition (CVD) (initiate CVD, hot wire CVD, plasma enhanced CVD, and other forms of CVD), physical vapor deposition, sputter deposition, magnetron sputtering, radio frequency sputtering, atomic layer deposition, pulsed laser deposition, plating, electroplating, immersion coating, brushing, spray coating, sol-gel method (by immersion coating, brushing or spray coating), electrostatic spray coating, 3D printing, spin coating, electrodeposition, powder coating, sintering, self-assembly method, and any combination of those techniques.

[0138]

[1180] In some embodiments, the properties of the deposited anode current collector can be optimized by varying the deposition parameters during deposition. For example, physical properties such as surface morphology, including the texture of the coating, the thickness of the coating, the uniformity of the thickness, and surface roughness, porosity, as well as general mechanical properties such as fracture toughness, ductility, and tensile strength, can be optimized by fine-tuning the deposition parameters. Similarly, chemical properties such as chemical resistance and corrosion resistance to electrolytes and salts, as well as other chemical properties such as specific reactivity, adhesiveness, and affinity, can be optimized by varying the deposition parameters to fabricate a functional current collector. In some embodiments, various physical and chemical properties of the current collector formed by deposition or coating can be further improved or modified after deposition by subsequent surface treatments or temperature treatments such as annealing or rapid thermal (flash) annealing, or electrochemical polishing, or using any combination of these techniques.

[0139]

[1181] FIG. 11A is a top view showing a cathode assembly layout including a plurality of anodes according to some embodiments, and FIG. 11B is a cross-sectional view (taken along line 11B-11B of FIG. 11A) of the cathode assembly layout. Cathode assembly 1100 includes a plurality of cathodes 1101a, 1101b, 1101c, and 1101d disposed on pouch film 1140. Each cathode (1101a-1101d) includes a cathode material 1110a (taking the first cathode as an example) disposed on a cathode current collector 1120a laminated on the pouch film 1140. Each cathode further includes a tab 1122a for electrical connection. FIG. 11B is a cross-sectional view showing the cathode assembly 1100 including the cathode material 1110, the cathode current collector 1120, and the pouch film 1140 from top to bottom.

[0140]

[1182] The method of preparing the cathode assembly 1100 can be made substantially the same as the method of preparing the anode assembly 1000 described above. This method involves a plurality of cathode collectors It can start with laminating the electrical bodies in an array on the pouch film. Then, the cathode material can be disposed on each cathode current collector to form a cathode assembly.

[0141]

[1183] In some embodiments, the anode assembly 1000 shown in FIGS. 10A - 10B and the cathode assembly shown in FIGS. 11A - 11B can be prepared on the same pouch film (1040 or 1140). In some embodiments, the anode assembly 1000 and the cathode assembly 1100 can be prepared on separate pouch films.

[0142]

[1184] Similarly, the plurality of cathode current collectors can also be deposited on the pouch film by some of the deposition or coating techniques described above in connection with FIGS. 10A - 10B. Also, the properties of the deposited cathode current collectors can be optimized by the optimization techniques described above.

[0143]

[1185] FIG. 12 is a top view showing an electrode assembly layout 1200 that includes both an anode assembly 1201 and a cathode assembly 1202, with them being disposed on a common pouch film 1240. Since the anode assembly 1201 and the cathode assembly 1202 can be substantially the same as the anode assembly 1000 of FIG. 10A and the cathode assembly 1100 of FIG. 10B respectively, they will not be described in detail here. The anode assembly 1201 and the cathode assembly 1202 are aligned such that when the electrode assembly 1200 is folded along the central dashed line 10, each anode of the anode assembly 1201 overlaps the corresponding cathode of the cathode assembly 1202. Further, the tab 1221 of the anode assembly and the tab 1222 of the cathode assembly are arranged complementarily. More specifically, when folded along the dashed line 10, each anode tab 1221 is on one side of the respective current collector, and each cathode tab 1222 is on the opposite side of each current collector. In other words, when the electrode assembly 1200 is folded along the dashed line 10, the anode tab 1221 does not contact the cathode tab 1222.

[0144]

[1186] In some embodiments, the pouch film can be kept in a folded state for a long time by applying heat or by any other suitable method that prevents the loss of the folded state. In some embodiments, applying heat or any other suitable method for maintaining the folded state can be performed before laminating the current collector to the pouch film. In some embodiments, applying heat or any other suitable method for maintaining the folded state can be performed after laminating the current collector to the pouch film. Similarly, in some embodiments, applying heat or any other suitable method for maintaining the folded state can be performed before depositing the current collector on the pouch film or coating the pouch film with the current collector. In some embodiments, applying heat or any other suitable method for maintaining the folded state can be performed after depositing the current collector on the pouch film or coating the pouch film with the current collector. The electrode assembly 1200 can be prepared in a manner similar to that described in connection with FIGS. 10A-10B and FIGS. 11A-11B. However, the steps of the above methods (e.g., lamination of the current collector, deposition of the electrode material, etc.) can be arranged in various orders to prepare the electrode assembly 1200. In some embodiments, the method of preparing the electrode assembly 1200 starts with the pouch film, and then the anode current collector and the cathode current collector are laminated separately. Thereafter, the anode material may be disposed on each anode current collector, and the cathode material may be disposed on each cathode current collector.

[0145]

[1187] In some embodiments, the method of preparing the electrode assembly 1200 starts with laminating the anode current collector on the pouch film, and then disposing the anode material on each anode current collector. Thereafter, the method proceeds to the lamination of the cathode current collector and the disposition of the cathode material on each cathode current collector.

[0146]

[1188] In some embodiments, the anode current collector and / or the cathode current collector can be deposited on the pouch film in turn by some of the deposition or coating techniques described herein. The properties of the deposited anode current collector and / or cathode current collector can also be optimized as described above by the aforementioned optimization techniques or methods.

[0147]

[1189] In some embodiments, the current collectors can be alternately laminated on the pouch film. More specifically, each time a current collector of one type (anode or cathode) is laminated on the pouch film, a current collector of the other type (cathode or anode) is laminated in alignment with the current collector of the opposite type. These embodiments described herein are for illustrative purposes only. Those skilled in the art will understand that various other sequences can be implemented to prepare the electrode assembly 1200.

[0148]

[1190] The separator can be disposed on each electrode (anode or cathode) of the electrode assembly during or after the preparation of the electrode assembly 1200. In some embodiments, the separator is disposed on each anode material. In some embodiments, the separator is disposed on each cathode material. In some embodiments, the separator is disposed on the electrode material after preparing the electrode assembly 1200. In some embodiments, the separator is disposed on the electrode material during the preparation of the electrode assembly. For example, the separator can be disposed on the anode material after preparing the anode assembly 1201 and before preparing the cathode assembly 1202. Those skilled in the art will understand that various other process sequences can be implemented to dispose the separator on the electrode material.

[0149]

[1191] After placing the separator (or a sheet of a large separator) on the electrode assembly 1200 (anode assembly 1201 or cathode assembly 1202), the electrode assembly 1200 is folded along the central line 10 to form the unit cell assembly 1300 as shown in FIGS. 13A - 13B. The unit cell assembly 1300 includes a plurality of unit cells 1301a, 1301b, 1301c, and 1301d. The pouch film 1340 substantially houses these plurality of unit cells 1301a - 1301d except for the tabs 1321 and 1322 that protrude from the pouch film 1340 to enable electrical coupling with external components. Although four unit cells are shown in FIG. 13A, this is for illustrative purposes only. In reality, the number of unit cells in the unit cell assembly may be more or less than four depending on manufacturing specifications.

[0150]

[1192] Each unit cell of the unit cell assembly (taking the first unit cell 1301a as an example) includes a cathode tab 1321 on one side of the unit cell and an anode tab 1322 on the opposite side of the unit cell. Adjacent unit cells within the unit cell assembly 1300 have opposite tab 1321 and 1322 configurations. Taking the first unit cell 1301a and the second unit cell 1301b as examples. In the first unit cell 1301a, the cathode tab 1321 is on the left side of the unit cell and the anode tab 1322 is on the right side. On the other hand, in the second unit cell 1301b, the cathode tab 1321 is on the right side of the unit cell and the anode tab 1322 is on the left side. This alternating tab configuration enables convenient assembly of the cells and manufacturing of the battery in subsequent processes as described in detail below.

[0151]

[1193] FIG. 13B shows a unit cell assembly including, from top to bottom, the first pouch film 1340a, the cathode current collector 1310, the cathode material 1320, the separator 1330, the anode material 1330, the anode current collector 1350, and the second pouch film 1340b. It is a cross-sectional view showing the pouch 1300 (taken along line 13B-13B of FIG. 13A). In some embodiments, the first pouch film 1340a and the second pouch film 1340b can be different portions of the same film, as shown in FIG. 12 for example. In some embodiments, the first pouch film 1340a and the second pouch film 1340b can also be different pouch films, and the anode assembly and the cathode assembly are respectively disposed thereon.

[0152]

[1194] A sealing process can be performed on the unit cell assembly 1300 shown in FIGS. 13A to 13B to form individual unit cells, that is, single-pouch unit cells, respectively housed in pouches. FIG. 14 is a diagram showing a sealing method of a unit cell assembly 1400 that can be substantially the same as the unit cell assembly 1300. The unit cell assembly 1400 includes a plurality of unit cells 1401a to 1401d substantially housed in a pouch film 1440. The dashed line 20 indicates a sealing position that can be, for example, a vacuum seal or a heat seal.

[0153]

[1195] In some embodiments, the sealing process can first be performed along two horizontal lines (one at the top and the other at the bottom of the unit cell assembly 1400), and then along each vertical line. Some embodiments can reverse the above order, that is, perform vertical sealing first and then horizontal sealing. In some embodiments, both vertical and horizontal sealing can be performed simultaneously along a predetermined sealing line 20.

[0154]

[1196] Figures 15A - 15B are diagrams showing the procedure of stacking unit cells after sealing each unit cell in a pouch. Figure 15A shows a unit cell assembly 1500 that is substantially the same as the sealed unit cell assembly 1400 shown in FIG. 14. The unit cell assembly 1500 includes a plurality of unit cells 1501a - 1501d. The sealing is performed along the dashed line 20. The vertical dashed - dotted line 30 indicates the position of the line along which the unit cell assembly 1500 is to be folded to form a unit cell stack. After folding, the anode tab is at one edge of the resulting stack, and the cathode tab is at the other edge of the resulting stack, such that the anode tab is electrically insulated from the cathode tab.

[0155]

[1197] In some embodiments, the plurality of unit cells 1501a - 1501d are folded in a rounding manner. For example, unit cell 1501d can be folded over unit cell 1501c in a counter - clockwise direction, and then the resulting stack of 1501c and 1501d can also be folded over unit cell 1501b in a counter - clockwise direction. This rounding process can be continued until the last unit cell in the assembly (or the first unit cell depending on which unit cell started the rounding).

[0156]

[1198] In some embodiments, as shown in FIG. 15B, the plurality of unit cells 1501a - 1501d are folded in a zig - zag manner. For example, unit cells 1501a and 1501b can be folded in a counter - clockwise direction. However, unit cells 1501c and 1501d can be folded in a clockwise direction. The stack of 1501a and 1501b can be folded together with the stack of 1501c and 1501d either in a counter - clockwise direction or in a clockwise direction. In other words, the folding direction can be different for each unit cell within the unit cell assembly 1500.

[0157]

[1199] In some embodiments, the folding of the plurality of unit cells 1501a to 1501d can be performed simultaneously. For example, by applying forces from both the left and right sides of the unit cell assembly to push the unit cells, they can be stacked on top of each other in the same way as the side panels of a window air conditioner. They can also be stacked on top of each other.

[0158]

[1200] In some embodiments, the folded state of the plurality of unit cells 1501a to 1501d can be maintained for a long period of time by applying heat or any other suitable method to prevent the loss of the folded state. In some embodiments, applying heat or any other suitable method to maintain the folded state for a long time can be performed after folding in the counterclockwise folding direction, after folding in the clockwise folding direction, after folding in a zigzag folding direction, or any combination of these folding directions. In some embodiments, the folded state of the plurality of unit cells 1501a to 1501d can be maintained for a long period of time by applying heat or any other suitable method before folding the plurality of cells. In some embodiments, the folded state of the plurality of unit cells 1501a to 1501d can be maintained for a long period of time by applying heat or any other suitable method each time a respective one of the plurality of cells is folded. In some embodiments, the folded state of the plurality of unit cells 1501a to 1501d can be maintained for a long period of time by applying heat or any other suitable method after all of the plurality of cells have been folded.

[0159]

[1201] FIG. 16A is a top view showing a unit cell stack prepared by the method shown in FIGS. 15A to 15B, and FIG. 16B is a cross-sectional view of the unit cell stack (taken along line 16B-16B shown in FIG. 16A). The unit cell stack 1600 includes a plurality of unit cells 1601a to 1601d (collectively referred to as unit cell 1601). Each unit cell is sealed within a pouch 1640. The cathode tab 1621 is aligned with the left edge of the unit cell stack 1600, and the anode tab 1622 is aligned with the right edge of the unit cell stack 1600. Both the cathode tab 1621 and the anode tab 1622 protrude from the pouch 1640 to enable electrical coupling with other components in the system, such as other cell stacks, utilities, or connectors.

[0160]

[1202] Figures 17A-17B are diagrams showing an exemplary method of performing gas venting during the manufacture of a single pouch battery cell, showing a pouch cell with additional portions corresponding to gas generation and resealing. Figure 17A is a top view showing a unit cell assembly 1700 including unit cells 1701a, 1701b, 1701c, and 1701d sealed to respective pouches along a sealing line 20. Each of the unit cells 1701a-1701d further includes a portion for accommodating gas generated during cell formation, which is also referred to herein as gas venting portions 1761a-1761d. The gas venting portions 1761a-1761d extend from the electrode portions of the unit cells and include an empty pouch space. The gas generated during the gas venting process can be accommodated in these gas venting portions 1761a-1761d. After the gas venting process is completed, the gas venting portions 1761a-1761d can be cut along the white dotted line shown in Figure 17B to release the accommodated gas and removed from the unit cell assembly 1700. The gas-vented unit cell assembly 1700 can then be resealed along a new sealing line 25 to form a resealed unit cell assembly (e.g., the unit cell stack shown in Figures 15A-15B) for further processing. In some embodiments, the gas venting process can be performed after stacking the unit cells by sealing several stacked pouch materials at once. In this approach, the production can be made more effective.

[0161]

[1203] In some embodiments, the unit cell assembly 1700 including gas venting portions in each unit cell can be prepared in substantially the same manner as described above in connection with Figure 12, except that a larger-sized pouch film is used. More specifically, the regions on both sides of the central line 10 in Figure 12 can be enlarged so that gas venting portions can be formed when the electrode assembly is folded along the central line 10.

[0162]

[1204] In some embodiments, the cathode assembly and the anode assembly can be prepared on separate pouch films such that an additional film is located at the bottom of each assembly. The two assemblies can then be stacked on top of each other and sealed along the dashed line 20 as shown in FIG. 17A to form the unit cell assembly 1700.

[0163]

[1205] FIGS. 10A-17B illustrate a method of preparing a unit cell assembly having both an anode tab and a cathode tab on the same side of the unit cell assembly. In some embodiments, as shown in FIG. 18, the anode tab 1821 and the cathode tab 1822 are on opposite sides of the unit cell assembly 1800. In this example, the anode tabs 1821 and the cathode tabs 1822 of the unit cells 1801a-1801d can utilize a larger available width of the current collector. That is, the tabs can be made wider. By increasing the width of the tabs, the electrical resistance of the tabs can be reduced, thereby improving the performance of the resulting battery. Tabs having a larger width are less prone to corrosion, breakage, or other forms of impairment for physical and / or chemical reasons, so increasing the width can also improve the mechanical and electrical stability of the resulting battery.

[0164]

[1206] The unit cell assembly 1800 can be prepared by stacking the cathode assembly (e.g., 1100 shown in FIG. 11A with wide tabs) on top of the anode assembly (e.g., 1000 shown in FIG. 10A with wide tabs) turned upside down, such that the cathode tab and the anode tab are configured on opposite sides of the resulting unit cell assembly. The resulting unit cell assembly 1800 can then be sealed along the seal line 20 to form individually packaged single pouch battery cells.

[0165]

[1207] FIGS. 19A-19B illustrate an exemplary manufacturing method for preparing a single pouch battery cell in which the electrode assembly includes both an anode and a cathode within the same column. For purposes of illustration only, FIG. 19A shows an electrode assembly 1900 including two anodes (1901a and 1901c) and two cathodes (1901b and 1901d) disposed on the same pouch film 1940 and arranged alternately in the same order. The first anode 1901a and the first cathode 1901b form the first unit cell 1901 when folded along the first dashed line 50. The second anode 1901c and the second cathode 1901d form the second unit cell 1902 when folded along the second dashed line 55. In some embodiments, these two unit cells 1901 and 1902 are further folded along the solid line 40 to form a simple unit cell stack. In some embodiments, the folded state of the plurality of unit cells 1901 and 1902 along the solid line 40 can be maintained in the folded state for a long time by applying heat or other methods to prevent loss of any suitable folded state. In some embodiments, these two unit cells 1901 and 1902 are cut along the solid line to form two separate and independent unit cells, and further processing (such as stacking, sealing, etc.) is performed.

[0166]

[1208] FIG. 19B is a cross-sectional view showing the folded region of the first unit cell 1901, including a pouch film 1904 that substantially houses a cathode material 1920 disposed on a cathode current collector 1910, an anode material 1950 disposed on an anode current collector 1960, and a separator 1930 disposed between the anode material 1950 and the cathode material 1920 in three directions (bottom, top, and right side). In some embodiments, a longer pouch film can be used at the connection portion 1942 of the pouch film 1940 to form a gas vent portion.

[0167]

[1209] Figures 19C to 19D are diagrams showing an exemplary manufacturing method for preparing a cylindrical battery cell according to some embodiments. Figure 19C is a top view showing a cylindrical battery cell 1903 including a plurality of electrode stacks. Each electrode stack further includes a cathode 1913, an anode 1923, and a separator 1933 disposed between the cathode 1913 and the anode 1923. Adjacent electrode stacks are separated by a pouch layer 1943. Figure 19D is a schematic diagram showing the cylindrical battery cell 1903.

[0168]

[1210] Figures 19E to 19G are diagrams showing an exemplary manufacturing method for preparing a prismatic battery cell according to some embodiments. Figure 19E is a partial top view showing the prismatic battery cell 1905, which shows the detailed structure of the portion circled by the circle in Figure 19F, which is an overall top view of the prismatic battery cell 1905. The prismatic battery cell 1905 includes a plurality of electrode stacks, and each electrode stack further includes a cathode 1915, an anode 1925, and a separator 1935 disposed between the cathode 1915 and the anode 1925. Adjacent electrode stacks are separated by a pouch layer 1945. Figure 19G is a schematic diagram showing the prismatic battery cell 1905.

[0169]

[1211] Both the cylindrical battery cell 1903 and the rectangular battery cell 1905 can be prepared by the method described below. In some embodiments, the cathode (1913 or 1915) and the anode (1923 or 1925) can be prepared separately. For example, the cathode can be prepared by disposing a cathode material on a cathode current collector, and the anode can be prepared by disposing an anode material on an anode current collector. Then, a separator can be disposed on the anode material or the cathode material. Next, the prepared cathode and anode can be stacked on top of each other to form an electrode stack, and then a pouch layer can be disposed on one side (anode side or cathode side) of the electrode stack. Next, the electrode stack can be rolled together with the pouch layer to form a cylindrical battery cell or a rectangular battery cell. In some embodiments, the pouch layer can also be disposed on one of the electrodes before stacking the two electrodes on top of each other to facilitate the preparation of the electrodes.

[0170]

[1212] In some embodiments, the electrode stack (including the pouch layer) can be prepared layer by layer. For example, this manufacturing can start with disposing an anode current collector on the pouch layer, and then disposing an anode material on the anode current collector. Next, a separator can be disposed on the anode material, a cathode material can be disposed thereon, and then a cathode current collector can be disposed. After this layer-by-layer procedure, the obtained electrode stack can be rolled to form a battery cell in a cylindrical configuration or a rectangular configuration. In some embodiments, the pouch layer can be disposed after the formation of the electrode stack.

[0171]

[1213] In some embodiments, before rolling the electrode stack into a battery cell, a cutting process can be performed to achieve the desired shape factor of the battery cell obtained after rolling.

[0172]

[1214] In some embodiments, the battery cells shown in FIGS. 19C-19F can be further sealed within an external pouch or package. The external pouch or package can be used to reduce corrosion caused, for example, by moisture or chemicals in the ambient environment.

[0173]

[1215] FIGS. 19C-19F show only one pouch layer within each individual battery cell 1903 or 1905, but in practice, multiple pouch layers can also be used. In some embodiments, two pouch layers can be used. One pouch layer can be disposed on the anode current collector, and the other pouch layer can be disposed on the cathode current collector to facilitate the preparation of the electrodes (e.g., to avoid leakage or deformation of the electrode materials).

[0174]

[1216] FIG. 20 is a diagram showing a single-pouch battery cell manufactured according to the method described above. The battery cell 2000 includes a pouch 2040 that houses an anode 2010, a cathode, and a separator. The cathode and the separator are behind the anode 2010 and are not numbered. This battery cell also includes an anode tab 2010 made of copper and a cathode tab 2014 made of aluminum. As can be seen from FIG. 20, the pouch 2040 substantially houses the electrode portion, and the tabs 2012 and 2014 extend outside the pouch for external connection.

[0175]

[1217] FIG. 21 is a diagram showing the capacity retention curves of three groups of single pouch battery cells. The first group, also called the control group, includes single pouch battery cells that have undergone a degassing process before the capacity retention test. The second group, also called the "non-degassed" group, includes single pouch battery cells that have not undergone any degassing before the test. The single pouch battery cells of the third group, also called the "pre-charged" group, have undergone a pre-charging process before the pouch is sealed. The pre-charging is performed at a rate of C / 10 over about 1 hour. The batteries of the third group do not undergo a degassing process.

[0176]

[1218] The battery cells of all groups have a cathode slurry containing 50% by volume of lithium iron phosphate and 0.936% by volume of a carbon additive, which is mixed with a speed mixer. In some embodiments, the procedure for mixing the cathode slurry includes repeating the mixing at 650 RPM for 3 minutes twice, and then performing the mixing at 1250 RPM for 1 minute. The anode used in the battery cells also contains 50% by volume of graphite powder and 2% by volume of a carbon additive, which is mixed with a mixer. In some embodiments, the procedure for mixing the anode slurry includes performing the mixing at 650 RPM for 6 minutes. The anode has a thickness of about 265 μm. The electrolyte used in these battery cells contains a solvent of 50 / 50 ethylene carbonate / γ-butyrolactone (GBL) and 1 M LiTFSI dissolved in this solvent. This electrolyte further includes an additive such as 2% vinylene carbonate (VC). The overall thickness of the battery cell is about 900 μm.

[0177]

[1219] As shown in FIG. 21, the battery cells of the pre-charged group exhibit substantially the same capacity retention rate as the battery cells of the control group. Further, the battery cells of the non-gassing group show an increase in capacity in the first 15-20 cycles, indicating that the full capacity of the battery cells in the non-gassing group cannot be obtained during those cycles. By comparing the capacity retention rates, it can be seen that performing the pre-charging process on a single pouch cell can eliminate the need for the gassing process and further omit the re-sealing process of conventional battery manufacturing.

[0178] Exemplary battery module and battery pack including single pouch battery cells

[1220] FIG. 22 is a top view showing a battery module 2200 including an array of single pouch battery cells 2210(1)-2210(8) (collectively referred to as battery cells 2210) enclosed within a case 2220. Each battery cell 2210 includes an anode tab 2212 and a cathode tab 2214 that can be used to couple the battery cell to other battery cells. The battery module 2200 shown in FIG. 22 includes eight single pouch battery cells, which is for illustrative purposes only. In practice, the number of single pouch battery cells in a battery module may be more or less than eight, depending on, for example, the desired battery specifications.

[0179]

[1221] Further, the plurality of battery cells 2210 are arranged in a two-dimensional array, which is also for illustrative purposes only. In some embodiments, the plurality of battery cells 2210 are arranged in a row (i.e., in a one-dimensional array). In some embodiments, the plurality of battery cells 2210 are arranged radially toward a common center point such that the battery module 2200 can have a cylindrical configuration. This is also for illustrative purposes only. In some embodiments, the plurality of battery cells 2210 are arranged in a row (i.e., in a one-dimensional array). In some embodiments, the plurality of battery cells 2210 are arranged radially toward a common center point such that the battery module 2200 can have a cylindrical configuration.

[0180]

[1222] Furthermore, although FIG. 22 shows only one layer of battery modules, this is for illustrative purposes only. In reality, one or more battery modules similar to battery module 2200 can be coupled to each other to achieve a desired output specification such as capacity, voltage, or current.

[0181]

[1223] FIGS. 23A to 23B are an exploded view and a completed view showing a battery module including a plurality of single pouch battery modules enclosed in a metal case, respectively. As shown in FIG. 23A, battery module 2300 includes an upper cover 2310, an upper foam 2320, a cell stack 2330, and an integral case 2340 that houses the cell stack.

[0182]

[1224] The cell stack 2330 further includes an anode tab 2334 and a cathode tab 2332. The anode tab 2334 is in electrical communication with each anode of the battery cells in the cell stack 2330, and the cathode tab 2332 is in electrical communication with each cathode of the battery cells in the cell stack 2330. The integral case 2340 further includes an anode connector 2344 and a cathode connector 2342. When the cell stack 2330 is properly disposed within the integral case 2340, the anode tab 2334 is electrically coupled to the anode connector 2344, and the cathode tab 2332 is electrically coupled to the cathode connector 2342, enabling the battery module 2300 to provide power (during discharge) or receive power (during power reception) via the anode connector 2344 and the cathode connector 2342.

[0183]

[1225] In some embodiments, the upper cover 2310 includes the same metal material (such as stainless steel, aluminum, copper, etc.) used for the integral case 2340. In some embodiments, the upper cover 2310 includes a lightweight material (such as polymer, plastic, light metal, etc.) to facilitate removal and reinstallation of the upper cover 2310.

[0184]

[1226] In some embodiments, the upper foam 2320 is soft (e.g., cushion foam) to reduce the possibility of damage to the cell stack 2330 during impact. In some embodiments, the upper foam 2320 includes a flame-retardant foam, particularly a synthetic foam, a water film-forming foam, an alcohol-resistant foam, and a protein foam.

[0185]

[1227] FIGS. 24A-24B are respectively an exploded view and an assembled view showing a battery module including a plurality of single pouch battery modules enclosed in a plastic case. As shown in FIG. 24A, the battery module 2400 includes an upper cover 2410, an upper foam 2420, a cell stack 2430, an inner liner 2450, and an integral case 2440 that houses the cell stack. The upper cover 2410, the upper foam 2420, and the cell stack 2430 can be substantially the same as the upper cover 2310, the upper foam 2320, and the cell stack 2330 shown and described above with reference to FIG. 23A. The integral case 2440 includes a plastic material, for example, to reduce the weight of the battery module 2400.

[0186]

[1228] In some embodiments, the inner liner 2450 includes a soft material (e.g., plastic, polymer, rubber, etc.) to reduce the possibility of damage to the cell stack 2430 during impact. In some embodiments, the inner liner 2450 reduces the fire hazard It contains a flame-retardant material. In some embodiments, the inner liner 2450 contains an antistatic material such as a long-chain aliphatic amine (optionally ethoxylated) and amide, a quaternary ammonium salt (such as behentrimonium chloride or cocamidopropyl betaine), a phosphate ester, a polyethylene glycol ester, or a material based on a polyol. In some embodiments, the inner liner 2450 contains a moisture-resistant material to prevent short circuits in the cell stack 2430 caused by moisture. In some embodiments, the inner liner 2450 contains a composite material. For example, the inner liner 2450 can contain a soft cushioning material coated with a flame-retardant material to reduce the fire hazard.

[0187]

[1229] The battery modules 2300 shown in FIGS. 23A to 23B and the battery modules 2400 shown in FIGS. 24A to 24B, generally referred to as battery modules, can have several features that can facilitate actual applications. In some embodiments, the battery module can enable inter-module interlocking so that a battery pack having specific desired specifications (such as voltage, current, capacity, etc.) can be conveniently constructed. In some embodiments, the battery module includes a modular design such that in each individual application field, each battery module can function independently as a power source or cooperate with other components.

[0188]

[1230] In some embodiments, the battery module can have the following specifications. That is, the output voltage is 3.2V, the cell capacity is 280Ah, the cell weight is 4.5 kg, the total energy is 0.896 kWh, the cell volume is 4.14 L, the volumetric energy density is 216 Wh / L, and the specific energy density is 200 Wh / kg. This specification is for illustrative purposes only. In practice, various specifications can be utilized to meet the various actual requirements in the application field.

[0189]

[1231] FIG. 25 is a schematic diagram showing a battery pack 2500 including a plurality of battery modules 2510(1) to 2510(4), collectively referred to as battery module 2510. The battery module 2510 can be substantially the same as the battery module 2300 shown in FIGS. 23A to 23B or the battery module 2400 shown in FIGS. 24A to 24B. The battery pack 2500 shown in FIG. 25 includes four battery modules 2510 arranged in a two-dimensional array, which is for illustrative purposes only. In reality, the number of battery modules in the battery pack can vary depending on, for example, the desired specifications. This array configuration can also be changed. For example, FIG. 26 shows a battery module 2600 including an array of four battery modules 2610(1) to 2610(4) arranged in a one-dimensional row, for example, to conform to specific space requirements.

[0190]

[1232] FIGS. 27A to 27C are schematic diagrams showing a battery pack including vertically stacked battery modules and an enlarged portion of the stacked modules for explaining the interlock mechanism of the battery pack. The battery pack 2700 shown in FIG. 27A includes a first battery module 2710a and a second battery module 2710b stacked vertically on each other. Stacking pressure can be applied to the second battery module 2710b by the weight of the first battery module 2710a. In some embodiments, when 28 modules are stacked in sequence, the pressure difference between the top battery module and the bottom battery module can be about 5 PSI.

[0191]

[1233] The battery pack 2700 includes a left contact portion 2712a and a right contact portion 2712b between the two battery modules. The two contact portions 2712a and 2712b are shown in FIGS. 27B and 27C, respectively. FIGS. 27B and 27C show the upper part of the lower battery module 2710b receiving the bottom of the upper battery module 2710a It shows that it can be configured in this way. With this configuration, a plurality of battery modules can be conveniently coupled to each other to form a battery pack having a desired specification.

[0192]

[1234] FIGS. 28A to 28B are a completed view and an exploded view showing a battery rack 2800 including a plurality of battery modules 2850 (for example, battery modules 2300 and / or 2400) arranged in a rack configuration (i.e., a two-dimensional vertical array). A plurality of support frames 2840 are arranged at four edges of the plurality of battery modules 2850 to hold the battery modules 2850 together. The support frames 2840 are mechanically coupled to the battery modules 2850 by a plurality of bolts 2870. An upper end plate 2810 and a bottom end plate 2880 surround the plurality of battery modules 2850 from above and below, respectively. A plurality of compression plates 2830 and a plurality of compression springs 2820 arranged thereon can be arranged between the upper end plate 2810 and the plurality of battery modules 2850 for shock buffering. Each battery module includes a battery cable 2860 to facilitate electrical coupling between that battery module and other battery modules. The completed view of the resulting battery rack 2800 is shown in FIG. 28A.

[0193]

[1235] One exemplary specification of the battery rack 2800 can be as follows. That is, the output voltage is 716V, the cell capacity is 280Ah, the cell weight is 1150 kg, the total energy is 200 kWh, the rack dimensions are 600 mm × 760 mm × 2100 mm, the volumetric energy density is 210 Wh / L, and the specific energy density is 175 Wh / kg. This specification is for illustrative purposes only. In practice, various specifications can be utilized to meet various actual requirements in the application field.

[0194]

[1236] Although the above various embodiments have been described, it should be understood that they are presented for illustrative purposes only and not for purposes of limitation. For example, although the embodiments of the present specification describe electrochemical devices such as lithium-ion batteries, the systems, methods, and principles described herein can be applied to all devices including electrochemically active media. In other words, any electrodes and devices including at least an active material (source or sink of charge carriers), a conductive additive, and an ion-conductive medium (electrolyte), such as a battery, a capacitor, an electric double layer capacitor (e.g., an ultracapacitor), a lithium-ion capacitor (hybrid capacitor), a pseudocapacitor, etc., are included within the scope of the present disclosure. Further, the above embodiments can be used with non-aqueous and / or aqueous electrolyte battery chemistries.

[0195]

[1237] The above-described methods and steps are shown as specific events occurring in a specific order, but those skilled in the art having the benefits of the present disclosure will recognize that the order of the specific steps can be modified and that such modifications are by way of variations of the present invention. Further, certain of these steps can, where possible, be executed simultaneously in a parallel process or executed in sequence as described above. Further, a particular step can proceed to subsequent steps where it is partially completed and / or can be omitted and proceed to subsequent steps.

[0196]

[1238] Although the various embodiments have been specifically illustrated and described, various changes can be added to the form and details. For example, although the various embodiments have been described as having a particular combination of features and / or components, other embodiments having any combination or partial combination of any features and / or components of any of the embodiments described herein are also possible. The specific configurations of these various components can also be varied.

Claims

1. An electrochemical cell comprising: a first current collector coupled to a first portion of a pouch and having a first electrode material disposed thereon; a second current collector coupled to a second portion of the pouch and having a second electrode material disposed thereon; a separator disposed between the first electrode material and the second electrode material and having a cross-sectional area larger than the cross-sectional areas of the first electrode material and the second electrode material; wherein the first portion of the pouch is coupled to the second portion of the pouch to form a sealed region, the separator extends partially into the sealed region and is sealed between the first portion and the second portion, and the sealed region extends beyond the peripheral edge of the separator; an electrochemical cell, wherein at least one of the first current collector or the second current collector has a thickness of less than 20 μm.

2. The electrochemical cell according to claim 1, wherein the pouch is folded along a fold line between the first portion of the pouch and the second portion of the pouch, and the separator is disposed between the first electrode material and the second electrode material.

3. The electrochemical cell according to claim 1, wherein at least one of the first electrode material or the second electrode material comprises a semi-solid electrode material.

4. The electrochemical cell according to claim 1, wherein at least one of the first electrode material or the second electrode material has a thickness in the range of 250 μm to 2000 μm.

5. The electrochemical cell according to claim 4, wherein at least one of the first electrode material or the second electrode material has a thickness in the range of 250 μm to 500 μm.

6. The electrochemical cell according to claim 1, wherein at least one of the first current collector or the second current collector has a thickness of less than 12 μm.

7. The electrochemical cell according to claim 6, wherein at least one of the first current collector or the second current collector has a thickness of less than 5 μm.

8. The electrochemical cell according to claim 1, wherein the electrochemical cell has an energy capacity in the range of 0.1 Ah to 40 Ah.

9. An electrochemical cell comprising: a first current collector coupled to a first portion of a pouch and having a first electrode material disposed thereon; a second current collector coupled to a second portion of the pouch and having a second electrode material disposed thereon; A third current collector disposed between the first and second electrode materials, wherein a third electrode material is disposed on a first side surface of the third current collector facing the first electrode material and a second side surface of the third current collector facing the second electrode material; A first separator disposed between the first electrode material and the third current collector; A second separator disposed between the second electrode material and the third current collector, each of the first and second separators having a cross-sectional area larger than the cross-sectional areas of the first electrode material, the second electrode material, and the third electrode material; An electrochemical cell in which a first portion of the pouch is coupled to a second portion of the pouch to form a sealed region, each of the first and second separators extends partially into the sealed region and is sealed between the first portion and the second portion, and the sealed region extends beyond the peripheral edges of each of the first and second separators.

10. The first and second electrode materials include a cathode material; The electrochemical cell according to claim 9, wherein the third electrode material includes an anode material.

11. The first and second electrode materials include an anode material; The electrochemical cell according to claim 9, wherein the third electrode material includes a cathode material.

12. The electrochemical cell according to claim 9, wherein at least one of the first electrode material and the second electrode material includes a semi-solid electrode material.

13. The electrochemical cell according to claim 9, wherein at least one of the first electrode material and the second electrode material has a thickness in the range of 250 μm to 2000 μm.

14. The electrochemical cell according to claim 13, wherein at least one of the first electrode material and the second electrode material has a thickness in the range of 250 μm to 500 μm.

15. The electrochemical cell according to claim 9, wherein at least one of the first current collector and the second current collector has a thickness of less than 20 μm.

16. The electrochemical cell according to claim 9, wherein the ratio of the thickness of the second electrode material to the thickness of the second current collector is equal to or greater than 12:

1.

17. The electrochemical cell according to claim 9, wherein the electrochemical cell has an energy capacity in the range of 0.1 Ah to 40 Ah.

18. An electrochemical cell assembly A housing defining an internal volume, and a plurality of electrochemical cells disposed within the internal volume of the housing, each of the plurality of electrochemical cells comprising a first current collector coupled to a first portion of the pouch and having a first electrode material disposed thereon, a second current collector coupled to a second portion of the pouch and having a second electrode material disposed thereon, a separator disposed between the first electrode material and the second electrode material and having a cross-sectional area greater than the cross-sectional areas of the first electrode material and the second electrode material, the first portion of the pouch being coupled to the second portion of the pouch to form a sealed region, the separator extending partially into the sealed region and being sealed between the first portion and the second portion such that the sealed region extends beyond the peripheral edge of the separator, each of the plurality of electrochemical cells including an electrolyte, an electrochemical cell assembly in which an electrolyte of one of the plurality of electrochemical cells is isolated from an electrolyte of another of the plurality of electrochemical cells by the sealed region.

19. a first tab extending from the first current collector of each of the plurality of electrochemical cells, and a second tab extending from the second current collector of each of the plurality of electrochemical cells, the electrochemical cell assembly according to claim 18, wherein each of the first tab and the second tab extends through the sealed region into a region of the internal volume of the housing located outside the sealed region.

20. a first electrical connector disposed within the housing and to which each of the first tabs of the plurality of electrochemical cells is coupled, and a second electrical connector disposed within the housing and to which each of the second tabs of the plurality of electrochemical cells is coupled, the electrochemical cell assembly according to claim 19.

21. the electrochemical cell assembly according to claim 18, wherein at least one of the first electrode material and the second electrode material of each of the plurality of electrochemical cells includes a semi-solid electrode material.

22. the electrochemical cell assembly according to claim 18, wherein at least one of the first electrode material or the second electrode material of each of the plurality of electrochemical cells has a thickness within the range of 250 μm to 2000 μm.

23. The electrochemical cell assembly according to claim 18, wherein at least one of the first current collector or the second current collector of each of the plurality of electrochemical cells has a thickness of less than 20 μm.

24. The electrochemical cell assembly according to claim 18, wherein each of the plurality of electrochemical cells has an energy capacity in the range of 0.1 Ah to 40 Ah.

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