Battery electrode assembly including current limiter

Abstract

An electrode assembly for cycling between charged and discharged states within a normal operating temperature range of minus 20 degrees Celsius (°C) to 80°C includes a group of unit cells, a group of current limiters, an electrode bus bar, and a counter electrode bus bar. Each constituent unit of the group of unit cells includes an electrode structure, a separator structure, and a counter electrode structure. At least one constituent unit of the group of current limiters is electrically connected between the unit cell and the electrode bus bar or the counter electrode bus bar. For each unit cell, at least one constituent unit of the group of current limiters has a resistance sufficient to limit a current through the unit cell below a threshold current I when the electrode assembly is within a normal operating temperature range, the threshold current I being below a current that would induce thermal runaway of the unit cell.

Description

[Technical Field]

[0001] Cross-reference of related applications This application claims priority to U.S. Provisional Patent Application No. 63 / 168,430, filed on 31 March 2021, and U.S. Provisional Patent Application No. 63 / 202,922, filed on 30 June 2021, the full disclosures of which are incorporated herein by reference in their entirety.

[0002] The field of this disclosure generally relates to energy storage technologies, such as battery technologies. More specifically, the field of this disclosure relates to electrode assemblies, including current limiters and secondary batteries having such electrode assemblies. [Background technology]

[0003] Secondary batteries, such as lithium-ion batteries, are a desirable energy source due to their relatively high energy density, power output, and long storage life. Examples of lithium secondary batteries include non-aqueous batteries such as lithium-ion batteries and lithium polymer batteries.

[0004] Known energy storage devices such as batteries, fuel cells, and electrochemical capacitors typically have a two-dimensional laminated structure, such as a planar or helically wound (i.e., jelly roll) laminated structure, where the surface area of ​​each laminate is approximately equal to its geometric footprint (neglecting porosity and surface roughness).

[0005] Figure 1 illustrates a cross-sectional view of a known layered secondary battery, represented as 10 in its entirety. The battery 10 includes a positive electrode current collector 15 in contact with a positive electrode 20. The negative electrode 25 is separated from the positive electrode 20 by a separator 30. The negative electrode 25 is in contact with a negative electrode current collector 35. As shown in Figure 1, the battery 10 is formed in a stack. The stack may be assembled by covering it with another separator layer (not shown) over the negative electrode current collector 35, then rolling it and placing it in a can (not shown). During the charging process, carrier ions (typically lithium) move away from the positive electrode 20 and through the separator 30 into the negative electrode 25. Depending on the anode material used, the carrier ions either intercalate with the negative electrode material (e.g., located in the matrix of the negative electrode material without forming an alloy) or form an alloy. During the discharge process, carrier ions leave the negative electrode 25, travel through the separator 30 in the opposite direction, and return to the positive electrode 20.

[0006] Three-dimensional secondary batteries can offer increased capacity and longer lifespan compared to layered secondary batteries. Three-dimensional battery architectures (e.g., interlocking electrode arrays) have been proposed in the literature to offer higher electrode surface area, higher energy and power density, improved battery capacity, and improved active material utilization compared to two-dimensional architectures (e.g., flat and helical thin layers). For example, Long et al., “Three-dimensional battery architectures,” Chemical Reviews, 2004, 104, 4463-4492 may be useful in illustrating state-of-the-art techniques in proposed three-dimensional battery architectures and is therefore incorporated herein by reference as non-essential subject matter.

[0007] Energy storage devices, including rechargeable batteries, can release energy in undesirable or uncontrolled ways through accidents, abuse, or exposure to extreme conditions. Incorporating safety features into rechargeable batteries can mitigate this risk and improve abuse tolerance.

[0008] The safety of current lithium-ion batteries can be compromised by various mechanisms, many of which are related to temperature rise. Excessive heat and thermal runaway can occur due to electrolyte decomposition during overcharging and at high operating temperatures. In the case of high-voltage cathode materials such as LiCoO2, thermal runaway can also occur due to oxygen evolution. In some cases, mechanical abuse can also cause short circuits between active materials, thereby leading to thermal runaway. This can result from battery overcharging, electrical short circuits, or short circuits related to mechanical abuse. Rapid heat release during chemical reactions related to electrolyte or cathode decomposition can increase the risk of thermal runaway in conventional two-dimensional batteries.

[0009] Self-stopping devices, such as polymer or ceramic materials with resistance having a positive temperature coefficient (PTC), have been used to enhance the safety of conventional two-dimensional batteries. Such materials are sometimes referred to as resettable fuses or self-regulating thermostats. Other systems have been proposed, including non-resettable fuses or sacrificial fuses that melt to mechanically create an open circuit that interrupts the flow of overcurrent through the battery. For example, reference to PG Balakrishnan, R. Ramesh, and T. Prem Kumar, “Safety mechanisms in lithium-ion batteries,” Journal of Power Sources, 2006, 155, 401-414 may be useful in illustrating the latest technologies in safety mechanisms in conventional lithium-ion batteries and is therefore incorporated herein by reference as non-essential subject matter.

[0010] In at least some known lithium-ion secondary batteries, resettable or non-resettable fuses have a measurable delay between the flow of overcurrent and the tripping of the fuse. This delay occurs because the fuse is typically activated by the heat generated when the overcurrent flows through the battery. Therefore, in the case of a non-resettable fuse, the overcurrent will flow through the battery for a while until the temperature experienced by the fuse reaches the temperature required to melt the fuse, or, in the case of a resettable fuse using PTC material, until the resistance is increased sufficiently to limit the current flowing through the battery. In some situations, the delay between the onset of the overcurrent and the tripping of the fuse can result in the fuse failing to prevent thermal runaway.

[0011] Furthermore, non-resettable fuses permanently disconnect at least a portion of the battery when they trip. As a result, even if the fuse prevents thermal runaway and catastrophic failure, the battery will either become completely inoperable or operate at a limited capacity.

[0012] Therefore, to address the problems of known technologies, it would be desirable to manufacture a three-dimensional battery that includes a current limiter to limit the current that can flow through the battery, independently of the battery temperature. [Overview of the project]

[0013] In one embodiment, a method for assembling an electrode assembly includes stacking a group of unit cells on top of each other in the stacking direction. Each constituent unit of the group of unit cells includes an electrode structure, a separator structure, and a counter electrode structure, wherein the electrode structure comprises an electrode current collector and an electrode active material layer, and the counter electrode structure comprises a counter electrode current collector and a counter electrode active material layer, the electrode structure and the counter electrode structure extend in a longitudinal direction perpendicular to the stacking direction, and the end portions of the electrode current collectors extend longitudinally beyond the electrode active material and separator structure. The method includes bending the end portions of each electrode current collector in a direction perpendicular to the longitudinal direction of the electrode structure to extend in the stacking direction or in the opposite direction to the stacking direction. An electrode busbar is positioned with its surface adjacent to the end portions of the electrode current collectors and extending in the stacking direction. Heat and pressure are applied to the electrode busbar to bond the end portions of the electrode current collectors to the busbar via an adhesive layer containing a resistant polymer material.

[0014] In another embodiment, an electrode assembly for cycling between a charging state and a discharging state includes a group of unit cells, electrode busbars, counter electrode busbars, and a group of current limiters. Each component of the unit cell group comprises an electrode structure, a separator structure, and a counter electrode structure, wherein the electrode structure of each component of the unit cell group has a capacitance C and comprises an electrode current collector and an electrode active material layer, and the counter electrode structure of each component of the unit cell group comprises a counter electrode current collector and a counter electrode active material layer. For each component of the unit cell group, (a) the electrode current collector of the electrode structure is electrically connected to the electrode busbar, (b) the counter electrode current collector of the counter electrode structure is electrically connected to the counter electrode busbar, and (c) the component of the current limiter group is electrically connected (i) between the electrode current collector and the electrode busbar, or (ii) between the counter electrode current collector and the counter electrode busbar. Each component of the unit cell group has a maximum charging voltage V between the electrode current collector and the counter electrode current collector. TOC It has a unit cell resistance R determined at a non-zero frequency between the electrode current collector and the counter electrode current collector. blIt has. Each constituent unit of the current limiter group limits the amount of current that can be conducted from the electrode bus bar or the counter electrode bus bar to the constituent unit of the unit cell group during the discharge of the electrode assembly having an electrical short circuit between the electrode and the counter electrode of one constituent unit of the unit cell group to a value I determined according to the following formula by a resistor R cld having: [Number]

[0015] R S is the hard short-circuit resistance of the constituent unit of the unit cell group determined using a dry forced internal short circuit (FISC) test, and R t is the combined resistance of the electrode bus bar and the counter electrode bus bar determined at a non-zero frequency, and R cld has a non-zero value as follows, I c *R cld <0.5 volts wherein I c is the current at a 1C rate.

[0016] In another embodiment, an electrode assembly for cycling between a charged state and a discharged state includes a group of unit cells, a group of current limiters, an electrode bus bar, and a counter electrode bus bar. Each constituent unit of the unit cell group includes an electrode structure, a separator structure, and a counter electrode structure. The electrode structure of each constituent unit of the unit cell group includes an electrode current collector and an electrode active material layer, and the counter electrode structure of each constituent unit of the unit cell group includes a counter electrode current collector and a counter electrode active material layer. For each constituent unit of the unit cell group, (a) the electrode current collector of the electrode structure is electrically connected to the electrode bus bar, (b) the counter electrode current collector of the counter electrode structure is electrically connected to the counter electrode bus bar, and (c) the constituent unit of the current limiter group is located at the electrical connection between (i) the electrode current collector and the electrode bus bar or (ii) the counter electrode current collector and the counter electrode bus bar. Each constituent unit of the group of current limiters includes a conductive adhesive, and the conductive adhesive has a resistance of 0.25 ohms (Ω) or more at 25 degrees Celsius (°C).

[0017] In another embodiment, an electrode assembly for cycling between a charged state and a discharged state within a normal operating temperature range of minus 20 degrees Celsius to 80 degrees Celsius comprises a group of unit cells, a group of current limiters, an electrode busbar, and a counter electrode busbar. Each component of the unit cell group comprises an electrode structure, a separator structure, and a counter electrode structure, the electrode structure of each component of the unit cell group comprises an electrode current collector and an electrode active material layer, and the counter electrode structure of each component of the unit cell group comprises a counter electrode current collector and a counter electrode active material layer. For each component of the unit cell group, (a) the electrode current collector of the electrode structure is electrically connected to an electrode busbar, (b) the counter electrode current collector of the counter electrode structure is electrically connected to a counter electrode busbar, and (c) at least one component of the current limiter group is electrically connected (i) between the electrode current collector and the electrode busbar, or (ii) between the counter electrode current collector and the counter electrode busbar. For each unit cell, at least one component of the current limiter group has sufficient resistance to limit the current through the unit cell to a threshold current I, which is less than the current that would induce thermal runaway of the unit cell, when the electrode assembly is within the normal operating temperature range.

[0018] Various refinements of the features of interest exist in relation to the embodiments mentioned above. Further features may also be incorporated into the embodiments mentioned above. These refinements and additional features may exist individually or in any combination. For example, various features discussed below in relation to any of the exemplary embodiments may be incorporated individually or in any combination into any of the embodiments described above. [Brief explanation of the drawing]

[0019] [Figure 1] This is a cross-section of an existing layered battery. [Figure 2] This is a simplified diagram of an exemplary electrode assembly for cycling between the charged and discharged states in a secondary battery. [Figure 3A] Figure 2 is a simplified diagram of the end of the opposing electrode current collector in the electrode assembly. [Figure 3B] This is a diagram of the end of the counter electrode current collector in Figure 3A, which is connected to the counter electrode busbar. [Figure 4A] Figure 2 is a top view of the electrode structure of the electrode assembly, where the current collectors are attached to the busbar via a current limiter. [Figure 4B] Figure 4A is a side view of one of the electrode structures, where the current collector is attached to the busbar via a current limiter. [Figure 5] This is a simplified diagram of an exemplary electrode assembly for cycling between the charged and discharged states in a secondary battery. [Figure 6] This is a simplified diagram of yet another exemplary electrode assembly for cycling between the charged and discharged states in a secondary battery. [Figure 7] This is a simplified diagram of yet another exemplary electrode assembly for cycling between the charged and discharged states in a secondary battery. [Figure 8A] This is a simplified isometric view of the anode electrode structure for use in electrode assemblies. [Figure 8B] This is a simplified isometric view of the cathode electrode structure for use in electrode assemblies. [Figure 9] This is an isometric view of an exemplary stacked cell created as part of the manufacturing process for secondary batteries. [Figure 10] This is a portion of the top view of the stacked cell shown in Figure 9. [Figure 11A] This is an isometric view of the stacked cells shown in Figure 9, positioned at the packing station. [Figure 11B] This is an isometric view of the stacked cell shown in Figure 11A, with the battery package positioned on top. [Figure 12] This is a simplified diagram of a unit cell of an electrode assembly being tested in a forced internal short-circuit test. [Figure 13] This is a simplified diagram of a portion of another exemplary electrode assembly for cycling between the charged and discharged states in a secondary battery. [Figure 14]This is a side view electrode structure including a current collector with an electrode structure attached to a busbar via a current limiter, and an interface layer attached to the busbar. [Figure 15] This is a side view electrode structure including a current collector with an electrode structure attached to a busbar via a current limiter, and an interface layer attached to the electrode current collector. [Figure 16] This is a side view electrode structure including a current collector with an electrode structure attached to a busbar via a current limiter, an interface layer attached to the current electrode current collector, and an interface layer attached to the busbar. [Figure 17] This is a side view of a counter electrode current collector connected to a counter electrode busbar without using a slot in the current collector. [Figure 18] This is a side view of one electrode structure in which the current collector of the electrode structure is attached to a busbar via a current limiter formed as a single layer without using slots in the current collector. [Figure 19] This is a side view of one electrode structure in which the current collector of the electrode structure is attached to a busbar via individual current limiters formed as single layers without using slots in the current collector.

[0020] Corresponding reference numerals indicate the corresponding parts throughout the drawing.

[0021] definition As used herein, “a,” “an,” and “the” (i.e., singular) refer to multiple objects unless the context explicitly indicates otherwise. For example, in one instance, a reference to “electrode” includes both a single electrode and multiple similar electrodes.

[0022] As used herein, “about” and “approximately” refer to plus or minus 10%, 5%, or 1% of the stated value. For example, in one instance, about 250 μm includes 225 μm to 275 μm. As a further example, in one instance, about 1,000 μm includes 900 μm to 1,100 μm. Unless otherwise indicated, all numbers representing quantities (e.g., measured values, etc.) used herein and in the claims should be understood in all instances to be modified by the term “about.” Therefore, unless otherwise indicated, the numerical parameters described herein and in the appended claims are approximations. Each numerical parameter should be interpreted in light of at least the number of significant digits reported and by applying common rounding techniques.

[0023] As used herein in the context of secondary batteries, "anode" refers to the negative electrode of a secondary battery.

[0024] As used herein, "anodic material" or "anodic activity" refers to a material suitable for use as the negative electrode of a secondary battery.

[0025] As used herein in the context of secondary batteries, "cathode" refers to the positive electrode of a secondary battery.

[0026] As used herein, "cathode material" or "cathode activity" refers to a material suitable for use as the positive electrode of a secondary battery.

[0027] "Converted chemical active material" or "converted chemical substance" refers to a substance that undergoes a chemical reaction during the charge-discharge cycle of a secondary battery.

[0028] As used herein, “counter electrode” may refer to the negative or positive electrode (anode or cathode) of a secondary battery on the opposite side of the electrode, unless the context explicitly indicates otherwise.

[0029] As used herein, "opposing electrode current collector" may refer to the current collector of the negative or positive electrode (anode or cathode) of a secondary battery on the opposite side of the electrode, unless the context explicitly indicates otherwise.

[0030] As used herein in the context of cycling a secondary battery between a charged state and a discharged state, “cycle” means charging and / or discharging the battery to move it from a first state, which is either a charged state or a discharged state, to a second state, which is the opposite of the first state (i.e., a charged state if the first state was discharged, or a discharged state if the first state was charged), and then returning the battery to the first state to complete the cycle. For example, a single cycle of a secondary battery between a charged state and a discharged state may include charging the battery from a discharged state to a charged state, and then discharging it back to a discharged state, as in a charging cycle, to complete the cycle. A single cycle may also include discharging the battery from a charged state to a discharged state, and then charging it back to a charged state, as in a discharge cycle, to complete the cycle.

[0031] As used herein, "electrochemical active material" means either an anode active material or a cathode active material.

[0032] As used herein, the term "electrode" may refer to the negative or positive electrode (anode or cathode) of a secondary battery unless the context explicitly indicates otherwise.

[0033] As used herein, "electrode current collector" may refer to the current collector of the negative or positive electrode (anode or cathode) of a secondary battery unless the context explicitly indicates otherwise.

[0034] As used herein, “electrode material” may refer to either an anode material or a cathode material unless the context explicitly indicates otherwise.

[0035] As used herein, “electrode structure” may refer to an anode structure (e.g., negative electrode structure) or a cathode structure (e.g., positive electrode structure) suitable for use in a battery, unless the context explicitly indicates otherwise.

[0036] As used herein, “longitudinal axis,” “transverse axis,” and “vertical axis” refer to axes perpendicular to each other (i.e., each is orthogonal to the others). For example, as used herein, “longitudinal axis,” “transverse axis,” and “vertical axis” are analogous to the Cartesian coordinate system used to define a three-dimensional aspect or orientation. Thus, the description of elements of the subject matter disclosed herein is not limited to the specific axes used to describe the three-dimensional orientation of the elements. Alternatively, axes may be interchangeable when referring to the three-dimensional aspects of the subject matter disclosed. [Modes for carrying out the invention]

[0037] Embodiments of the present disclosure relate to a battery, such as a three-dimensional secondary battery, and an electrode assembly for the battery, which includes a current limiter for limiting the current that may flow through the battery, thereby helping to limit the heat increase and prevent thermal runaway, and improving the safety of the battery.

[0038] Figure 2 is a simplified diagram of an exemplary electrode assembly 200 for cycling between the charged and discharged states of a battery. The electrode assembly 200 includes a group of electrode structures 202, a group of counter electrode structures 204, a group of separator structures 205, a group of current limiters 206, an electrode busbar 208, and a counter electrode busbar 210. The exemplary embodiment is an electrode assembly suitable for use in a three-dimensional secondary battery, where the electrode structures 202 and counter electrode structures 204 each extend mainly along the width W and height H of the assembly and are separated from each other along the length (or longitudinal) direction L. In other embodiments, the electrode assembly 200 may be for use in a layered secondary battery.

[0039] A voltage difference V exists between adjacent electrode structures 202 and counter electrode structures 204, and such adjacent pairs can be considered as unit cells. Each unit cell has a capacity C determined by the structure and configuration of the electrode structures 202 and counter electrode structures 204. In an exemplary embodiment, each unit cell generates a voltage difference of about 4.35 volts. In other embodiments, each unit cell has a voltage difference of about 0.5 volts, about 1.0 volt, about 1.5 volts, about 2.0 volts, about 2.5 volts, about 3.0 volts, about 3.5 volts, about 4.0 volts, 4.5 volts, about 5.0 volts, 4 to 5 volts, or any other suitable voltage. During cycling between charging and discharging, the voltage may fluctuate, for example, from about 2.5 volts to about 4.35 volts. In an exemplary embodiment, the capacity C of a unit cell is about 25 mAh. In other embodiments, the capacity C of a unit cell is about 50 mAh, less than 50 mAh, or any other suitable capacity. In some embodiments, the capacity C of a unit cell can be up to approximately 500 mAh.

[0040] In exemplary embodiments, the electrode structure 202 and the counter electrode structure 204 are generally rectangular and arranged in a structure that interlocks with each other. That is, the electrode structure 202 and the counter electrode structure 204 extend from opposite electrode busbars 208 and 210 and alternate along the longitudinal direction L. In other embodiments, other shapes and arrangements of the electrode structure 202 and the counter electrode structure 204 are used. For example, the electrode assembly 200 (and the battery containing the electrode assembly 200) may have any of the shapes and / or arrangements described or shown in U.S. Patent No. 9,166,230, which is incorporated herein by reference in its entirety.

[0041] Each component of the group of electrode structures 202 includes an electrode active material 212 and an electrode current collector 214. The electrode structures 202 are electrically connected in parallel to the electrode busbar 208 via a current limiter 206. The electrode structures 202 may be anode or cathode, but in exemplary embodiments, all electrode structures 202 in the group are of the same type (anode or cathode). In some other embodiments, the electrode structures 202 may include anode and cathode structures. Each component of the group of counter electrode structures 204 includes a counter electrode active material 216 and a counter electrode current collector 218. The counter electrode structures 204 are electrically connected in parallel to the counter electrode busbar 210. In exemplary embodiments, all counter electrode structures 204 are of the same type (anode or cathode) and are of the opposite type to electrode structures 204. In some other embodiments, the counter electrode structures 202 may include anode and cathode structures. Although only two electrode structures 202 and two counter electrode structures 204 are shown in Figure 2, the electrode assembly 200 may have any number of electrode structures 202 and counter electrode structures 204. The group of electrode structures 202 and counter electrode structures 204 generally contain the same number of constituent units, but in some embodiments, they may contain different numbers of electrode structures 202 and counter electrode structures 204. For example, some embodiments may start and end with the same electrode structure 202 or counter electrode structure, resulting in one or more electrode structures 202 or counter electrode structures. In some embodiments, the group of electrode structures 202 and counter electrode structures 204 each contain at least 20 constituent units. Some embodiments include groups of electrode structures 202 and counter electrode structures 204 having about 10 constituent units each, 10 to 25 constituent units each, 25 to 250 constituent units each, 25 to 150 constituent units each, 50 to 150 constituent units each, or up to 500 constituent units each. In some embodiments, the electrode structure 202 or the counter electrode structure 204 does not contain active material when discharged, and only the other of the counter electrode structure 204 or the electrode structure 202 contains active material when discharged.

[0042] The cathode-type electrode structure 202 or counter electrode structure 204 includes a current collector 214 or 218 which is a cathode current collector. The cathode current collector may include aluminum, nickel, cobalt, titanium, and tungsten, or alloys thereof, or any other material suitable for use as a cathode current collector layer. Generally, the cathode current collector has at least about 10 3 It has an electrical conductivity of Siemens / cm. For example, in one such embodiment, the cathode current collector has at least about 10 4 It has a conductivity of siemens / cm. As a further example, in one such embodiment, the cathode current collector is at least about 10 5 It has a conductivity of siemens / cm. The anode-type electrode structure 202 or counter electrode structure 204 includes a current collector 214 or 218 which is the anode current collector. The anode current collector may include conductive materials such as copper, carbon, nickel, stainless steel, cobalt, titanium, and tungsten, and their alloys, or any other material suitable as the anode current collector layer.

[0043] The cathode-type electrode structure 202 or counter electrode structure 204 includes an active material 212 or 216 which is a cathode active material. The cathode active material may be an intercalation-type chemical active material, a conversion chemical active material, or a combination thereof.

[0044] Examples of conversion chemical materials useful in this disclosure include S (or Li2S in its lithium state), LiF, Fe, Cu, Ni, FeF2, and FeO d F 3.2d Examples include, but are not limited to, FeF3, CoF3, CoF2, CuF2, and NiF2 (where 0≦d≦0.5 in the formula).

[0045] Exemplary cathode active materials also include any of the broad range of intercalation-type cathode active materials. For example, in the case of lithium-ion batteries, the cathode active material may include a cathode active material selected from transition metal oxides, transition metal sulfides, transition metal nitrides, lithium transition metal oxides, and lithium transition metal sulfides, with lithium transition metal nitrides being selectively used. The transition metal elements in these transition metal oxides, transition metal sulfides, and transition metal nitrides may include metallic elements having a d-shell or f-shell. Specific examples of such metallic elements are Sc, Y, lanthanides, actinides, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pb, Pt, Cu, Ag, and Au. Additional cathode active materials include LiCoO2 and LiNi 0.5 Mn 1.5 O4, Li(Ni x Co y Al z )O2, LiFePO4, Li2MnO4, V2O5, molybdate sulfide, phosphate, silicate, vanadate, sulfur, sulfur compounds, oxygen (air), Li(Ni x Mn y Co z Examples include O2 and combinations thereof.

[0046] Generally, the cathode active material has a thickness of at least about 20 μm, regardless of whether the electrode structure 202 or the counter electrode structure 204 is a cathode-type structure. For example, in one embodiment, the cathode active material layer has a thickness of at least about 40 μm. As a further example, in such an embodiment, the cathode active material has a thickness of at least about 60 μm. As yet another example, in such an embodiment, the cathode active material has a thickness of at least about 100 μm. However, typically, the cathode active material has a thickness of less than about 90 μm, or even less than about 70 μm.

[0047] The anode-type electrode structure 202 or counter electrode structure 204 includes an active material 212 or 216 which is the anode active material. Generally, the anode active material may be selected from the group consisting of: (a) silicon (Si), germanium (Ge), tin (Sn), lead (Pb), antimony (Sb), bismuth (Bi), zinc (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (Co), and cadmium (Cd); (b) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, or Cd with other elements; and (c) Si, Ge, Sn, Pb, Sb, (d) Oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Bi, Zn, Al, Ti, Fe, Ni, Co, V, or Cd, as well as mixtures, composites, or lithium-containing composites thereof; (d) Salts and hydroxides of Sn; (e) Lithium titanate, lithium manganate, lithium aluminate, lithium-containing titanium oxide, lithium transition metal oxides, ZnCo2O4; (f) Particles of graphite and carbon; (g) Lithium metal; (h) Combinations thereof.

[0048] Examples of anode active materials include graphite and soft or hard carbon, or carbon materials such as graphene (e.g., single-walled or multi-walled carbon nanotubes), or any of the range of metals, metalloids, alloys, oxides, nitrides, and compounds that can intercalate lithium or form alloys with lithium. Specific examples of metals or metalloids that can constitute anode materials include graphite, tin, lead, magnesium, aluminum, boron, gallium, silicon, Si / C composites, Si / graphite blends, silicon oxide (SiOx), porous Si, intermetallic Si alloys, indium, zirconium, germanium, bismuth, cadmium, antimony, silver, zinc, arsenic, hafnium, yttrium, lithium, sodium, graphite, carbon, lithium titanate, palladium, and mixtures thereof. In one exemplary embodiment, the anode active material includes aluminum, tin, or silicon, or their oxides, nitrides, fluorides, or other alloys thereof. In another exemplary embodiment, the anode active material includes silicon, or an alloy or oxide thereof.

[0049] In one embodiment, the anode active material is microstructured to provide a significant void volume fraction to accommodate volume expansion and contraction as lithium ions (or other carrier ions) are incorporated into or detached from the anode active material during the charge-discharge process. Generally, the void volume fraction of each anode active material layer is at least 0.1. However, typically, the void volume fraction of each anode active material layer is 0.8 or less. For example, in one embodiment, the void volume fraction of each anode active material layer is about 0.15 to about 0.75. As a further example, in one embodiment, the void volume fraction of each anode active material layer is about 0.2 to about 0.7. As a further example, in one embodiment, the void volume fraction of each anode active material layer is about 0.25 to about 0.6.

[0050] Depending on the composition and method of forming the microstructured anode active material, the microstructured anode active material may include macroporous, microporous, or mesoporous material layers, or combinations thereof, such as a combination of microporous and mesoporous materials, or a combination of mesoporous and macroporous materials. Microporous materials typically feature pore dimensions of less than 10 nm, wall dimensions of less than 10 nm, pore depths of 1 to 50 micrometers, and a pore morphology generally characterized by a “spongy” and irregular appearance, non-smooth walls, and branched pores. Mesoporous materials typically feature pore dimensions of 10 to 50 nm, wall dimensions of 10 to 50 nm, pore depths of 1 to 100 micrometers, and a pore morphology generally characterized by somewhat well-defined branched or dendritic pores. Macroporous materials typically feature pore dimensions greater than 50 nm, wall dimensions greater than 50 nm, pore depths of 1 to 500 micrometers, and pore morphologies that can be linear, branched, or dendritic, and have smooth or rough walls. Furthermore, the void volume may include open or closed voids, or a combination thereof. In one embodiment, the void volume includes open voids, i.e., the anode active material includes voids having openings on the lateral surface of the anode active material from which lithium ions (or other carrier ions) can enter or leave the anode active material, for example, lithium ions can enter the anode active material through the void openings after leaving the cathode active material. In another embodiment, the void volume includes closed voids, i.e., the anode active material includes voids that are sealed by the anode active material. Generally, open voids can provide a larger interfacial surface area for carrier ions, while closed voids tend to be less affected by the solid electrolyte interface, while each provides room for the anode active material to expand upon the entry of carrier ions. Therefore, in certain embodiments, the anode active material preferably includes a combination of open and closed voids.

[0051] In one embodiment, the anode active material comprises porous aluminum, tin, or silicon, or alloys, oxides, or nitrides thereof. The porous silicon layer may be formed, for example, by anodic oxidation, by etching (for example, by depositing a noble metal such as gold, platinum, silver, or gold / palladium onto the surface of single-crystal silicon and etching the surface with a mixture of hydrofluoric acid and hydrogen peroxide), or by other methods known in the art, such as patterned chemical etching. Furthermore, the porous anode active material generally has a porosity of at least about 0.1, but less than 0.8, and a thickness of about 1 to about 100 micrometers. For example, in one embodiment, the anode active material comprises porous silicon, has a thickness of about 5 to about 100 micrometers, and has a porosity of about 0.15 to about 0.75. As a further example, in one embodiment, the anode active material comprises porous silicon, has a thickness of about 10 to about 80 micrometers, and has a porosity of about 0.15 to about 0.7. As a further example, in one such embodiment, the anode active material comprises porous silicon, having a thickness of about 20 to about 50 micrometers and a porosity of about 0.25 to about 0.6. As a further example, in one embodiment, the anode active material comprises a porous silicon alloy (e.g., nickel silicide), having a thickness of about 5 to about 100 micrometers and a porosity of about 0.15 to about 0.75.

[0052] In another embodiment, the anode active material includes aluminum, tin, or silicon fibers, or tin or silicon alloys. Individual fibers may have a diameter (thickness dimension) of about 5 nm to about 10,000 nm and a length generally corresponding to the thickness of the anode active material. Silicon fibers (nanowires) may be formed by other techniques known in the art, such as chemical vapor deposition or vapor-liquid-solid (VLS) growth and solid-liquid-solid (SLS) growth. Furthermore, the anode active material generally has a porosity of at least about 0.1, but less than 0.8, and a thickness of about 1 to about 200 micrometers. For example, in one embodiment, the anode active material includes silicon nanowires, has a thickness of about 5 to about 100 micrometers, and a porosity of about 0.15 to about 0.75. As a further example, in one embodiment, the anode active material includes silicon nanowires, has a thickness of about 10 to about 80 micrometers, and a porosity of about 0.15 to about 0.7. As a further example, in one such embodiment, the anode active material comprises silicon nanowires having a thickness of about 20 to about 50 micrometers and a porosity of about 0.25 to about 0.6. As a further example, in one embodiment, the anode active material comprises nanowires of a silicon alloy (such as nickel silicide) having a thickness of about 5 to about 100 micrometers and a porosity of about 0.15 to about 0.75.

[0053] In other embodiments, the anode negative electrode (i.e., the electrode or counter electrode) is coated with a particulate lithium material selected from the group consisting of stabilized lithium metal particles, such as lithium carbonate stabilized lithium metal powder, lithium silicate stabilized lithium metal powder, or other sources of stabilized lithium metal powder or ink. The particulate lithium material is present in a concentration of approximately 0.05 to 5 mg / cm³. 2 For example, approximately 0.1-4 mg / cm³ 2 , or even more, approximately 0.5-3 mg / cm³ 2 The lithium particulate material can be attached to the negative electrode active material layer by spraying, loading, or otherwise arranging it on the negative electrode active material layer with a loading amount of [amount]. The average particle size (D) of the lithium particulate material 50The average particle size (D) can be 5-200 μm, for example, about 10-100 μm, 20-80 μm, or even about 30-50 μm. 50 ) can be defined as the particle size corresponding to 50% in the cumulative volume-based particle size distribution curve. Average particle size (D 50 ) can be measured, for example, using laser diffraction.

[0054] The anode-type electrode structure 202 or counter electrode structure 204 includes a current collector 214 or 218 which is an anode current collector. Generally, the anode current collector has at least about 10 3 It has an electrical conductivity of siemens / cm. For example, in one such embodiment, the anode current collector has at least about 10 4 It has a conductivity of siemens / cm. As a further example, in one such embodiment, the anode current collector has at least about 10 5 It has a conductivity of Siemens / cm. Examples of electrically conductive materials suitable for use as anode current collectors include metals such as copper, nickel, cobalt, titanium, and tungsten, as well as their alloys.

[0055] In one embodiment, the anode current collector, i.e., the electrode current collector 214 or counter electrode current collector 218, whichever is of the anode type, has a substantially greater electrical conductivity than the electrical conductivity of its associated electrode active material 212 or counter electrode active material 216. For example, in one embodiment, the ratio of the electrical conductivity of the anode current collector to the electrical conductivity of the anode active material layer is at least 100:1 when there is an applied current to store energy in the device or an applied load to discharge the device. As a further example, in some embodiments, the ratio of the electrical conductivity of the anode current collector to the electrical conductivity of the anode active material layer is at least 500:1 when there is an applied current to store energy in the device or an applied load to discharge the device. As a further example, in some embodiments, the ratio of the electrical conductivity of the anode current collector to the electrical conductivity of the anode active material layer is at least 1000:1 when there is an applied current to store energy in the device or an applied load to discharge the device. As a further example, in some embodiments, the ratio of the electrical conductivity of the anode current collector to the electrical conductivity of the anode active material layer is at least 5000:1 when there is an applied current to store energy in the device or an applied load to discharge the device. As a further example, in some embodiments, the ratio of the electrical conductivity of the anode current collector to the electrical conductivity of the anode active material layer is at least 10000:1 when there is an applied current to store energy in the device or an applied load to discharge the device.

[0056] In general, cathode-type current collectors, i.e., electrode current collectors 214 or counter electrode current collectors 218, regardless of whether they are cathode-type, may contain metals such as aluminum, carbon, chromium, gold, nickel, NiP, palladium, platinum, rhodium, ruthenium, silicon and nickel alloys, titanium, or combinations thereof (see “Current collectors for positive electrodes of lithium-based batteries” by AH Whitehead and M. Schreiber, Journal of the Electrochemical Society, 152(11) A2105-A2113 (2005)). As a further example, in one embodiment, the cathode current collector includes gold or an alloy of gold such as gold silicide. As a further example, in one embodiment, the cathode current collector includes nickel or an alloy of nickel such as nickel silicide.

[0057] Referring to Figure 8A, each anode electrode structure, i.e., each electrode structure 202 or counter electrode structure 204 which is an anode type, has a longitudinal axis (A E Length (L) measured along ) E ) and width (W E ) and length L E and width W E The height (H) is measured in a direction perpendicular to each of the measurement directions. E ) and have.

[0058] Length L of the constituent unit of the anode electrode structure group E This varies depending on the energy storage device and its intended application. However, generally, the anode electrode structure typically has a length L ranging from about 5 mm to about 500 mm. E It has, for example, in one such embodiment, the anode electrode structure has a length L of about 10 mm to about 250 mm. E It has. As a further example, in one such embodiment, the constituent unit of the anode group has a length L of about 25 mm to about 100 mm. EThe anode electrode structure includes one or more first electrode constituent units having a first length and one or more second electrode constituent units having a second length other than the first. In yet another embodiment, the different lengths of the one or more first electrode constituent units and the one or more second electrode constituent units may be selected to accommodate a predetermined shape of the electrode assembly, such as the shape of an electrode assembly having different lengths along one or more of the longitudinal and / or transverse axes, and / or to provide predetermined performance characteristics of the secondary battery.

[0059] Width W of the cathode electrode structure E However, this also varies depending on the energy storage device and its intended application. Generally, however, each anode electrode structure typically has a width W in the range of approximately 0.01 mm to 2.5 mm. E It has, for example, the width W of each anode electrode structure. E The width is in the range of approximately 0.025 mm to approximately 2 mm. As a further example, in one embodiment, the width W of each anode electrode structure is... E The width is in the range of approximately 0.05 mm to approximately 1 mm. According to one embodiment, the anode electrode structure includes one or more first electrode constituent units having a first width and one or more second electrode constituent units having a second width other than the first. In another embodiment, the different widths of the one or more first electrode constituent units and the one or more second electrode constituent units may be selected to accommodate a predetermined shape of the electrode assembly, such as the shape of an electrode assembly having different widths along one or more of the longitudinal and / or transverse axes, and / or to provide predetermined performance characteristics of the secondary battery.

[0060] Height H of the anode electrode structure E However, this also varies depending on the energy storage device and its intended application. Generally, however, the anode electrode structure typically has a height H in the range of approximately 0.05 mm to approximately 25 mm. E It has, for example, the height H of each anode electrode structure. EThe height is in the range of approximately 0.05 mm to approximately 5 mm. As a further example, in one embodiment, the height H of each anode electrode structure is E The height is in the range of approximately 0.1 mm to approximately 1 mm. According to one embodiment, the anode electrode structure includes one or more first electrode constituent units having a first height and one or more second electrode constituent units having a second height other than the first. In yet another embodiment, the different heights of the one or more first electrode constituent units and the one or more second electrode constituent units may be selected to accommodate a predetermined shape of an electrode assembly, such as the shape of an electrode assembly having different heights along one or more of the longitudinal and / or transverse axes, and / or to provide predetermined performance characteristics of the secondary battery.

[0061] Generally, the anode electrode structure has a width W of the anode electrode structure. E and the height H of the anode electrode structure E A length L that is substantially larger than each of the following: E It has. For example, in one embodiment, for each constituent unit of the anode group, L E and W E and H E The ratio of each to each is at least 5:1 (i.e., L E and W E The ratios to L are at least 5:1, and E and H E The ratios to each are at least 5:1). As a further example, in one embodiment, L E and W E and H E The ratio of each to is at least 10:1. As a further example, in one embodiment, L E and W E and H E The ratio of each to is at least 15:1. As a further example, in one embodiment, for each constituent unit of the anode group, L E and W E and H E The ratio of each to the others is at least 20:1.

[0062] In one embodiment, the height H of the anode electrode structure E and width WE The ratios to are each at least 0.4:1. For example, in one embodiment, H E and W E For each constituent unit of the anode group, the ratios to are each at least 2:1. As a further example, in one embodiment, H E and W E The ratios to are each at least 10:1. As a further example, in one embodiment, H E and W E The ratios to are each at least 20:1. However, typically, the ratios of H E and W E are generally each less than 1,000:1. For example, in one embodiment, the ratios of H E and W E are each less than 500:1. As a further example, in one embodiment, the ratios of H E and W E are each less than 100:1. As a further example, in one embodiment, the ratios of H E and W E are each less than 10:1. As a further example, in one embodiment, for each constituent unit of the anode electrode structure group, the ratios of H E and W E are each in the range of about 2:1 to about 100:1.

[0063] Referring to FIG. 8B, each cathode electrode structure, that is, each electrode structure 202 of the cathode type or the counter electrode structure 204 has a length (L CE ) measured along the longitudinal axis (A CE ), a width (W CE ), and a height (H CE and width W CE ) measured in a direction orthogonal to each of the directions of measurement of the length L CE ).

[0064] The length L of the cathode electrode structure CEvaries depending on the energy storage device and the intended use of the energy storage device. However, generally, each constituent unit of the cathode group typically has a length L in the range of about 5 mm to about 500 mm CE For example, in one such embodiment, each cathode electrode structure has a length L in the range of about 10 mm to about 250 mm CE For a further example, in one such embodiment, each cathode electrode structure has a length L in the range of about 25 mm to about 100 mm CE According to one embodiment, the cathode electrode structure includes one or more first electrode constituent units having a first length and one or more second electrode constituent units having a second length different from the first. In yet another embodiment, the different lengths of the one or more first electrode constituent units and the one or more second electrode constituent units may be selected to accommodate a predetermined shape of the electrode assembly, such as the shape of an electrode assembly having different lengths along one or more of the longitudinal axis and / or the transverse axis, and / or to provide predetermined performance characteristics of the secondary battery

[0065] The width W of the cathode electrode structure CE also varies depending on the energy storage device and the intended use of the energy storage device. However, generally, the cathode electrode structure typically has a width W within the range of about 0.01 mm to 2.5 mm CE For example, in one embodiment, the width W of each cathode electrode structure CE is in the range of about 0.025 mm to about 2 mm. For a further example, in one embodiment, the width W of each cathode electrode structure CE is in the range of about 0.05 mm to about 1 mm. According to one embodiment, the cathode electrode structure includes one or more first electrode constituent units having a first width and one or more second electrode constituent units having a second width different from the first. In yet another embodiment, the different widths of the one or more first electrode constituent units and the one or more second electrode constituent units may be selected to accommodate a predetermined shape of the electrode assembly, such as the shape of an electrode assembly having different widths along one or more of the longitudinal axis and / or the transverse axis, and / or to provide predetermined performance characteristics of the secondary battery

[0066] Cathode electrode structure height H CE However, this also varies depending on the energy storage device and its intended application. Generally, however, the cathode electrode structure typically has a height H in the range of approximately 0.05 mm to approximately 25 mm. CE It has, for example, the height H of each cathode electrode structure. CE The height is in the range of approximately 0.05 mm to approximately 5 mm. As a further example, in one embodiment, the height H of each cathode electrode structure is CE The height is in the range of approximately 0.1 mm to approximately 1 mm. According to one embodiment, the cathode electrode structure includes one or more first cathode constituent units having a first height and one or more second cathode constituent units having a second height other than the first. In yet another embodiment, the different heights of the one or more first cathode constituent units and the one or more second cathode constituent units may be selected to accommodate a predetermined shape of the electrode assembly, such as the shape of an electrode assembly having different heights along one or more of the longitudinal and / or transverse axes, and / or to provide predetermined performance characteristics of the secondary battery.

[0067] Generally, each cathode electrode structure has a width W CE It is substantially larger than the height H of the cathode electrode structure. CE It is substantially larger than, in length L CE It has, for example, in one embodiment, for each cathode electrode, L CE and W CE and H CE The ratio of each to each is at least 5:1 (i.e., L CE and W CE The ratios to L are at least 5:1, and CE and H CE The ratios are at least 5:1 each). As a further example, in one embodiment, for each cathode electrode structure, L CE and W CE and H CE The ratio of each of them is at least 10:1. As a further example, in one embodiment, for each cathode electrode structure, L CEand W CE and H CE The ratio of each of them is at least 15:1. As a further example, in one embodiment, for each cathode electrode structure, L CE and W CE and H CE The ratio of each to the others is at least 20:1.

[0068] In one embodiment, the height H of the cathode electrode structure is CE and width W CE The ratios are at least 0.4:1, respectively. For example, in one embodiment, for each cathode electrode structure, H CE and W CE The ratios are at least 2:1 for each. As a further example, in one embodiment, for each cathode electrode structure, H CE and W CE The ratios are at least 10:1, respectively. As a further example, in one embodiment, for each cathode electrode structure, H CE and W CE The ratios are at least 20:1, respectively. However, typically, for each constituent unit of the anode group, H CE and W CE The ratios are generally less than 1,000:1 for each. For example, in one embodiment, for each cathode electrode structure, H CE and W CE The ratios are at least 500:1, respectively. As a further example, in one embodiment, H CE and W CE The ratios to each are less than 100:1. As a further example, in one embodiment, H CE and W CE The ratios to each are less than 10:1. As a further example, in one embodiment, for each cathode electrode structure, H CE and W CE The ratios are in the range of approximately 2:1 to 100:1, respectively.

[0069] Returning to Figure 2, the separator structure 205 separates the electrode structure 202 from the counter electrode structure. The separator structure 205 is made of an electrically insulating but ion-permeable separator material. The separator structure 205 is adapted to electrically isolate each component of the group of electrode structures 202 from each component of the group of counter electrode structures 204. Each separator structure 205 typically comprises a microporous separator material that can permeate a non-aqueous electrolyte, for example, in one embodiment the microporous separator material comprises pores having a diameter in the range of at least 50 Å, more typically in the range of about 2,500 Å, and a porosity in the range of about 25% to about 75%, more typically in the range of about 35% to 55%.

[0070] Generally, electrical insulating separator materials have a thickness of at least about 4 μm. For example, in one embodiment, the electrical insulating separator material has a thickness of at least about 8 μm. As a further example, in such an embodiment, the electrical insulating separator material has a thickness of at least about 12 μm. As a further example, in such an embodiment, the electrical insulating separator material has a thickness of at least about 15 μm. In some embodiments, the electrical insulating separator material has a thickness of up to 25 μm, up to 50 μm, or any other preferred thickness. However, typically, the electrical insulating separator material has a thickness of less than about 12 μm, or even less than about 10 μm.

[0071] Generally, the material for the separator structure 205 can be selected from a wide range of materials that have the ability to conduct carrier ions between the positive and negative active materials of the unit cell. For example, the separator structure 205 may include a microporous separator material that can allow a liquid non-aqueous electrolyte to permeate. Alternatively, the separator structure 205 may include a gel electrolyte or solid electrolyte that can conduct carrier ions between the positive and negative electrodes of the unit cell.

[0072] In one embodiment, the separator structure 205 may include a polymer-based electrolyte. Exemplary polymer electrolytes include PEO-based polymer electrolytes, polymer-ceramic composite electrolytes, polymer-ceramic composite electrolytes, and polymer-ceramic composite electrolytes.

[0073] In another embodiment, the separator structure 205 may include an oxide-based electrolyte. An example of an oxide-based electrolyte is lithium lanthanum titanate (Li 0.34 La 0.56 TiO3), Lithium lanthanum (Li) doped zirconate. 6.24 La3Zr2Al 0.24 O 11.98 ), Ta-doped lithium lanthanum (Li 6.4 La3Zr 1.4 Ta 0.6 O 12 ), and lithium titanium aluminum phosphate (Li 1.4 Al 0.4 Ti 1.6 (PO4)3) is one example.

[0074] In another embodiment, the separator structure 205 may include a solid electrolyte. An example of a solid electrolyte is lithium tin sulfide (Li 10 SnP2S 12 ), lithium phosphate sulfide (β-Li3PS4) and lithium phosphorus sulfur chloride iodide (Li6PS5Cl) 0.9 I 0.1 Examples of sulfide-based electrolytes include ) and others.

[0075] In some embodiments, the separator structure 205 may include a solid lithium ion conductive ceramic such as lithium-containing garnet.

[0076] In one embodiment, the separator structure 205 includes a microporous separator material comprising particulate material and a binder, and having a porosity (void fraction) of at least about 20 volume%. The pores of the microporous separator material have a diameter of at least 50 Å and typically fall in the range of about 250 to 2500 Å. The microporous separator material typically has a porosity of less than about 75%. In one embodiment, the microporous separator material has a porosity (void fraction) of at least about 25 volume%. In one embodiment, the microporous separator material has a porosity of about 35 to 55%.

[0077] Binders for microporous separator materials can be selected from a wide range of inorganic or polymeric materials. For example, in one embodiment, the binder is an organic material selected from the group consisting of silicates, phosphates, aluminates, aluminosilicates, and hydroxides such as magnesium hydroxide and calcium hydroxide. For example, in one embodiment, the binder is a fluoropolymer derived from monomers such as vinylidene fluoride, hexafluoropropylene, and tetrafluoropropene. In another embodiment, the binder is a polyolefin such as polyethylene, polypropylene, or polybutene having any of a range of molecular weights and densities. In yet another embodiment, the binder is selected from the group consisting of ethylene-dienepropenter polymers, polystyrene, polymethyl methacrylate, polyethylene glycol, polyvinyl acetate, polyvinyl butyral, polyacetal, and polyethylene glycol diacrylate. In another embodiment, the binder is selected from the group consisting of methylcellulose, carboxymethylcellulose, styrene rubber, butadiene rubber, styrene-butadiene rubber, isoprene rubber, polyacrylamide, polyvinyl ether, polyacrylic acid, polymethacrylic acid, and polyethylene oxide. In another embodiment, the binder is selected from the group consisting of acrylate, styrene, epoxy, and silicone. In yet another embodiment, the binder is a copolymer or blend of two or more of the aforementioned polymers.

[0078] The particulate material composed of a microporous separator material can also be selected from a wide range of materials. Generally, such materials have relatively low electronic and ionic conductivity at the operating temperature and do not corrode under the operating voltage of the battery electrodes or current collectors that come into contact with the microporous separator material. For example, in one embodiment, the particulate material is 1 × 10⁻¹⁶ -4 It has a conductivity for carrier ions (e.g., lithium) of less than S / cm. As a further example, in one embodiment, the particulate material is 1 × 10 -5 It has a conductivity for carrier ions of less than S / cm. As a further example, in one embodiment, the particulate material is 1 × 10 -6 It has a conductivity to carrier ions of less than S / cm. Exemplary particulate materials include particulate polyethylene, polypropylene, TiO2-polymer composites, silica aerogel, fumed silica, silica gel, silica hydrogel, silica cellogel, silica sol, colloidal silica, alumina, titania, magnesia, kaolin, talc, diatomaceous earth, calcium silicate, aluminum silicate, calcium carbonate, magnesium carbonate, or combinations thereof. For example, in one embodiment, the particulate material includes particulate oxides or nitrides such as TiO2, SiO2, Al2O3, GeO2, B2O3, Bi2O3, BaO, ZnO, ZrO2, BN, Si3N4, and Ge3N4. (See, for example, P. Arora and J. Zhang, “Battery Separators” Chemical Reviews 2004, 104, 4419-4462). In one embodiment, the particulate material has an average particle size of about 20 nm to 2 micrometers, more typically 200 nm to 1.5 micrometers. In another embodiment, the particulate material has an average particle size of about 500 nm to 1 micrometer.

[0079] In alternative embodiments, particulate materials composed of microporous separator materials may be bonded by techniques such as sintering, bonding, or curing, while maintaining a void fraction desirable for electrolyte entry, in order to provide ionic conductivity for the function of the battery.

[0080] In the assembled battery, the microporous separator material of separator structure 205 permeates a non-aqueous electrolyte suitable for use as a secondary battery electrolyte. Typically, the non-aqueous electrolyte includes lithium salts and / or mixtures of salts dissolved in organic solvents and / or solvent mixtures. Exemplary lithium salts include inorganic lithium salts such as LiClO4, LiBF4, LiPF6, LiAsF6, LiCl, and LiBr, as well as LiB(C6H5)4, LiN(SO2CF3)2, LiN(SO2CF3)3, LiNSO2CF3, LiNSO2CF5, LiNSO2C4F9, and LiNSO2C5F 11 LiNSO2C6F 13 , and LiNSO2C7F 15 Examples of organolithium salts include the following. Exemplary organic solvents for dissolving lithium salts include cyclic esters, chain esters, cyclic ethers, and chain ethers. Specific examples of cyclic esters include propylene carbonate, butylene carbonate, γ-butyrolactone, vinylene carbonate, 2-methyl-γ-butyrolactone, acetyl-γ-butyrolactone, and γ-bellerolactone. Specific examples of chain esters include dimethyl carbonate, diethyl carbonate, dibutyl carbonate, dipropyl carbonate, methyl ethyl carbonate, methyl butyl carbonate, methyl propyl carbonate, ethyl butyl carbonate, ethyl propyl carbonate, butyl propyl carbonate, alkylpropionate, dialkylmalonate, and alkyl acetate. Specific examples of cyclic ethers include tetrahydrofuran, alkyltetrahydrofuran, dialkyltetrahydrofuran, alkoxytetrahydrofuran, dialkoxytetrahydrofuran, 1,3-dioxolane, alkyl-1,3-dioxolane, and 1,4-dioxolane. Specific examples of linear ethers include 1,2-dimethoxyethane, 1,2-diethoxyethane, diethyl ether, ethylene glycol dialkyl ether, diethylene glycol dialkyl ether, triethylene glycol dialkyl ether, and tetraethylene glycol dialkyl ether.

[0081] In one embodiment, a microporous separator with a separator structure can permeate a non-aqueous organic electrolyte containing a mixture of a lithium salt and a high-purity organic solvent. In addition, the electrolyte may be a polymer electrolyte or a polymer using a solid electrolyte.

[0082] The electrode busbar 208 is a cathode electrode busbar when the electrode structure 202 is of the cathode type, and an anode electrode busbar when the electrode structure 202 is of the anode type. Similarly, the counter electrode busbar is a cathode electrode busbar when the counter electrode structure 204 is of the cathode type, and an anode electrode busbar when the counter electrode structure 204 is of the anode type. In exemplary embodiments, the anode type busbar is a copper busbar, and the cathode type busbar is an aluminum busbar. In other embodiments, the electrode busbar 208 and the counter electrode busbar 210 may be any suitable conductive material to enable the electrode assembly 200 to function as described herein.

[0083] The counter electrode structure 204, more specifically the counter electrode current collector 218, is directly connected to the counter electrode busbar 210. That is, the counter electrode current collector 218 is welded, soldered, or glued to the counter electrode busbar 210 without any electrically or physically positioned components between them. The welding may be performed using a laser welding machine, friction welding, ultrasonic welding, or any suitable welding method for welding the counter electrode busbar 210 to the counter electrode current collector 218.

[0084] Figures 3A and 3B illustrate exemplary techniques for connecting one of the counter electrode current collectors 218 to a counter electrode busbar 210. Figure 3A is a diagram of one end portion of the counter electrode current collector 218. The end of the counter electrode current collector 218 includes a slot 300 which is sized and shaped to receive the counter electrode busbar 210. A portion 302 of the counter electrode current collector 218 extends beyond the slot 300. The counter electrode busbar 210 is inserted through the slot 300, and as shown in Figure 3B, the portion 302 of the counter electrode current collector 218 is bent to contact the counter electrode busbar 210. The portion 302 of the counter electrode current collector 218 that is in contact with the counter electrode busbar 210 is then welded to the counter electrode busbar 210.

[0085] Figure 17 illustrates another exemplary technique for connecting one of the counter electrode current collectors 218 to a counter electrode busbar 210. In this example, the counter electrode current collector 218 does not include a slot 300. A portion 1700 of the counter electrode current collector 218 is bent at an angle of approximately 90 degrees, and the counter electrode busbar 210 is positioned on portion 1700. The counter electrode busbar 210 is then directly attached to portion 1700 of the counter electrode current collector 218 by means of adhesive, welding, soldering, or using any other suitable technique for joining the counter electrode current collector 218 to the counter electrode busbar 210.

[0086] Returning to Figure 2, each component unit of the group of current limiters 206 is electrically connected between different electrode current collectors 214 and electrode busbars 208. The current limiters 206 are configured to limit the current that can flow through the electrode current collectors 214 and, correspondingly, through the electrode structure 202 to which the electrode current collectors are connected. Therefore, for example, if a short circuit is formed between one of the electrode current collectors 214 and one of the counter electrode current collectors 218, the current limiters 206 limit the amount of current that can flow from the other electrodes and counter electrodes of the electrode assembly, thereby limiting the temperature experienced by the electrode assembly 200 and preventing thermal runaway. Specifically, the current limiters 206 limit the amount of current that can be conducted through the unit cells during discharge of an electrode assembly where there is an electrical short circuit between the electrodes of the unit cells and the counter electrodes, which would induce thermal runaway of the component units of the group of unit cells. tr or I L It limits the current to a value I smaller than (sometimes referred to as). The current limiter provides a soft landing for the battery in the event of a short circuit. The current limiter allows a non-zero level of current to flow in the event of a short circuit, but continuously limits that current to a level below which it would cause thermal runaway. This current continues to flow until the battery is discharged and the risk of thermal runaway has ended.

[0087] The current limiter 206 is a resistive current limiter. The current limiter 206 has non-zero resistance within the normal operating temperature range of the electrode assembly 200. In one example, the normal operating temperature is -20°C to 80°C. In other embodiments, the normal operating temperature is -40°C to 85°C, -40°C to 150°C, or any other preferred range of normal operating temperatures. The resistance is such that the current limiter 206 limits the current that can pass through any unit cell and prevents the current from reaching a level that could cause catastrophic failure or any other maximum current level determined for other performance or abuse tolerance reasons determined during the battery design. The current limiter 206 does not rely on the fusing characteristics of the resistive material or any PTC characteristics. That is, the current limiter 206 may exhibit PTC, but PTC is not required for the current limiter 206 to function as described herein. Rather, the resistance of the current limiter 206 within the normal operating temperature range of the electrode assembly 200 is sufficient to limit the current. In some embodiments, the resistance may increase or decrease within the normal operating temperature range (i.e., the current limiter may have a negative temperature coefficient). Each current limiter 206 is electrically in series with the electrode current collector 214 to which the current limiter 206 is attached. Therefore, the resistance of each current limiter 206 and the associated electrode structure 202 of each current limiter 206 is increased by adding the resistance of the associated electrode structure 202 to the resistance of the current limiter 206 attached to the associated electrode structure 202. Adding resistance to a battery is conventionally not recommended because it increases the losses the battery experiences when current flows into the electrode structure 202 (during charging) and out of the electrode structure (during discharging). However, since all electrode current collectors 214 are connected in parallel (electrically in parallel) to the electrode busbars 208, the increase in total resistance observed in the electrode busbars 208 is much smaller than the resistance of each individual current limiter 206. Furthermore, the resistance of the current limiter 206 in this disclosure is selected to be sufficiently small so that there is a voltage drop limited through the current limiter 206 and thus a power loss limited.In exemplary embodiments, the current limiter resistors are selected to have a drop of 20 mV or less through each of the current limiters 206 during charging or discharging at a 1C rate, in order to limit losses during normal operation while continuing to protect the battery during short circuits.

[0088] In exemplary embodiments, each individual unit cell, which consists of a pair of one electrode structure 202 and one counter electrode structure 204, without a current limiter 206, has a relatively small size (compared to a layered battery), a relatively low capacity, and a high internal resistance such that even if there is a short circuit between the electrode structure 202 and the counter electrode structure 204 of the unit cell, the current passing through the isolated unit cell cannot reach a level sufficient to cause thermal runaway and catastrophic failure. However, in an electrode assembly such as electrode assembly 200, if multiple unit cells are connected in parallel to a busbar such as busbar 208, all unit cells will supply current to the unit cell with an internal short circuit. In such circumstances, without a current limiter 206, a sufficient current could pass through the short-circuited unit cell, causing thermal runaway and catastrophic failure of the electrode assembly 200 and the battery including the electrode assembly 200. By adding a current limiter 206, the resistance of the unit cell is effectively increased. At a fixed voltage V of the unit cell, increasing the resistance results in a corresponding reduction of the maximum current according to Ohm's law.

[0089] More specifically, the capacitance of the electrode assembly 200 is subdivided into the number (n) of electrode unit cells, each of which contains one electrode structure 202 and one counter electrode structure 204. Each unit cell forms a voltage (V). Each individual electrode unit cell has its own characteristic resistance (R), which is a function of the conductivity and geometry of the unit cell assembly. bl Each individual unit cell has a forced internal short circuit (FISC) resistance (R s ) power through short circuits such as

number

number

[0090] When the electrode structure 202 and counter electrode structure 204 of each unit cell are connected in parallel to their respective busbars 208 and 210, all unit cells are connected to the FISC of the affected (i.e., short-circuited) individual unit cells.

number

number

[0091] Each of the current limiters 206 has a non-zero resistance (R cld Adding a current limiter 206 having ) results in the FISC power of a short-circuited unit cell, given by:

number

[0092] Resistor R of each current limiter 206 cld This refers to the short-circuited unit cell.

number

number

[0093] The required resistance of the current limiter 206 may also be considered in terms of the resistance needed to limit the current through the short-circuited unit cell to below a threshold current sufficient to cause thermal runaway. Therefore, by knowing the voltage generated by each unit cell, the capacitance of each unit cell, the internal resistance of each unit cell, the resistance of the electrode busbar 208, and the resistance of the counter electrode busbar 210, the resistance of the current limiter 206 that limits the current through the short-circuited unit cell to below the threshold current required to cause thermal runaway can be calculated. The threshold current required to cause thermal runaway may vary somewhat depending on the construction of the electrode assembly and the capacitance of the individual unit cells, but for similarly constructed electrode assemblies, the threshold current remains relatively constant. In exemplary embodiments, the threshold current is approximately 8 amperes. In other embodiments, the threshold current may be approximately 4 amperes, approximately 8 amperes, approximately 10 amperes, approximately 12 amperes, or 8 to 12 amperes. The required resistance of the current limiter 206 varies depending on the specific configuration of the battery and its components. For similar electrode assemblies, the resistance required to limit the current below the threshold current generally increases as the capacitance of the individual unit cells increases.

[0094] More specifically, the capacity of a traditional stacked battery cell is subdivided into the number (N) of electrode unit cells, each positive and negative electrode forming a voltage (V). The number of unit cells in a complete stack is represented by the uppercase letter N, while the number of unit cells as a variable is represented by the lowercase letter n, for example, when performing iterative assays with different numbers of unit cells. Each individual electrode unit cell has its own characteristic resistance (R), which is a function of the conductivity and geometry of the unit cell assembly. bl Each individual unit cell has a forced internal short circuit (FISC) resistance (R s ) through which current (I bl It is possible to discharge ) into the individual unit cell. The FISC current of each unit cell is given by the following:

number

[0095] Each unit cell's positive and negative electrodes have their own characteristic resistance (R) through their respective current collection terminals. t When connected in parallel, all unit cells of the cell will discharge current (I) through the FISC of each affected unit cell. cell ) contributes to the following. The FISC current of all unit cells in a row of connected cells is given by:

number

[0096] In at least some cases, the characteristic resistance of an individual unit cell is the thermal runaway current (I), which is the current at which the unit cell can discharge through FISC that is sufficient to cause self-accelerated thermal decomposition and thermal runaway. tr It is low enough to exceed ). When multiple electrode unit cells are interconnected via a shared terminal, the discharge current across the FISC of each affected unit cell is low enough to cause a thermal runaway current (I tr This increases the likelihood of exceeding the limit and causing catastrophic cell failure.

[0097] The resistance of each current limiter 206 prevents thermal runaway current (I) from passing through any individual unit cell. tr The resistor (R) of each current limiter is selected to be sufficient to limit the current to less than ). cld ) is determined to be a resistor that satisfies the following conditions:

number

[0098] Other embodiments may use impedance or DC resistance at any other frequency. In some embodiments, the actual short-circuit resistance of a short-circuited unit cell is calculated, and the worst-case internal short-circuit resistance R s,WCFISC It is used in equation (6) instead of . When used herein, the short-circuit resistance R s Unless otherwise specified, this refers to the actual measured short-circuit resistance of a unit cell, or the worst-case internal short-circuit resistance R. s,WCFISC This could refer to any of the following. An exemplary method for determining the actual short-circuit resistance is provided below.

[0099] The resistance of an individual unit cell is determined by the impedance at maximum charge, further considering the number of unit cell subdivisions and the terminal resistances calculated based on the material composition and geometry of the unit cell subdivisions. For an example using a 20kHz impedance, the resistance of a unit cell is given by:

number

[0100] In an exemplary embodiment, the thermal runaway current (I) used in the above formula (6) is tr ) is determined by performing the worst-case forced internal short-circuit assay described below. In other embodiments, the thermal runaway current (I tr ) can be estimated, derived from simulation, determined using different assays, or obtained by any other suitable method. Whatever is determined, the thermal runaway current (I) can then be determined. tr Using ) in equation (6), we set a current limiter (R) to satisfy the inequality. cld Determine the required resistance using the following method. Connect the current limiter 206 to resistor R. cldBy choosing to provide this, the current limiter 206 prevents thermal runaway current (I) from passing through any unit cell, even if an internal short circuit occurs in the unit cell. tr Effectively restricts it to less than ).

[0101] In an exemplary embodiment, the resistance of each current limiter 206 at 25 degrees Celsius (°C) is approximately 0.25 ohms (Ω), limiting the short-circuit current to less than approximately 8 amperes. This results in a voltage drop of less than 20 mV across each current limiter 206 when the electrode assembly 200 is charging or discharging at a 1C rate. In other embodiments, the resistance of each current limiter 206 is between 0.25 Ω and 2.5 Ω. In some embodiments, the resistance of each current limiter 206 is between 0.1 Ω and 1.5 Ω. These ranges provide a range of resistances that balances the need to limit current during a short circuit while simultaneously limiting losses during normal battery operation. The exact values ​​within the range, and which range should be selected, may be chosen based on the voltage, capacity, or other characteristics of a particular battery. More generally, in some embodiments, the resistance of each current limiter 206 is determined by selecting a resistance that produces a voltage drop of less than 0.5 volts when the electrode assembly 200 (or individual unit cells) is being charged or discharged at a 1C rate, when it is being discharged from its maximum charge (TOC) condition. That is, the product of the current at a 1C rate and the resistance of the current limiter 206 is less than 0.5 volts, so as to minimize losses during normal operation while keeping the current sufficiently limited during a short circuit.

[0102] In exemplary embodiments, the current limiter 206 is located on the electrode busbar 208. The current limiter is physically located between the electrode current collector 214 and the electrode busbar 208. In other embodiments, the current limiter 206 is electrically located between the electrode current collector 214 and the electrode busbar 208, but physically located outside the connection between the electrode current collector 214 and the electrode busbar 208.

[0103] Referring here to Figures 4A and 4B, an exemplary current limiter 206 consists of a single layer 400 of conductive adhesive disposed on the surface 402 of the electrode busbar 208 to which the electrode current collector 214 is welded. The electrode current collector 214 includes slots 404 (Figure 4B) and portions 406 similarly used to connect the electrode current collector 214 to the electrode busbar 108, similar to the slots 300 and portions 302 of the counter electrode current collector 218 shown in Figures 3A and 3B. Each individual current limiter 206 is a portion 408 of the single layer 400 bent onto the electrode busbar 208 and located between the portions 406 of the current collector welded to the electrode busbar 208. In other embodiments, the conductive adhesive is applied to the electrode busbar 208 in one individual portion for each electrode current collector 214 connected to the electrode busbar 208. For example, conductive adhesive is applied to the electrode busbar 208 around the location of portion 406 where the electrode current collector is positioned above when portion 406 is bent onto the electrode busbar. Each application of conductive adhesive, and therefore each current limiter 206, is physically isolated from each other. In other embodiments, the conductive adhesive of the current limiter 206 is applied to each electrode current collector 214 such that the conductive adhesive is positioned around the location of portion 406 in Figure 4B and each current limiter 206 is physically isolated from other current limiters 206. In other embodiments, the busbar is connected to the current collector by any other preferred connection arrangement (e.g., the busbar is above the end of the current collector without using slots), and the conductive adhesive is positioned between the current collector and the busbar.

[0104] Figure 18 illustrates another exemplary embodiment in which the exemplary electrode current collector 214 does not include a slot 300. The current limiter 206 consists of a single layer 1801 of conductive adhesive disposed on the surface 1800 of the electrode busbar 208 to which the electrode current collector 214 is attached. A portion 1802 of the electrode current collector 214 is bent at an angle of approximately 90 degrees, and the electrode busbar 208 is positioned above the portion 1802. It should be understood that the portion 1802 does not need to be bent at exactly 90 degrees and can generally be perpendicular to the rest of the current collector. The electrode busbar 208 is then attached to the portion 1802 of the electrode current collector 214 by means of adhesive, welding, soldering, or using any other preferred technique for joining the electrode current collector 214 to the electrode busbar 208. In exemplary embodiments, the electrode busbar 208 is attached to portion 1802 by hot-pressing the electrode busbar to soften the conductive adhesive and applying pressure to the busbar to bond the electrode busbar 208 to portion 1802 using the conductive adhesive. Although illustrated in contact with the conductive adhesive, it should be understood that portion 1802 of the current collector may extend into the conductive adhesive. Each individual current limiter 206 is a portion 1804 of a single layer 1801 that is bent onto the electrode busbar 208 and located between portions 1802 of the current collector attached to the electrode busbar 208. In other embodiments, as shown, for example, in Figure 19, the conductive adhesive is applied to the electrode busbar 208 in one individual portion 1900 for each electrode current collector 214 connected to the electrode busbar 208. For example, the conductive adhesive is applied to the electrode busbar 208 around the location of portion 1802 where the electrode current collector is positioned above when portion 1802 is bent onto the electrode busbar. Each conductive adhesive is applied to each current limiter 206, and therefore each current limiter 206 is physically separated from each other. In other embodiments, the conductive adhesive of the current limiter 206 is applied to each electrode current collector 214 such that the conductive adhesive is positioned around the location of portion 1802 and each current limiter 206 is physically separated from the other current limiters 206.

[0105] In yet another embodiment, resistors other than conductive adhesives are used in the current limiter 206. For example, a conductive film having a desired resistance may be attached to the electrode busbar 208 in a single strip, to the electrode busbar in individual portions, or to each electrode current collector 214 in individual portions in a manner similar to that of a conductive adhesive. Alternatively, a non-adhesive conductive polymer may be attached instead of a conductive adhesive. Furthermore, in some embodiments, discrete resistors may be electrically connected between the electrode current collector 214 and the electrode busbar 208. The discrete resistors may be physically located between the electrode current collector 214 and the electrode busbar 208, outside the interface between the electrode current collector 214 and the electrode busbar 208, or electrically located between the electrode current collector 214 and the electrode busbar 208. The discrete resistors may be any suitable resistors, including wire-wound resistors, thick-film resistors, thin-film resistors, carbon film resistors, carbon pile resistors, metal film resistors, foil resistors, and the like.

[0106] In some embodiments, one or more interface layers are included between the current limiter 206 and the electrode busbars 208, or between the current limiter 206 and the electrode current collectors 214. Generally, the resistance between the electrode busbars 208 and each electrode current collector 214 is defined by the resistance of the current limiter 206 plus the interface resistance between the current limiter 206 and the electrode current collectors 214, plus the interface resistance between the current limiter 206 and the electrode busbars 208. Generally, interface resistance can be generated by imperfect (e.g., "actual" connections rather than "ideal" connections) electrical connections between the current limiter 206 and the electrode busbars 208 and the electrode current collectors 214. Imperfect electrical connections can be caused, for example, by microscopic structural variations on the surfaces of the electrode busbars 208 and / or electrode current collectors 214, the distribution and structure of conductive particles in the current limiter 206, and so on. The interface layer is provided to improve the electrical connection between these components and reduce the series resistance of the electrical connection between the current limiter 206, the electrode busbar 208, and the electrode current collector 214. Referring here to Figures 14-16, embodiments similar to those shown in Figure 4B are shown. Similar reference numbers in Figures 14-16 refer to similar components in Figure 4B. In Figure 14, the interface layer 1400 is attached to the electrode busbar 208. In Figure 15, the interface layer 1500 is attached to the electrode current collector 214. The interface layer 1500 may be attached to each current collector 214, or to fewer current collectors 214 than all of them. In Figure 16, the interface layer 1400 is attached to the electrode busbar 208 and the interface layer 1500 is attached to the electrode current collector 214.

[0107] In some embodiments, the interface layers 1400 and 1500 are carbon-based coatings. For example, the interface layers 1400 and / or 1500 may be coatings produced by slurry coating carbon nanotubes onto the electrode busbars 208 and / or electrode current collectors 214. In other embodiments, the interface layers are graphite coatings or any other suitable conductive coatings. In some embodiments, the interface layers 1400 and / or 1500 are applied using a thermal anvil technique, in which heat is applied to the electrode busbars 208 and / or electrode current collectors 214 to coat them with a selected material for forming the interface layers 1400 and / or 1500.

[0108] In exemplary embodiments, the conductive adhesive used in the current limiter 206 is an adhesive polymer, an adhesive copolymer, or a blend with a conductive material suspended therein. In exemplary embodiments, the conductive adhesive is a thermoplastic material. In other embodiments, the conductive adhesive is a thermosetting material. The adhesive polymer is substantially nonconductive (e.g., insulating) before the suspension of the conductive material in the adhesive polymer. Generally, the desired polymer is any polymer that (a) is stable in the environment of a Li-ion battery cell (i.e., does not dissolve in the electrolyte, does not react with electrolyte components or any other battery components, or undergoes redox chemistry or reactions that decompose the material during cell operation), and (b) has a melting point higher than the typical operating temperature of a Li-ion battery. Since adhesion is an important property of the conductive adhesive, a polymer exhibiting adhesion is desirable as at least one component of the conductive adhesive. Flexibility of the polymer is another desirable property. Therefore, materials or blends of materials with some elasticity, particularly a glass transition temperature (Tg) higher than 0°C, are preferred but not required. In some embodiments, the conductive adhesive is a polymer blend having at least one component having high elasticity (measured by standard methods such as the coefficient of break and / or elongation at break). In some embodiments, the adhesive polymer is a flowable adhesive polymer. In such embodiments, the conductive adhesive should have flow properties that enable melt processing, including, if desired, the formulation of conductive additives and other additives, and film / sheet preparation by standard methods such as cast film, blown film, and calendering. For example, the melt flow index (I2, 190°C, ASTM D1238) of the polymer blend used in the conductive adhesive should be in the range of 0.1 to 1000 grams (g) / 10 minutes (min), preferably 0.1 to 100 g / 10 minutes, and most preferably 0.5 to 20 g / 10 minutes. The melting point of the polymer used in the conductive adhesive should be above the typical operating temperature range of the cell, enabling melt processing and melt bonding to the cell via melt pressing or related techniques. Polymers that melt at 40°C to 300°C may be used in the conductive adhesive.Polymers with a melting point in the range of 60°C to 200°C are preferred, and polymers with a melting point in the range of 70°C to 165°C are most preferred.

[0109] Examples of suitable adhesive polymers or copolymers for use in conductive adhesives include EAA (ethylene-co-acrylic acid) and EMAA (ethylene-co-methacrylic acid), ionomers of EAA or EMAA, polyethylene and polyethylene copolymers (such as ethylene / 1-octene, ethylene / 1-hexene, ethylene / 1-butene, and ethylene / propylene copolymers), polypropylene and polypropylene copolymers, and functionalized or derivatized polyethylene or polypropylene (such as maleic anhydride graft materials).

[0110] The conductive material suspended in the polymer to form a conductive adhesive can be any powder, fiber, or particle that imparts the desired conductivity to the conductive adhesive after compounding with the polymer blend. High loading of the additive can alter the properties of the polymer blend undesirably; therefore, materials that impart the desired conductivity at lower loading levels are most desirable. For example, high loading can lead to a significant decrease in melt processability, affecting the ability to manufacture films or sheets of conductive polymers using conventional equipment. In addition, conductive additives are often expensive materials, and lower loading levels are desirable to maintain lower manufacturing costs.

[0111] The conductive material may be metal powder or fiber, conductive carbon black, metal-coated carbon fiber, and carbon nanotubes, or blends thereof. In various embodiments, the conductive material may be carbon black, nickel particles, copper particles, gold particles, silver particles, tin particles, titanium particles, graphite particles, molybdenum particles, platinum particles, chromium particles, aluminum particles, or any other metal particles, including alloys. Preferred conductive materials for use in conductive adhesives are metal-coated carbon fiber and conductive carbon black, or blends thereof. Metal-coated carbon fiber may be coated with any other metal coating, including nickel, copper, gold, silver, tin, titanium, molybdenum, platinum-chromium, aluminum, or alloys. In most preferred examples, the conductive material may be nickel-coated carbon fiber and "superconducting" carbon black (examples include, but are not limited to, Nouryon Ketjenblack EC 300-J and EC 600-JD materials, Orion Printex XE2B, and Cabot Vulcan XCmax® 22).

[0112] In embodiments where the conductive material is a fiber (such as nickel-coated carbon fiber), the conductive material generally has a long shape. In such embodiments, it is preferable that the fiber has a relatively large aspect ratio (length to diameter). In one exemplary embodiment, nickel-coated carbon fiber used as the conductive material in a conductive adhesive has an aspect ratio of about 850:1. Other useful aspect ratios for conductive materials are 10:1 to 10,000:1, preferably 50:1 to 5,000:1, and most preferably 100:1 to 2,000:1.

[0113] The loading of conductive material into the polymer to form a conductive adhesive can range from 1% to 50% of the conductive material (as weight percent of the total mixture). Preferably, the loading of conductive material is 2% to 40%, and most preferably, 3% to 30%.

[0114] The resistivity of the conductive adhesive is 5.0 × 10⁻⁶.-7 and 5.0 × 10 3 Ω·cm, preferably 5.0 × 10 -5 and 5.0 × 10 1 Ω·cm, most preferably 5.0 × 10 -3 and 5.0 × 10 -1 The resistivity should be in the range of Ω·cm. Polymer resistivity is measured by preparing a sheet or film of a polymer blend with a conductive additive, and then laminating the sheet or film onto a copper test structure consisting of four adjacent rectangular bars bonded together in an array with a specified spacing. Lamination can be achieved using methods such as hot pressing or heated calendering. Once lamination is complete, resistivity measurement is achieved using a typical four-point needle method, where a source-end needle applies a current through the sheet-like film by contacting the two outermost bars, and a sense-end needle measures the potential between the innermost bars, which allows for the determination of the bulk resistivity when the geometry of the four-point test structure array and the thickness of the sheet or film are specified.

[0115] In exemplary embodiments, the conductive material is carbon black. The conductive adhesive is formed by mixing carbon black into the adhesive polymer until the adhesive polymer has a volume resistivity of about 0.01 to 1.0 Ω·cm. The resistivity can be adjusted by adjusting the amount of carbon black added to the adhesive polymer. Adding more carbon black decreases the resistivity (i.e., makes the adhesive polymer more conductive), while adding less carbon black increases the resistivity (i.e., makes the adhesive polymer less conductive). In exemplary embodiments, carbon black is added to the adhesive polymer in an amount of 5% to 30% by weight to achieve the desired resistivity. The conductive adhesive thus prepared is applied to the electrode busbar 208 with a thickness between 20 microns and 200 microns. By adjusting the resistivity of the adhesive polymer and the thickness to which it is applied, the desired resistance of the current limiter 206 can be achieved.

[0116] Figure 5 is a simplified diagram of another exemplary electrode assembly 500 for cycling between the charged and discharged states of a battery. Electrode assembly 500 is similar to electrode assembly 200, and the same reference numbers are used to identify common components. For clarity in the example, a separator structure 205 is not shown in Figure 5, but is included in this exemplary electrode assembly 500. Unlike electrode assembly 200, electrode assembly 500 includes a group of additional current limiters 502. Each additional current limiter 502 is electrically connected between different of the counter electrode current collectors 218 and counter electrode busbars 210. In some embodiments, the additional current limiters 502 are the same as the current limiters 206 discussed above, and the connections are made in the same way as with the current limiters 206. However, in some embodiments, the additional current limiters 502 have a different composition and / or differ from the current limiters 206. For example, a conductive film may be used as the resistor for the additional current limiter 502, while a conductive adhesive is used for the current limiter 206. Alternatively, one type of conductive adhesive may be used for the current limiter 206, and different types of conductive adhesives may be used for the additional current limiter 502. This may be particularly useful if the counter electrode busbars 210 and 208 are made of different materials that can adhere differently to different conductive adhesives. As another example, the additional current limiter 502 may use a conductive material suspended in a conductive adhesive, different from that used for the current limiter 206. Furthermore, in some embodiments, the additional current limiter 502 has a different resistance than the current limiter 206. In certain embodiments, the additional current limiter 502 has a lower resistance than the current limiter 206, including having a resistance of less than 0.25 Ω when sufficient to limit the current below a threshold where the resistance of the current limiter 206 would lead to a catastrophic failure.

[0117] Figure 6 is a simplified diagram of another exemplary electrode assembly 600 for cycling between the charged and discharged states of a battery. Electrode assembly 600 is similar to electrode assembly 200, and the same reference numbers are used to identify common components. Some details of electrode structure 202 and counter electrode structure 204 have been omitted for clarity in the illustration, but all aspects of electrode structure 202 and counter electrode structure 204 discussed above are the same in electrode assembly 600. Unlike electrode assembly 200, electrode assembly 600 includes a group of additional electrode structures 602 directly connected to the electrode busbar 208. That is, the additional electrode structures 602 are connected to the electrode busbar 208 without a current limiter 206.

[0118] Figure 7 is a simplified diagram of another exemplary electrode assembly 700 for cycling between the charged and discharged states of a battery. Electrode assembly 700 is similar to electrode assembly 500, and the same reference numbers are used to identify common components. Some details of electrode structure 202 and counter electrode structure 204 have been omitted for clarity in the illustration, but all aspects of electrode structure 202 and counter electrode structure 204 discussed above are the same in electrode assembly 700. Unlike electrode assembly 500, electrode assembly 500 includes a group of additional electrode structures 602 and a group of additional counter electrode structures 704, all directly connected to the electrode busbar 208. That is, the additional electrode structures 602 and additional counter electrode structures 704 are connected to the electrode busbar 208 without a current limiter 206 or additional current limiter 502.

[0119] Figure 9 shows an exemplary stacked cell 900 created as part of the manufacturing of a secondary battery. To form the secondary battery, electrode assemblies such as electrode assemblies 200, 500, 600, or 700 are first assembled. Electrode structures 202, counter electrode structures 204, and (if applicable) additional electrode structures 602 and / or additional counter electrode structures 704 are assembled. The formed electrodes, counter electrodes, additional electrodes, and additional counter electrode structures 202, 204, 602, and 704 are referred to as “electrode subunits” in the following paragraphs. A predetermined number of electrode subunits are stacked with a separator 205 in the stacking direction (e.g., the width direction in Figure 2) to form a multi-unit electrode stack. Generally, at least 10 electrode structures 202 and at least 10 counter electrode structures 204 are included in a multi-unit electrode stack. In some embodiments, at least 20 electrode structures 202 and at least 20 counter electrode structures 204 are included in a multi-unit electrode stack. Other embodiments may include a multi-unit electrode stack comprising any preferred number of electrode structures 202 and at least 10 counter-electrode structures 204. The multi-unit electrode stack is then placed in a pressurized constraint having a pressure plate that applies pressure to the multi-unit electrode stack to bond all of the electrode subunits together.

[0120] In a multi-unit electrode stack, the electrode structure and the counter electrode structure extend in a longitudinal direction perpendicular to the stacking direction (e.g., the length direction in Figure 2). The end portion of the electrode current collector (e.g., the portion of the electrode current collector 214 extending above the remainder of the electrode structure 202 in Figures 4B, 14, 15, 16, 18, and 19) extends longitudinally beyond the electrode active material and separator structure. The end portion extending above the electrode active material and separator structure is bent substantially perpendicular to the longitudinal direction of the electrode structure, as shown in Figures 4B, 14, 15, 16, 18, and 19, to extend in the stacking direction or in the opposite direction. In embodiments without slots (e.g., Figures 18 and 19), the end portion is bent before the electrode busbar is positioned by bringing the surface of the electrode busbar into contact with the end portion of the electrode current collector (i.e., the bent end portion) to extend the electrode busbar in the stacking direction. In exemplary embodiments, a conductive adhesive layer (e.g., a conductive adhesive functioning as a current limiting device, as discussed herein) is located between the surface of the electrode busbar and the end portion of the electrode current collector. In some embodiments, the conductive adhesive layer is disposed on the surface of the electrode busbar in contact with the electrode current collector. In other embodiments, the conductive adhesive layer is disposed on the electrode current collector. In yet another embodiment, the conductive adhesive layer is a separate layer located between the electrode busbar and the electrode current collector. Heat and pressure are applied to the electrode busbar to bond the end portion of the electrode current collector to the busbar via the conductive adhesive layer. The applied heat may be 100°C to 300°C, preferably 125°C to 250°C, most preferably 150°C to 225°C. The pressure may be 10 psi to 1000 psi, preferably 15 psi to 750 psi, more preferably 20 psi to 500 psi.

[0121] In embodiments using slots in the current collector (e.g., Figures 4B and 14-16), the busbars are inserted into the slots before bending the current collector. In such embodiments, the electrode busbar 208 and the counter electrode busbar 210 are positioned through slots 404, 300 (shown in Figures 3A-4B) of the respective current collectors 214, 218, with a current limiter 206 (and 502, if applicable) between the busbars 208, 210 and the current collectors 214, 218. Once the busbars 208, 210 are positioned through slots 404, 300, portions 406, 302 are folded back toward the respective busbars 208, 210. The electrode busbar 208 is welded to portion 406 of the electrode current collector 214, and the counter electrode busbar 210 is welded to portion 302 of the counter electrode current collector 218. Welding may be performed using a laser welding machine, friction welding, ultrasonic welding, or any suitable welding method for welding the busbars 208 and 210 to the current collectors 214 and 218. After welding the busbars to the multi-unit electrode stack, the stacked cell 900 may be completed and placed in a battery-formed pouch, metal can, or other suitable container. In other embodiments, any other suitable method may be used to connect the electrode busbars 208 and the counter electrode busbars 210 to the current collectors, including a method such as mounting the busbars on tabs on the current collectors without slots.

[0122] Figure 10 is a portion of a top view (i.e., viewed from the height direction H) of the stacked cell 900. The portion of the stacked cell 900 shown in Figure 9 includes one electrode structure 202 and two counter electrode structures 204. In this example, electrode structure 202 is an anode electrode structure, and counter electrode structures 204 are cathode electrode structures.

[0123] Referring to Figures 11A and 11B, after the formation of the laminated cell 900, the laminated cell 900 proceeds to the packaging station 1100, where the laminated cell 900 is coated with an insulating packaging material 1101, such as a multilayer aluminum polymer material or plastic, to form the battery package 1102. In one embodiment, the battery package 1102 is evacuated using a vacuum and filled with electrolyte material through openings (not shown). The insulating packaging material may be sealed around the laminated cell 900 using heat sealing, laser welding, adhesive, or any preferred sealing method. After sealing, the battery insulating packing material forms a sealed housing. The ends of the busbars 208 and 210 are left exposed and not covered by the battery package 1102, and the exposed ends function as external electrode terminals and counter electrode terminals of the sealed battery housing. The exposed ends of the busbars allow the user to connect the busbars to a powered device or battery charger. In other embodiments, separate external electrode terminals and counter electrode terminals are welded to busbars 208 and 210 and positioned outside the sealed battery package 1102. In some embodiments, the connection between such external electrode terminals and counter electrode terminals is located inside the battery package 1102, and the ends of busbars 208 and 210 do not extend outside the battery package 1102.

[0124] Referring to Figure 12, the thermal runaway current (I) used in equation (6) is trA wet (i.e., unit cells contain a liquid electrolyte) forced internal short circuit (FISC) assay can be performed to determine the unit cell. The FISC assay is a repeatable test. The test is performed on an electrode assembly containing n unit cells (where n is a positive integer). Each unit cell contains a single electrode structure 202 adjacent to a single counter electrode 204, with a separator 205 between them and a current limiter 206. The first iteration is performed using an electrode assembly electrically disconnected from any other electrode structures 202, 204, in the case n=1 (i.e., a single unit cell is present). Figure 12 shows the electrode assembly to be tested, containing a single unit cell 1200. Note that Figure 12 is not to scale. To perform the test, a conductive particle 1202 is positioned in the area between the fully charged positive and negative electrodes of the unit cell (e.g., on the separator structure 205 between the electrode structure 202 and the counter electrode structure 204). In one example, the conductive particle 1202 is an L-shaped nickel particle measuring 2 mm × 0.2 mm × 0.1 mm. In other embodiments, the conductive particle 1202 may have any other suitable shape and / or may be made of any other suitable conductive material. A servo motor 1204 press displaces a 5 mm × 5 mm flat acrylic resin indenter 1206 at a speed of 1.0 mm / s over the unit cell 1200 where the embedded conductive particle is located. This causes the conductive particle 1202 to electrically connect with the electrode structure 202 and the counter electrode structure 204 by short-circuiting them. The servo motor 1204 continues to displace the indenter 1206 until a voltage drop of more than 80% of the unit cell voltage occurs. If the unit cell 1200 experiences a catastrophic failure (e.g., the unit cell 1200 ignites or explodes), the test is stopped. If a single unit cell 1200 fails the test, the configuration of the faulty unit cell is such that it causes a thermal runaway current (I tr This test is not a candidate for use in determining the thermal runaway current (I) for this configuration of 1200 unit cells, but rather requires performing different tests, estimations, simulations, etc. tr) must be determined. Furthermore, if a single unit cell 1200 fails the test, the configuration of the failed unit cell may not be a good candidate for use in the current limiters described herein, because the resistance required for the current limiter to suitably limit the current is likely to be high enough to cause undesirable energy loss under normal charge and discharge conditions.

[0125] If unit cell 1200 does not experience a catastrophic failure, the configuration of unit cell 1200 goes through the first iteration, n is incremented by 1, and a new assembly is assembled containing two unit cells (i.e., n=2), one of which unit cells is configured with conductive particles 1202 as discussed above for the first step. The FISC test is repeated for this new assembly with two unit cells. If the new assembly passes the test, the steps above in this paragraph are performed again. That is, a new assembly with n=n+1 unit cells is assembled, one of which unit cells contains conductive particles, and the FISC test is performed again. The worst-case forced internal short-circuit resistance is given at each step by: R s、WCFISC (n) = R 20kHz(Vtoc,n) (9)

[0126] In this example, an impedance of 20 kHz is used, but any other suitable non-zero frequency impedance may be used. This iteration is repeated until an electrode assembly fails the test. When one of the electrode assemblies fails the test, the test is stopped. The number of unit cells from the last successful iteration (i.e., the electrode assembly has n-1 unit cell current values) is used to calculate the thermal runaway current (I tr Determine the thermal runaway current (I). tr ) is given by:

number

[0127] Next, the thermal runaway current (I) determined from equation (10)tr Using ) in inequality (6), the required resistance for each current limiter 206 can be determined, and an electrode assembly can be generated that includes current limiters 206, each having the determined resistance.

[0128] Although the above discussion assumed starting with a single unit cell and n=1, the assay may be started with any suitable, non-zero number of unit cells. For example, if a particular unit cell configuration is expected to fail the test at n=4 (e.g., estimated, calculated, etc.), the test may be started at n=3 with an electrode assembly containing three unit cells.

[0129] R in equation (6) s The actual short-circuit resistance for use can be determined using a dry FISC assay. The dry FISC assay is similar to the FISC assay discussed above, but is performed on one or more unit cells. In the dry FISC assay, one or more unit cells without electrolytes are subjected to FISC using the assembly and technique described above with reference to Figure 12. That is, a unit cell (including a single electrode structure 202 adjacent to a single counter electrode 204 with a separator 205) has a conductive particle 1202 positioned in the area between the positive and negative electrodes of the unit cell (for example, on the separator structure 205 between the electrode structure 202 and the counter electrode structure 204), and an indenter 1206 crushes the unit cell so that the conductive particle 1202 short-circuits and electrically connects the electrode structure 202 and the counter electrode structure 204. The actual short-circuit resistance of the short-circuited unit cell is then measured and can be used in equation (6).

[0130] Figure 13 is a simplified diagram of a portion of another electrode assembly 1300 for cycling between a charged state and a discharged state in a battery. The electrode assembly 1300 includes components similar to those of the electrode assembly described above, and unless otherwise specified, these components are the same. The group of counter electrode structures, the group of separator structures, and the counter electrode busbars are omitted from the figure for clarity. The group of current limiters 206 in the electrode assembly 1300 has fewer constituent units than the group of electrode structures 202. The group of electrode structures is divided into groups 1302 of electrode structures 202. Each group 1302 of electrode structures 202 includes two electrode structures 202 in Figure 13. In other embodiments, a group 1302 may include any number of electrode structures 202, as long as the group includes two or more electrode structures 202 or more. Each electrode structure 202 in a group 1302 is electrically connected in parallel to the other electrode structures 202 in that group 1302. The parallel connections of the electrode structures 202 in group 1302 are connected to the electrode busbar 208 by a single current limiter 206. That is, all electrode structures in group 1302 share a single current limiter 206. Other embodiments include, additionally or alternatively, an arrangement of similarly grouped counter electrode structures 204 that share a single current limiter 206. Furthermore, in some embodiments, some of the electrode structures 202 and / or some of the counter electrode structures 204 in the electrode assembly may be grouped as described above, while the other electrode structures 202 and / or counter electrode structures 204 in the assembly are not grouped and each has its own current limiter 206.

[0131] The resistance of the current limiter 206 in the electrode assembly 1300 is determined by a modification of inequality (6) discussed above. Specifically, the resistance of the shared current limiter 206 in the electrode assembly 1300 is determined to satisfy the following:

number

[0132] In some embodiments, the resistance of the current limiter 206 is defined by the relationship between the current limiter resistance and the cell resistance of the unit cell. Specifically, within the normal operating temperature range of -30°C to 80°C, each unit cell has a cell resistance R1. Each current limiter has a resistance R2 such that: R2 / R1>0.01 (12) This is when the electrode assembly is within its normal operating temperature range. The exact value of the R2 / R1 ratio may vary depending on the battery capacity and / or voltage. In exemplary embodiments, R2 / R1 is approximately equal to 0.5, 0.95, or 0.0275. In some embodiments, R2 / R1 may be greater than 0.1, greater than 0.5, greater than 0.95, or greater than 0.1.

[0133] The following embodiments are provided to illustrate aspects of the present disclosure, but these embodiments are not intended to limit, and other embodiments and / or forms may also be provided.

[0134] Embodiment 1 An electrode assembly for cycling between a charging state and a discharging state, wherein the electrode assembly comprises a group of electrode structures, a group of counter electrode structures, a group of current limiters, an electrode busbar, and a counter electrode busbar. Each component unit of the electrode structure group comprises an electrode active material and an electrode current collector, the electrode current collector being composed of the component units of the electrode structure group and electrically connected in parallel to the electrode busbar. Each component unit of the counter electrode structure group comprises a counter electrode active material and a counter electrode current collector, the counter electrode current collector being composed of the component units of the counter electrode structure group and electrically connected in parallel to the counter electrode busbar. The group of current limiters includes at least 10 current limiters. Each electrode current collector is electrically connected to the electrode busbar by the component units of the group of current limiters, and at a temperature of 25 degrees Celsius (°C), each component unit of the group of current limiters has a resistance of 0.25 ohms (Ω) or more.

[0135] Embodiment 2 An electrode assembly for cycling between a charged state and a discharged state includes a group of electrode structures, each component of the group of electrode structures comprising an electrode active material and an electrode current collector; an electrode busbar, the electrode current collectors of each component of the group of electrode structures being electrically connected in parallel to the electrode busbar; a group of counter electrode structures, each component of the group of counter electrode structures comprising a counter electrode active material and a counter electrode current collector; a counter electrode busbar, the counter electrode current collectors of each component of the group of counter electrode structures being electrically connected in parallel to the counter electrode busbar; and a group of current limiters. Each component of the current limiter group electrically connects the electrode current collectors of each component of the group of electrode structures to the electrode busbar, and at a temperature of 25 degrees Celsius (°C), each component of the current limiter group has a resistance of 0.25 ohms (Ω) or more.

[0136] Embodiment 3 An electrode assembly for cycling between a charging state and a discharging state includes a group of electrode structures, a group of counter electrode structures, a group of separator structures for electrically isolating the electrode structure group and the counter electrode structure group, a group of current limiters, an electrode busbar, and a counter electrode busbar. Each component of the electrode structure group comprises an electrode active material and an electrode current collector, the electrode current collector being composed of the component units of the electrode structure group and electrically connected in parallel to the electrode busbar. Each component of the counter electrode structure group comprises a counter electrode active material and a counter electrode current collector, the counter electrode current collector being composed of the component units of the counter electrode structure group and electrically connected in parallel to the counter electrode busbar. Each component of the current limiter group is electrically connected between different electrode current collectors and electrode busbars, and at a temperature of 25 degrees Celsius (°C), each component of the current limiter group has a resistance greater than 0.25 ohms (Ω).

[0137] Embodiment 4 An electrode assembly for cycling between a charging state and a discharging state includes a group of electrode structures, a group of counter electrode structures, a group of separator structures for electrically isolating the electrode structure group and the counter electrode structure group, a group of current limiters, an electrode busbar, and a counter electrode busbar. Each component unit of the electrode structure group comprises an electrode active material and an electrode current collector, the electrode current collector being composed of the component units of the electrode structure group and electrically connected in parallel to the electrode busbar. Each component unit of the counter electrode structure group comprises a counter electrode active material and a counter electrode current collector, the counter electrode current collector being composed of the component units of the counter electrode structure group and electrically connected in parallel to the counter electrode busbar. Each component unit of the current limiter group is positioned between different electrode current collectors and electrode busbars and is electrically connected to the associated electrode current collector and electrode busbar of the component unit, and at a temperature of 25 degrees Celsius (°C), each component unit of the current limiter group has a resistance greater than 0.25 ohms (Ω).

[0138] Embodiment 5 An electrode assembly for cycling between a charged state and a discharged state includes a group of electrode structures, a group of counter electrode structures, a group of separator structures for electrically isolating the electrode structure group and the counter electrode structure group, a group of current limiters, an electrode busbar, and a counter electrode busbar. The electrode assembly has a capacity C fully charged at 25C, and a current threshold I that can cause failure of the electrode assembly. Th Each component of the electrode structure group has an electrode structure resistance and comprises an electrode active material and an electrode current collector. The electrode current collector is composed of the component units of the electrode structure group and is electrically connected in parallel to the electrode busbar. Each component of the counter electrode structure group comprises a counter electrode active material and a counter electrode current collector. The counter electrode current collector is composed of the component units of the counter electrode structure group and is electrically connected in parallel to the counter electrode busbar. Each component of the current limiter group is electrically connected between different electrode current collectors and electrode busbars, and at a temperature of 25 degrees Celsius (°C), each component of the current limiter group limits the current passing through the component unit of the electrode structure group associated with the component unit to ITh The resistor has a limiting resistance, and the resistance is determined as a function of V, the electrode structure resistance of the constituent unit of the associated electrode structure group, the short-circuit resistance between the constituent unit of the associated electrode structure group and the constituent unit of the counter electrode structure group, and the number of constituent units of the electrode structure group connected to the electrode busbar.

[0139] Embodiment 6 I Th The electrode assembly according to Embodiment 5, wherein the current is 8 amperes or more and 12 amperes or less.

[0140] Embodiment 7 I Th However, the electrode assembly according to Embodiment 5 or Embodiment 6 has a current of 8.0 amperes.

[0141] Embodiment 8 An electrode assembly according to any one of embodiments 5 to 7, wherein V is 4.35 volts.

[0142] Embodiment 9 An electrode assembly for cycling between a charged state and a discharged state includes a group of electrode structures, a group of counter electrode structures, a group of separator structures for electrically isolating the electrode structure group and the counter electrode structure group, a group of current limiters, an electrode busbar, and a counter electrode busbar. The electrode assembly has a capacity C when fully charged at 25 degrees Celsius (°C). Each component unit of the electrode structure group comprises an electrode active material and an electrode current collector, the electrode current collector being composed of the component units of the electrode structure group and electrically connected in parallel to the electrode busbar. Each component unit of the counter electrode structure group comprises a counter electrode active material and a counter electrode current collector, the counter electrode current collector being composed of the component units of the counter electrode structure group and electrically connected in parallel to the counter electrode busbar. The current limiter group is located at the electrical connection between the electrode busbar and each electrode current collector of the electrode group's constituent units, and at a temperature of 25°C, (i) each component of the current limiter group includes a resistor that limits the amount of current that can flow between the electrode busbar and the associated electrode current collector of the constituent unit to a maximum of 8 amperes, and (ii) when current is passed between the electrode busbar and each component of the electrode current collector subset to charge or discharge the electrode assembly at a C rate of 1 C, the voltage drop across each component of the current limiter group does not exceed 20 mV.

[0143] Embodiment 9.1 An electrode assembly for cycling between a charged state and a discharged state within a normal operating temperature range of minus 30 degrees Celsius (°C) to 80 degrees Celsius, wherein the electrode assembly comprises a group of unit cells, electrode busbars, counter electrode busbars, and a group of current limiters. Each component of the unit cell group has a cell resistance R1 and comprises an electrode structure, a separator structure, and a counter electrode structure, the electrode structure of each component of the unit cell group comprises an electrode current collector and an electrode active material layer, and the counter electrode structure of each component of the unit cell group comprises a counter electrode current collector and a counter electrode active material layer. For each component of the unit cell group, (a) the electrode current collector of the electrode structure is electrically connected to the electrode busbar, (b) the counter electrode current collector of the counter electrode structure is electrically connected to the counter electrode busbar, and (c) the component of the current limiter group is electrically connected (i) between the electrode current collector and the electrode busbar, or (ii) between the counter electrode current collector and the counter electrode busbar. Each component of the current limiter group has a resistance R2 such that R2 / R1 > 0.01 when the electrode assembly is within the normal operating temperature range.

[0144] Embodiment 9.2 An electrode assembly for cycling between a charged state and a discharged state within a normal operating temperature range of minus 20 degrees Celsius (°C) to 80 degrees Celsius, wherein the electrode assembly comprises a group of unit cells, a group of current limiters, an electrode busbar, and a counter electrode busbar. Each component of the unit cell group comprises an electrode structure, a separator structure, and a counter electrode structure, the electrode structure of each component of the unit cell group comprises an electrode current collector and an electrode active material layer, and the counter electrode structure of each component of the unit cell group comprises a counter electrode current collector and a counter electrode active material layer. For each component of the unit cell group, (a) the electrode current collector of the electrode structure is electrically connected to an electrode busbar, (b) the counter electrode current collector of the counter electrode structure is electrically connected to a counter electrode busbar, and (c) at least one component of the current limiter group is electrically connected (i) between the electrode current collector and the electrode busbar, or (ii) between the counter electrode current collector and the counter electrode busbar. For each unit cell, at least one component of the current limiter group has sufficient resistance to substantially continuously limit the current through the unit cell to a non-zero current less than a threshold current I, which is less than the current that would induce thermal runaway of the unit cell, when the electrode assembly is within the normal operating temperature range, until the electrode assembly is discharged.

[0145] Embodiment 10 An electrode assembly according to any one of embodiments 5 to 9.2, wherein the resistance of each component unit of the current limiter group at a temperature of 25 degrees Celsius (°C) is greater than 0.25 ohms (Ω).

[0146] Embodiment 11 An electrode assembly according to any one of embodiments 3 to 10, wherein the resistance of each component unit of the current limiter group does not increase at temperatures higher than 25°C.

[0147] Embodiment 12 An electrode assembly according to any one of embodiments 1 to 11, wherein the group of current limiters includes a conductive adhesive.

[0148] Embodiment 13 The electrode assembly according to Embodiment 12, wherein the conductive adhesive consists of a single layer of conductive adhesive, and each component unit of the group of current limiters includes a different portion of the single layer of conductive adhesive.

[0149] Embodiment 14 The electrode assembly according to embodiment 13, wherein a single layer of conductive adhesive is disposed on an electrode busbar.

[0150] Embodiment 15 The electrode assembly according to Embodiment 12, wherein the conductive adhesive of each component unit of the group of current limiters is physically separated from the conductive adhesive of each other component unit of the group of current limiters.

[0151] Embodiment 16 The electrode assembly according to embodiment 15, wherein a conductive adhesive is disposed on a portion of each component unit of the electrode current collector group.

[0152] Embodiment 17 The electrode assembly according to any one of embodiments 12 to 16, wherein the conductive adhesive comprises an adhesive polymer having a conductive material suspended therein.

[0153] Embodiment 18 The electrode assembly according to Embodiment 17, wherein the conductive material includes carbon black.

[0154] Embodiment 18.1 The electrode assembly according to Embodiment 17, wherein the conductive material includes metal-coated carbon fibers.

[0155] Embodiment 18.2 The electrode assembly according to Embodiment 18.1, wherein the metal-coated carbon fibers include nickel-coated carbon fibers.

[0156] Embodiment 18.3 The electrode assembly according to Embodiment 18.1 or 18.2, wherein the metal-coated carbon fiber has length and diameter, and the aspect ratio of length to diameter is 10:1 or greater.

[0157] Embodiment 18.4 The electrode assembly according to Embodiment 18.3, wherein the aspect ratio of length to diameter is 10:1 to 10,000:1 (including both ends).

[0158] Embodiment 18.5 The electrode assembly according to Embodiment 18.3, wherein the aspect ratio of length to diameter is 50:1 to 5,000:1 (including both ends).

[0159] Embodiment 18.6 The electrode assembly according to Embodiment 18.3, wherein the aspect ratio of length to diameter is 100:1 to 2,000:1 (including both ends).

[0160] Embodiment 18.7 The electrode assembly according to Embodiment 18.3, wherein the aspect ratio of length to diameter is approximately 850.

[0161] Embodiment 19 The electrode assembly according to Embodiment 17, wherein the conductive material contains nickel particles.

[0162] Embodiment 20 The electrode assembly according to Embodiment 17, wherein the conductive material comprises one or more of carbon black, nickel, copper, gold, silver, titanium, graphite, molybdenum, chromium, and aluminum.

[0163] Embodiment 21 The electrode assembly according to Embodiment 17, wherein the conductive material includes metal particles.

[0164] Embodiment 22 An electrode assembly according to any one of embodiments 12 to 21, wherein the conductive adhesive comprises a hot-melt adhesive polymer.

[0165] Embodiment 22.1 The electrode assembly according to any one of Embodiments 12 to 21, wherein the melt flow index of the conductive adhesive determined according to ASTM D 1238 at 190°C is 0.1 to 1000 grams (g) / 10 minutes (min).

[0166] Embodiment 22.2 The electrode assembly according to Embodiment 22.1, wherein the melt flow index is 0.1 to 100 g / 10 min.

[0167] Embodiment 22.3 The electrode assembly according to Embodiment 22.1, wherein the melt flow index is 0.5 to 20 g / 10 min.

[0168] Embodiment 22.4 The electrode assembly according to any one of Embodiments 12 to 22.3, wherein the melting point of the conductive adhesive is 40°C to 300°C.

[0169] Embodiment 22.5 The electrode assembly according to Embodiment 22.4, wherein the melting point of the conductive adhesive is 60°C to 200°C.

[0170] Embodiment 22.6 The electrode assembly according to Embodiment 22.4, wherein the melting point of the conductive adhesive is 70°C to 165°C.

[0171] Embodiment 第23 The electrode assembly according to any one of Embodiments 12 to 22.6, wherein the conductive adhesive has a resistivity of 0.01 Ω·cm or more.

[0172] Embodiment 24 The electrode assembly according to any one of Embodiments 12 to 23, wherein the conductive adhesive has a resistivity of 1.0 Ω·cm or less.

[0173] Embodiment 25 The electrode assembly according to any one of embodiments 12 to 24, wherein the conductive adhesive comprises one of ethylene-co-acrylic acid, an ionomer of ethylene-co-acrylic acid, and a polymer of ethylene-co-acrylic acid.

[0174] Embodiment 26 The electrode assembly according to any one of embodiments 12 to 24, wherein the conductive adhesive comprises one of ethylene-co-methacrylic acid, an ionomer of ethylene-co-methacrylic acid, and a polymer of ethylene-co-methacrylic acid.

[0175] Embodiment 27 An electrode assembly according to any one of embodiments 12 to 24, wherein the conductive adhesive comprises functionalized polyethylene.

[0176] Embodiment 28 An electrode assembly according to any one of embodiments 12 to 24, wherein the conductive adhesive comprises functionalized polypropylene.

[0177] Embodiment 29 An electrode assembly according to any one of embodiments 1 to 11, wherein each component unit of the current limiter group includes a conductive film.

[0178] Embodiment 30 An electrode assembly according to any one of embodiments 1 to 29, wherein each component unit of the current limiter group is physically located between an electrode busbar and an electrode current collector associated with the electrode busbar.

[0179] Embodiment 31 The electrode assembly according to any one of embodiments 1 to 30, further comprising a group of additional current limiters, wherein each component unit of the group of additional current limiters is electrically connected between a different counter electrode current collector and a counter electrode busbar.

[0180] Embodiment 32 The electrode assembly according to Embodiment 31, wherein each constituent unit of the additional current limiter group has a resistance greater than 0.25 ohms (Ω) at a temperature of 25 degrees Celsius (°C).

[0181] Embodiment 33 The electrode assembly according to Embodiment 31, wherein each constituent unit of the additional current limiter group has a resistance less than 0.25 ohms (Ω) at a temperature of 25 degrees Celsius (°C).

[0182] Embodiment 34 The electrode assembly according to any one of Embodiments 31 to 33, wherein the resistance of each constituent unit of the second current limiter group does not increase at a temperature higher than 25 °C.

[0183] Embodiment 35 The electrode assembly according to any one of Embodiments 31 to 34, wherein the group of additional current limiters includes an additional conductive adhesive.

[0184] Embodiment 36 The electrode assembly according to Embodiment 35, wherein the additional conductive adhesive includes an additional adhesive polymer having an additional conductive material suspended therein.

[0185] Embodiment 37 The electrode assembly according to Embodiment 36, wherein the additional conductive material includes carbon black.

[0186] Embodiment 37.1 The electrode assembly according to Embodiment 36, wherein the additional conductive material includes metal-coated carbon fibers.

[0187] Embodiment 37.2 The electrode assembly according to Embodiment 37.1, wherein the metal-coated carbon fibers include carbon fibers coated with nickel.

[0188] Embodiment 37.3 The electrode assembly according to Embodiment 37.1 or 37.2, wherein the metal-coated carbon fiber has length and diameter, and the aspect ratio of length to diameter is 10:1 or greater.

[0189] Embodiment 37.4 The electrode assembly according to Embodiment 37.3, wherein the aspect ratio of length to diameter is 10:1 to 10,000:1 (including both ends).

[0190] Embodiment 37.5 The electrode assembly according to Embodiment 37.3, wherein the aspect ratio of length to diameter is 50:1 to 5,000:1 (including both ends).

[0191] Embodiment 37.6 The electrode assembly according to Embodiment 37.3, wherein the aspect ratio of length to diameter is 100:1 to 2,000:1 (including both ends).

[0192] Embodiment 37.7 The electrode assembly according to Embodiment 37.3, wherein the aspect ratio of length to diameter is approximately 850.

[0193] Embodiment 38 The electrode assembly according to embodiment 36, wherein the additional conductive material comprises nickel particles.

[0194] Embodiment 39 The electrode assembly according to Embodiment 36, wherein the additional conductive material includes one or more of carbon black, nickel, copper, gold, silver, titanium, graphite, molybdenum, chromium, and aluminum.

[0195] Embodiment 40 The electrode assembly according to embodiment 36, wherein the additional conductive material includes metal particles.

[0196] Embodiment 41 The electrode assembly according to Embodiment 36, wherein the additional conductive material and the conductive material are of the same type.

[0197] Embodiment 42 The electrode assembly according to any one of embodiments 35 to 41, wherein the additional conductive adhesive comprises a hot melt adhesive polymer.

[0198] Embodiment 42.1 An electrode assembly according to any one of embodiments 35 to 41, wherein the melt flow index of the additional conductive adhesive, determined according to ASTM D 1238 at 190°C, is 0.1 to 1000 grams (g) / 10 minutes (min).

[0199] Embodiment 42.2 The electrode assembly according to Embodiment 42.1, wherein the melt flow index is 0.1 to 100 g / 10 min.

[0200] Embodiment 42.3 The electrode assembly according to Embodiment 42.1, wherein the melt flow index is 0.5 to 20 g / 10 min.

[0201] Embodiment 42.4 An electrode assembly according to any one of embodiments 35 to 42.3, wherein the melting point of the additional conductive adhesive is 40°C to 300°C.

[0202] Embodiment 42.5 The electrode assembly according to Embodiment 42.4, wherein the melting point of the additional conductive adhesive is 60°C to 200°C.

[0203] Embodiment 42.6 The electrode assembly according to Embodiment 42.4, wherein the melting point of the additional conductive adhesive is 70°C to 165°C.

[0204] Embodiment 43 An electrode assembly according to any one of embodiments 35 to 42.6, wherein the additional conductive adhesive has a resistivity of 0.01 Ω·cm or greater.

[0205] Embodiment 44 An electrode assembly according to any one of embodiments 35 to 43, wherein the additional conductive adhesive has a resistivity of 1.0 Ω·cm or less.

[0206] Embodiment 45 The electrode assembly according to any one of embodiments 35 to 44, wherein the additional conductive adhesive comprises one of ethylene-co-acrylic acid, an ionomer of ethylene-co-acrylic acid, and a polymer of ethylene-co-acrylic acid.

[0207] Embodiment 46 The electrode assembly according to any one of embodiments 35 to 44, wherein the additional conductive adhesive comprises one of ethylene-co-methacrylic acid, an ionomer of ethylene-co-methacrylic acid, and a polymer of ethylene-co-methacrylic acid.

[0208] Embodiment 47 An electrode assembly according to any one of embodiments 35 to 44, wherein an additional conductive adhesive comprises functionalized polyethylene.

[0209] Embodiment 48 An electrode assembly according to any one of embodiments 35 to 44, wherein an additional conductive adhesive comprises functionalized polypropylene.

[0210] Embodiment 49 An electrode assembly according to any one of embodiments 31 to 34, wherein each component unit of the additional current limiter group includes a conductive film.

[0211] Embodiment 50 An electrode assembly according to any one of embodiments 31 to 49, wherein each constituent unit of the additional current limiter group is physically located between the electrode busbar and the electrode current collector associated with the electrode busbar.

[0212] Embodiment 51 The electrode assembly according to any one of embodiments 1 to 50, further comprising a group of additional electrode structures, each component of the group of additional electrode structures comprising an electrode active material and an additional electrode current collector, the additional electrode current collector being electrically connected in parallel to the electrode busbar without being connected to the component of the group of current limiters.

[0213] Embodiment 52 An electrode assembly according to any one of Embodiments 1 to 51, wherein the electrode structure includes a cathode structure, the electrode active material includes a cathode active material, the electrode current collector includes a cathode current collector, and the electrode busbar includes a cathode busbar.

[0214] Embodiment 53 An electrode assembly according to any one of Embodiments 1 to 51, wherein the electrode structure includes an anode structure, the electrode active material includes an anode active material, the electrode current collector includes an anode current collector, and the electrode busbar includes a cathode busbar.

[0215] Embodiment 54 A secondary battery comprising a sealed battery housing, an electrode assembly described in any one of the prior embodiments located within the sealed housing, and electrode terminals and counter electrode terminals located outside the sealed battery housing.

[0216] Embodiment 55 A secondary battery for cycling between a charged state and a discharge state having a rated capacity C, comprising: (i) a sealed battery housing; (ii) an electrode assembly including a group of current limiters within the sealed housing; and (iii) electrode terminals and counter electrode terminals outside the sealed battery housing. The electrode assembly has mutually perpendicular horizontal, vertical, and vertical axes corresponding to the x, y, and z axes of a hypothetical three-dimensional Cartesian coordinate system, and comprises: (i) a group of at least 10 electrode structures and a group of at least 10 counter electrode structures arranged in an alternating vertical arrangement; (ii) electrode busbars electrically connected to the electrode terminals; (iii) counter electrode busbars electrically connected to the counter electrode terminals; and (iv) electrical isolation separators between the constituent units of the electrode group and the counter electrode group, and (v) each constituent unit of the electrode group is connected to the electrode busbar (vi) The electrode busbars are electrically connected in parallel to the electrode busbars, and (vii) each component of the electrode group is electrically connected in parallel to the counter electrode busbar, and (viiis, and (viii) each component of the counter electrode busbars is electrically connected to the counter electrode busbars, and (viii) each component of the electrode group is electrically connected to the counter electrode busbars, and (viii) each component of the electrode group is electrically connected to the counter electrode busbars, and (viii) each component of the counter electrode group is electrically connected to the counter electrode busbars, and (viii) each component of the electrode group is electrically connected to the counter electrode busbars, and (viii) each component of the counter electrode group is electrically connected to the counter electrode busbars, and (viii) each component of the electrode group is electrically connected to the counter electrode busbars, and (viii) each component of the counter electrode group is electrically connected to the counter electrode busbars, and (viii) each component of the electrode group is electrically connected to the counter electrode busbars, and (viii) each component of the electrode group is electrically connected to the counter electrode busbars, and (viii) each component of the electrode group is electrically connected to the counter electrode busbars, and (viii) each component of the electrode group is electrically connected to the counter electrode busbars, and (viii) each component of the electrode group is electrically connected to the counter electrode busbars, and (viii) each component of the electrode group is electrically connected to the counter electrode busbars, and (viii) each component of the electrode group is electrically connected to The group of current limiters is electrically connected between the electrode busbar and the electrode current collector, and at a temperature of 25 degrees Celsius (°C), each component of the current limiter group has a resistance greater than 0.25 ohms (Ω).

[0217] Embodiment 56 The secondary battery according to Embodiment 55, wherein the resistance of each component unit of the current limiter group does not increase at temperatures higher than 25°C.

[0218] Embodiment 57 A secondary battery according to Embodiment 56 or Embodiment 57, wherein the group of current limiters includes a conductive adhesive.

[0219] Embodiment 58 The secondary battery according to Embodiment 57, wherein the conductive adhesive is composed of a single layer of conductive adhesive, and each component unit of the group of current limiters includes a different portion of the single layer of conductive adhesive.

[0220] Embodiment 59 A secondary battery according to embodiment 58, wherein a single layer of conductive adhesive is disposed on an electrode busbar.

[0221] Embodiment 60 The secondary battery according to Embodiment 57, wherein the conductive adhesive of each component unit of the group of current limiters is physically separated from the conductive adhesive of each other component unit of the group of current limiters.

[0222] Embodiment 61 A secondary battery according to embodiment 60, wherein a conductive adhesive is disposed on a portion of each component unit of the electrode current collector group.

[0223] Embodiment 62 A secondary battery according to any one of embodiments 57 to 61, wherein the conductive adhesive comprises an adhesive polymer having a conductive material suspended therein.

[0224] Embodiment 63 A secondary battery according to Embodiment 62, wherein the conductive material includes carbon black.

[0225] Embodiment 63.1 A secondary battery according to Embodiment 62, wherein the conductive material includes metal-coated carbon fiber.

[0226] Embodiment 63.2 The secondary battery according to Embodiment 63.1, wherein the metal-coated carbon fiber includes nickel-coated carbon fiber.

[0227] Embodiment 63.3 A secondary battery according to Embodiment 63.1 or 63.2, wherein the metal-coated carbon fiber has length and diameter, and the aspect ratio of length to diameter is 10:1 or greater.

[0228] Embodiment 63.4 A secondary battery according to Embodiment 63.3, wherein the aspect ratio of length to diameter is 10:1 to 10,000:1 (including both ends).

[0229] Embodiment 63.5 A secondary battery according to Embodiment 63.3, wherein the aspect ratio of length to diameter is 50:1 to 5,000:1 (including both ends).

[0230] Embodiment 63.6 A secondary battery according to Embodiment 63.3, wherein the aspect ratio of length to diameter is 100:1 to 2,000:1 (including both ends).

[0231] Embodiment 63.7 A secondary battery according to Embodiment 63.3, wherein the aspect ratio of length to diameter is approximately 850.

[0232] Embodiment 64 A secondary battery according to Embodiment 62, wherein the conductive material contains nickel particles.

[0233] Embodiment 65 The secondary battery according to Embodiment 62, wherein the conductive material comprises one or more of carbon black, nickel, copper, gold, silver, titanium, graphite, molybdenum, chromium, and aluminum.

[0234] Embodiment 66 A secondary battery according to Embodiment 62, wherein the conductive material includes metal particles.

[0235] Embodiment 67 A secondary battery according to any one of embodiments 57 to 66, wherein the conductive adhesive comprises a hot melt adhesive polymer.

[0236] Embodiment 67.1 A secondary battery according to any one of embodiments 57 to 66, wherein the melt flow index of the conductive adhesive, as determined according to ASTM D 1238 at 190°C, is 0.1 to 1000 grams (g) / 10 minutes (min).

[0237] Embodiment 67.2 A secondary battery according to Embodiment 67.1, wherein the melt flow index is 0.1 to 100 g / 10 min.

[0238] Embodiment 67.3 A secondary battery according to Embodiment 67.1, wherein the melt flow index is 0.5 to 20 g / 10 min.

[0239] Embodiment 67.4 A secondary battery according to any one of embodiments 57 to 67.3, wherein the melting point of the conductive adhesive is 40°C to 300°C.

[0240] Embodiment 67.5 A secondary battery according to Embodiment 67.4, wherein the melting point of the conductive adhesive is 60°C to 200°C.

[0241] Embodiment 67.6 A secondary battery according to Embodiment 67.4, wherein the melting point of the conductive adhesive is 70°C to 165°C.

[0242] Embodiment 68 A secondary battery according to any one of embodiments 57 to 67.6, wherein the conductive adhesive has a resistivity of 0.01 Ω·cm or more.

[0243] Embodiment 69 A secondary battery according to any one of embodiments 57 to 68, wherein the conductive adhesive has a resistivity of 1.0 Ω·cm or less.

[0244] Embodiment 70 A secondary battery according to any one of embodiments 57 to 69, wherein the conductive adhesive comprises one of ethylene-co-acrylic acid, an ionomer of ethylene-co-acrylic acid, and a polymer of ethylene-co-acrylic acid.

[0245] Embodiment 71 A secondary battery according to any one of embodiments 57 to 69, wherein the conductive adhesive comprises one of ethylene-co-methacrylic acid, an ionomer of ethylene-co-methacrylic acid, and a polymer of ethylene-co-methacrylic acid.

[0246] Embodiment 72 A secondary battery according to any one of embodiments 57 to 69, wherein the conductive adhesive comprises functionalized polyethylene.

[0247] Embodiment 73 A secondary battery according to any one of embodiments 57 to 69, wherein the conductive adhesive comprises functionalized polypropylene.

[0248] Embodiment 74 A secondary battery according to Embodiment 55 or Embodiment 56, wherein each component unit of the current limiter group includes a conductive film.

[0249] Embodiment 75 A secondary battery according to any one of embodiments 55 to 74, wherein each component unit of the current limiter group is physically located between an electrode busbar and an electrode current collector associated with the electrode busbar.

[0250] Embodiment 76 A secondary battery according to any one of embodiments 55 to 75, wherein the electrode assembly further comprises a group of additional current limiters, each component unit of the group of additional current limiters being electrically connected between a different counter electrode current collector and a counter electrode busbar.

[0251] Embodiment 77 The secondary battery according to Embodiment 76, wherein at a temperature of 25 degrees Celsius (°C), each component of the additional current limiter group has a resistance greater than 0.25 ohms (Ω).

[0252] Embodiment 78 The secondary battery according to Embodiment 76, wherein at a temperature of 25 degrees Celsius (°C), each component of the additional current limiter group has a resistance less than 0.25 ohms (Ω).

[0253] Embodiment 79 A secondary battery according to any one of embodiments 76 to 78, wherein the resistance of each component unit of the second current limiter group does not increase at temperatures higher than 25°C.

[0254] Embodiment 80 A secondary battery according to any one of embodiments 76 to 79, wherein a group of additional current limiters includes an additional conductive adhesive.

[0255] Embodiment 81 The secondary battery according to Embodiment 80, wherein the additional conductive adhesive comprises an additional adhesive polymer having an additional conductive material suspended therein.

[0256] Embodiment 82 A secondary battery according to Embodiment 81, wherein the additional conductive material includes carbon black.

[0257] Embodiment 82.1 The secondary battery according to Embodiment 81, wherein the additional conductive material includes metal-coated carbon fiber.

[0258] Embodiment 82.2 The secondary battery according to Embodiment 82.1, wherein the metal-coated carbon fiber includes nickel-coated carbon fiber.

[0259] Embodiment 82.3 A secondary battery according to Embodiment 82.1 or 82.2, wherein the metal-coated carbon fiber has length and diameter, and the aspect ratio of length to diameter is 10:1 or greater.

[0260] Embodiment 82.4 A secondary battery according to Embodiment 82.3, wherein the aspect ratio of length to diameter is 10:1 to 10,000:1 (including both ends).

[0261] Embodiment 82.5 A secondary battery according to Embodiment 82.3, wherein the aspect ratio of length to diameter is 50:1 to 5,000:1 (including both ends).

[0262] Embodiment 82.6 A secondary battery according to Embodiment 82.3, wherein the aspect ratio of length to diameter is 100:1 to 2,000:1 (including both ends).

[0263] Embodiment 82.7 A secondary battery according to Embodiment 82.3, wherein the aspect ratio of length to diameter is approximately 850.

[0264] Embodiment 83 The secondary battery according to Embodiment 81, wherein the additional conductive material comprises nickel particles.

[0265] Embodiment 84 The secondary battery according to Embodiment 81, wherein the additional conductive material includes one or more of carbon black, nickel, copper, gold, silver, titanium, graphite, molybdenum, chromium, and aluminum.

[0266] Embodiment 85 The secondary battery according to Embodiment 81, wherein the additional conductive material includes metal particles.

[0267] Embodiment 86 The secondary battery according to Embodiment 81, wherein the additional conductive material and the conductive material are conductive materials of the same type.

[0268] Embodiment 87 A secondary battery according to any one of embodiments 80 to 86, wherein the additional conductive adhesive comprises a hot melt adhesive polymer.

[0269] Embodiment 87.1 A secondary battery according to any one of embodiments 80 to 86, wherein the melt flow index of the additional conductive adhesive, determined according to ASTM D 1238 at 190°C, is 0.1 to 1000 grams (g) / 10 minutes (min).

[0270] Embodiment 87.2 A secondary battery according to Embodiment 87.1, wherein the melt flow index is 0.1 to 100 g / 10 min.

[0271] Embodiment 87.3 A secondary battery according to Embodiment 87.1, wherein the melt flow index is 0.5 to 20 g / 10 min.

[0272] Embodiment 87.4 A secondary battery according to any one of embodiments 80 to 87.3, wherein the melting point of the additional conductive adhesive is 40°C to 300°C.

[0273] Embodiment 87.5 A secondary battery according to Embodiment 87.4, wherein the melting point of the additional conductive adhesive is 60°C to 200°C.

[0274] Embodiment 87.6 The secondary battery according to Embodiment 87.4, wherein the melting point of the additional conductive adhesive is 70°C to 165°C.

[0275] Embodiment 88 A secondary battery according to any one of embodiments 80 to 87.6, wherein the additional conductive adhesive has a resistivity of 0.01 Ω·cm or more.

[0276] Embodiment 89 A secondary battery according to any one of embodiments 80 to 88, wherein the additional conductive adhesive has a resistivity of 1.0 Ω·cm or less.

[0277] Embodiment 90 A secondary battery according to any one of embodiments 80 to 89, wherein the additional conductive adhesive comprises one of ethylene-co-acrylic acid, an ionomer of ethylene-co-acrylic acid, and a polymer of ethylene-co-acrylic acid.

[0278] Embodiment 91 A secondary battery according to any one of embodiments 80 to 89, wherein the additional conductive adhesive comprises one of ethylene-co-methacrylic acid, an ionomer of ethylene-co-methacrylic acid, and a polymer of ethylene-co-methacrylic acid.

[0279] Embodiment 92 A secondary battery according to any one of embodiments 80 to 89, wherein an additional conductive adhesive comprises functionalized polyethylene.

[0280] Embodiment 93 A secondary battery according to any one of embodiments 80 to 89, wherein an additional conductive adhesive comprises functionalized polypropylene.

[0281] Embodiment 94 A secondary battery according to any one of embodiments 76 to 79, wherein each component unit of the additional current limiter group includes a conductive film.

[0282] Embodiment 95 A secondary battery according to any one of embodiments 76 to 94, wherein each component unit of the additional current limiter group is physically located between the electrode busbar and the electrode current collector associated with the electrode busbar.

[0283] Embodiment 96 A secondary battery according to any one of embodiments 55 to 95, wherein the electrode assembly further comprises a group of additional electrode structures, each component of the group of additional electrode structures comprising an electrode active material and an additional electrode current collector, the additional electrode current collector being electrically connected in parallel to an electrode busbar without being connected to a component of the group of current limiters.

[0284] Embodiment 97 A secondary battery according to any one of embodiments 55 to 96, wherein the electrode structure includes a cathode structure, the electrode active material includes a cathode active material, the electrode current collector includes a cathode current collector, and the electrode busbar includes a cathode busbar.

[0285] Embodiment 98 A secondary battery according to any one of embodiments 55 to 96, wherein the electrode structure includes an anode structure, the electrode active material includes an anode active material, the electrode current collector includes an anode current collector, and the electrode busbar includes a cathode busbar.

[0286] Embodiment 99 A method for testing an electrode unit cell having a current limiter for use in an electrode assembly for cycling between a charged state and a discharge state, wherein the electrode unit cell comprises an electrode structure, a counter electrode structure, and a spacer between the electrode structure and the counter electrode structure, the current limiter is electrically connected to the electrode structure, and the electrode unit cell has capacitance C and voltage V. The method comprises electrically connecting the current limiter to the electrode structure, and at a temperature of 25 degrees Celsius (°C), the current limiter has a resistance of 0.25 ohms (Ω) or more. A conductive particle is inserted into the location of the electrode unit cell between the electrode structure and the counter electrode structure, and an indenter is positioned above the location of the electrode unit cell in which the conductive particle is inserted. The indenter is pressed into the electrode unit cell at a speed of 1.0 millimeter per second (mm) while preventing the electrode unit cell from moving in such a way that it pushes the conductive particle through the spacer and into contact with both the electrode unit cell and the counter electrode unit cell. An electrode unit cell with a current limiter fails the test if the electrode unit cell ignites, and passes the test if the electrode unit cell does not ignite.

[0287] Embodiment 100 The method according to embodiment 99, wherein pressing the indenter into the electrode unit cell includes pressing the indenter into the electrode unit cell until a voltage drop greater than 80 percent of the voltage V is observed.

[0288] Embodiment 101 The method according to Embodiment 99 or Embodiment 100, wherein inserting conductive particles includes inserting nickel particles.

[0289] Embodiment 102 The method according to Embodiment 101, wherein the insertion of nickel particles is a nickel particle measuring 2.0 mm × 0.2 mm × 0.1 mm in shape resembling the English letter "L".

[0290] Embodiment 103 The method according to any one of embodiments 99 to 102, further comprising: when an electrode unit cell is determined to have failed the test, attaching a different current limiter to a similar electrode unit cell having the same capacitance C and the same voltage V as the electrode unit cell, wherein the different current limiter has a greater resistance than the current limiter at a temperature of 25°C; positioning an indenter above the location of the similar electrode unit cell into which similar conductive particles have been inserted; pressing the indenter into the similar electrode unit cell at a speed of 1.0 mm per second while preventing the similar electrode unit cell from moving; determining that the similar electrode unit cell having the different current limiter has failed the test when the similar electrode unit cell has ignited; and determining that the similar electrode unit cell having the different current limiter has passed the test when the similar electrode unit cell has not ignited.

[0291] Embodiment 104 A method for designing an electrode assembly for cycling between a charging state and a discharging state involves assembling an electrode unit cell having a certain type, the electrode unit cell comprising an electrode structure, a counter electrode structure, and a spacer between the electrode structure and the counter electrode structure, the type being determined by the voltage generated by the electrode unit cell, the capacitance of the electrode unit cell, and the materials used to construct the electrode structure, the counter electrode structure, and the spacer. A current limiter is electrically connected to the electrode structure and, at a temperature of 25 degrees Celsius (°C), the current limiter has a resistance of 0.25 ohms (Ω) or more. Conductive particles are inserted at the location of the electrode unit cell between the electrode structure and the counter electrode structure. An indenter is positioned above the location of the electrode unit cell where the conductive particles are inserted. The indenter is pressed into the electrode unit cell at a speed of 1.0 millimeter per second (mm) while preventing the electrode unit cell from moving in a way that pushes the conductive particles through the spacer and into contact with both the electrode unit cell and the counter electrode unit cell. An electrode unit cell with a current limiter fails the test if the electrode unit cell ignites, and passes the test if the electrode unit cell does not ignite. When an electrode unit cell with a current limiter passes the test, an electrode structure including a group of this type of electrode unit cell and a group of current limiters is assembled, and each current limiter is electrically connected to a different electrode unit cell.

[0292] Embodiment 105 Assembling similar electrode unit cells of the same type as the electrode unit cell, electrically connecting different current limiters to similar electrode structures, wherein at a temperature of 25°C, the different current limiters have a greater resistance than the current limiters, electrically connecting them, inserting similar conductive particles at the locations of the similar electrode unit cells, positioning an indenter above the locations of the similar electrode unit cells where the conductive particles are inserted, pressing the indenter into the similar electrode unit cells at a speed of 1.0 mm per second while preventing the similar electrode unit cells from moving, and causing the similar electrode unit cells to ignite. The method according to Embodiment 104, further comprising: determining that a similar electrode unit cell having different current limiters fails the test; determining that a similar electrode unit cell having different current limiters passes the test when the similar electrode unit cell does not ignite; and assembling an electrode structure including a group of electrode unit cells having the same type as the electrode unit cell and a group of different current limiters, wherein each different current limiter is electrically connected to a different electrode unit cell.

[0293] Embodiment 106 A thermal runaway current I passing through an electrode unit cell can cause failure of the electrode assembly, including the group of electrode unit cells, if an internal short circuit occurs in one of the electrode unit cells. trA method for determining the number of electrodes, wherein each electrode unit cell comprises an electrode structure, a counter electrode structure, and a separator structure between the electrode structure and the counter electrode structure. This method involves (a) inserting a conductive particle at the location of one electrode unit cell between the electrode structure and the counter electrode structure in an electrode assembly of M unit cells electrically connected in parallel, where M is a positive integer; (b) positioning an indenter above the electrode assembly at the location of the electrode unit cell in which the conductive particle was inserted; (c) pressing the indenter into the electrode unit cell at a speed of 1.0 mm per second, while preventing the electrode assembly from moving in a way that pushes the conductive particle through the spacer and brings it into contact with both the electrode unit cell and the counter electrode unit cell; (d) determining that the electrode assembly has failed the test if it ignites, and determining that the electrode assembly has passed the test if it does not ignite; (e) increasing M by 1 when the electrode assembly has passed the test, repeating steps (a) to (e), and proceeding to step (f) when the electrode assembly has failed the test; and (f) determining the thermal runaway current I based on the electrode assembly containing M-1 unit cells. tr This includes determining the following.

[0294] Embodiment 107 Based on an electrode assembly containing M-1 unit cells, the thermal runaway current I tr Determining the thermal runaway current I tr The method according to Embodiment 106, comprising calculating as a function of the voltage of an individual unit cell when fully charged and the short-circuit resistance of an electrode unit cell into which conductive particles are inserted when the electrode assembly contains M-1 unit cells.

[0295] Embodiment 108 A method for designing an electrode assembly comprising a group of electrode unit cells for cycling between a charging state and a discharging state is: (a) assembling M electrode unit cells, each electrode unit cell comprising an electrode structure, a counter electrode structure, and a separator structure between the electrode structure and the counter electrode structure, where M is a positive integer; (b) electrically connecting the M unit cells in the electrode assembly in parallel; (c) inserting a conductive particle at the location of one electrode unit cell between the electrode structure and the counter electrode structure; (d) positioning an indenter above the electrode assembly at the location of the electrode unit cell in which the conductive particle was inserted; and (e) electrode (f) Pressing the indenter into the electrode unit cell while preventing the assembly from moving in a way that pushes conductive particles through the spacer and into contact with both the electrode unit cell and the counter electrode unit cell; (g) Determining that the electrode assembly has failed the test if it ignites, and that it has passed the test if it does not ignite; (h) Increasing M by 1 when the electrode assembly has passed the test, repeating steps (a) to (g), and proceeding to step (h) when the electrode assembly has failed the test; (h) Determining the thermal runaway current I based on the electrode assembly containing M-1 unit cells. tr (i) In the event of a short circuit in an individual electrode unit cell, the current passing through that individual electrode unit cell is determined to be the thermal runaway current I tr This includes deciding to add a resistor that limits the value to less than a certain value in series with each electrode structure when a group of electrode unit cells is assembled within an electrode assembly.

[0296] Embodiment 109 Based on an electrode assembly containing M-1 unit cells, the thermal runaway current I tr Determining the thermal runaway current I tr The method according to Embodiment 108, comprising calculating as a function of the voltage of an individual unit cell when fully charged and the short-circuit resistance of an electrode unit cell into which conductive particles are inserted when the electrode assembly contains M-1 unit cells.

[0297] Embodiment 110 The added resistor is

number

[0298] Embodiment 111 An electrode assembly for cycling between a charged state and a discharged state within a normal operating temperature range, wherein the electrode assembly comprises a group of electrode structures, a group of counter electrode structures, a group of current limiters, an electrode busbar, and a counter electrode busbar. Each component of the electrode structure group comprises an electrode current collector, the electrode current collector is composed of the component units of the electrode structure group, and is electrically connected in parallel to the electrode busbar. Each component of the counter electrode structure group comprises a counter electrode current collector, the counter electrode current collector is composed of the component units of the counter electrode structure group, and is electrically connected in parallel to the counter electrode busbar. Each electrode current collector is electrically connected to the electrode busbar by a component unit of the group of current limiters, and each component unit of the electrode limiter group limits the current passing through the electrode current collector to which the component unit is attached when the electrode assembly is within a normal operating temperature range to a current threshold I tr It has sufficient resistance to limit it to less than [a certain value].

[0299] Embodiment 112 An electrode assembly for cycling between a charged state and a discharged state within a normal operating temperature range, wherein the electrode assembly comprises a group of electrode structures, a group of counter electrode structures, a group of current limiters, an electrode busbar, and a counter electrode busbar. Each component of the electrode structure group comprises an electrode current collector, the electrode current collector is composed of the components of the electrode structure group, and is electrically connected in parallel to the electrode busbar. Each component of the counter electrode structure group comprises a counter electrode current collector, the counter electrode current collector is composed of the components of the counter electrode structure group, and is electrically connected in parallel to the counter electrode busbar. Each component of the current limiter group includes a conductive adhesive that electrically connects the electrode current collector to the electrode busbar, the conductive adhesive having a resistance greater than zero ohms (Ω) when the electrode assembly is within a normal operating temperature range.

[0300] Embodiment 113 An electrode assembly for cycling between a charged state and a discharged state within a normal operating temperature range, wherein the electrode assembly comprises a group of electrode structures, a group of counter electrode structures, a group of current limiters, an electrode busbar, and a counter electrode busbar. Each component of the electrode structure group comprises an electrode current collector, the electrode current collector is composed of the components of the electrode structure group, and is electrically connected in parallel to the electrode busbar. Each component of the counter electrode structure group comprises a counter electrode current collector, the counter electrode current collector is composed of the components of the counter electrode structure group, and is electrically connected in parallel to the counter electrode busbar. The group of current limiters includes at least 10 current limiters. Each electrode current collector is electrically connected to the electrode busbar by the components of the group of current limiters, and each component of the group of current limiters has a resistance of 0.25 ohms (Ω) or more when the electrode assembly is within a normal operating temperature range.

[0301] Embodiment 114 An electrode assembly for cycling between a charged state and a discharged state within a normal operating temperature range, wherein the electrode assembly comprises a group of electrode structures, a group of counter electrode structures, a group of separator structures for electrically isolating the electrode structure group and the counter electrode structure group, a group of current limiters, an electrode busbar, and a counter electrode busbar. Each component unit of the electrode structure group is subject to a thermal runaway current I tr A threshold is present. A voltage V exists between the constituent units of the electrode structure group and the constituent units of the counter electrode structure group. The electrode busbar and the counter electrode busbar together have terminal resistance. Each constituent unit of the electrode structure group has electrode structure resistance and is equipped with an electrode current collector, the electrode current collector is composed of constituent units of the electrode structure group and is electrically connected in parallel to the electrode busbar. Each constituent unit of the counter electrode structure group is equipped with a counter electrode current collector, the counter electrode current collector is composed of constituent units of the counter electrode structure group and is electrically connected in parallel to the counter electrode busbar. Each constituent unit of the current limiter group is electrically connected between different electrode current collectors and electrode busbars, and when the electrode assembly is within the normal operating temperature range, each constituent unit of the current limiter group limits the current passing through the constituent unit of the electrode structure group associated with the constituent unit to I tr The resistor has a limiting resistance, which is determined as a function of V, the short-circuit resistance between one electrode structure and one adjacent counter electrode structure, the electrode structure resistance, the counter electrode structure resistance, the terminal resistance, and the number of constituent units of the electrode structure group connected to the electrode busbar, within the normal operating temperature range.

[0302] Embodiment 115 An electrode assembly according to any one of embodiments 1 to 54, further comprising at least one interface layer, the at least one interface layer being electrically connected between one or both of a) a constituent unit of an electrode current collector and a constituent unit of a group of current limiters, and b) a constituent unit of a group of current limiters and an electrode busbar.

[0303] Embodiment 116 The electrode assembly according to embodiment 115, wherein the interface layer includes a conductive coating.

[0304] Embodiment 117 The electrode assembly according to Embodiment 116, wherein the conductive coating includes a coating of carbon nanotubes.

[0305] Embodiment 118 The electrode assembly according to Embodiment 116, wherein the conductive coating includes a carbon-based coating.

[0306] Embodiment 119 An electrode assembly according to any one of embodiments 116 to 118, wherein a conductive coating is coated on one or both of the constituent units of the electrode current collector and the electrode busbars.

[0307] Embodiment 120 A secondary battery according to any one of embodiments 55 to 98, further comprising at least one interface layer, the at least one interface layer being electrically connected between one or both of a) a constituent unit of an electrode current collector and a constituent unit of a group of current limiters, and b) a constituent unit of a group of current limiters and an electrode busbar.

[0308] Embodiment 121 The secondary battery according to Embodiment 120, wherein the interface layer includes a conductive coating.

[0309] Embodiment 122 A secondary battery according to Embodiment 121, wherein the conductive coating includes a coating of carbon nanotubes.

[0310] Embodiment 123 A secondary battery according to Embodiment 122, wherein the conductive coating includes a carbon-based coating.

[0311] Embodiment 124 A secondary battery according to any one of embodiments 121 to 123, wherein a conductive coating is coated on one or both of the constituent units of the electrode current collector and the electrode busbars.

[0312] Embodiment 125 A method for assembling an electrode assembly, comprising stacking a group of unit cells on top of each other in the stacking direction, wherein each constituent unit of the group of unit cells includes an electrode structure, a separator structure, and a counter electrode structure, the electrode structure comprising an electrode current collector and an electrode active material layer, the counter electrode structure comprising a counter electrode current collector and a counter electrode active material layer, the electrode structure and the counter electrode structure extending in a longitudinal direction perpendicular to the stacking direction, and the ends of the electrode current collectors extending in the longitudinal direction beyond the electrode active material and separator structure, the method comprising: bending the end portions of each electrode current collector in a direction perpendicular to the longitudinal direction of the electrode structure to extend in the stacking direction or in the opposite direction to the stacking direction; positioning an electrode busbar extending in the stacking direction with its surface adjacent to the end portion of the electrode current collector; and applying heat and pressure to the electrode busbar to bond the end portions of the electrode current collectors to the busbar via an adhesive layer containing a resistant polymer material.

[0313] Embodiment 126 The method according to Embodiment 125, wherein the resistant polymer layer includes a thermoplastic material.

[0314] Embodiment 127 The method according to embodiment 125, wherein the adhesive layer is formed on the surface of the electrode busbar that is in contact with the end portion of the electrode current collector.

[0315] Embodiment 128 The method according to Embodiment 127, wherein the resistant polymer material comprises an adhesive polymer, and the adhesive layer comprises a conductive material suspended in the adhesive polymer.

[0316] Embodiment 129 The method according to Embodiment 128, wherein the conductive material comprises one or more of carbon black, nickel, copper, gold, silver, titanium, graphite, molybdenum, chromium, and aluminum.

[0317] Embodiment 130 The method according to Embodiment 128, wherein the conductive material includes metal-coated carbon fibers.

[0318] Embodiment 131 The method according to Embodiment 130, wherein the metal-coated carbon fiber includes nickel-coated carbon fiber.

[0319] Embodiment 132 The method according to Embodiment 130, wherein the metal-coated carbon fiber has length and diameter, and the aspect ratio of the length to the diameter of the metal-coated carbon fiber is 10:1 to 10,000:1 (including both ends).

[0320] Embodiment 133 The method according to Embodiment 132, wherein the aspect ratio is 50:1 to 5,000:1 (including both ends).

[0321] Embodiment 134 The method according to Embodiment 132, wherein the aspect ratio is 100:1 to 2,000:1 (including both ends).

[0322] Embodiment 135 The method according to Embodiment 128, wherein the melt flow index of the conductive adhesive, as determined according to ASTM D 1238 at 190°C, is 0.1 to 1000 grams (g) / 10 minutes (min).

[0323] Embodiment 136 The method according to Embodiment 135, wherein the melt flow index is 0.1 to 100 g / 10 min.

[0324] Embodiment 137 The method according to Embodiment 135, wherein the melt flow index is 0.5 to 20 g / 10 min.

[0325] Embodiment 138 The method according to Embodiment 128, wherein the melting point of the conductive adhesive is 40°C to 300°C.

[0326] Embodiment 139 The method according to Embodiment 138, wherein the melting point of the conductive adhesive is 60°C to 200°C.

[0327] Embodiment 140 The method according to Embodiment 138, wherein the melting point of the conductive adhesive is 70°C to 165°C.

[0328] Embodiment 141 The method according to Embodiment 125, wherein bending the end portion of each electrode current collector positions the electrode busbar in contact with the unbent end portion of each electrode current collector and applies pressure toward the electrode current collector in the stacking direction.

[0329] Embodiment 142 The method according to Embodiment 125, wherein the end portion of each counter electrode current collector extends beyond the counter electrode active material and separator structure in the longitudinal direction opposite to the end portion of the electrode current collector, and the method further includes bending the end portion of each counter electrode current collector so that it is substantially perpendicular to the longitudinal direction of the counter electrode structure and extends in the stacking direction or the opposite direction of the stacking direction, positioning a counter electrode busbar extending in the stacking direction such that the surface of the counter electrode busbar is in contact with the end portion of the counter electrode current collector, and attaching the counter electrode busbar to the end portion of the counter electrode current collector.

[0330] Embodiment 143 The method according to Embodiment 142, wherein attaching the counter electrode busbar to the end portion of the counter electrode current collector includes attaching the counter electrode busbar to the end portion of the counter electrode current collector with an adhesive.

[0331] Embodiment 144 The method according to Embodiment 142, wherein attaching the counter electrode busbar to the end portion of the counter electrode current collector includes attaching the counter electrode busbar to the end portion of the counter electrode current collector by welding or soldering.

[0332] Embodiment 145 The method according to Embodiment 142, wherein the surface of the counter electrode busbar in contact with the end portion of the counter electrode current collector has a resistive polymer layer disposed on the surface, and attaching the counter electrode busbar to the end portion of the counter electrode current collector includes applying heat and pressure to the counter electrode busbar to bond the end portion of the counter electrode current collector to the busbar via the resistive polymer layer.

[0333] This written description, using examples, discloses the invention including best modes and enables any person skilled in the art to practice the invention, including the manufacture and use of any device or system and the execution of any incorporated methods. The patentable scope of the present invention is defined by the claims and may include other examples found in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements that are not different from the literal words of the claims, or if they include equivalent structural elements with differences that are not substantially different from the literal words of the claims.

Claims

1. An energy storage device, A unit cell stacked along a stacking axis, each unit cell comprising an electrode separated from a counter electrode by a separator, the electrode comprising an electrode current collector and an electrode active material, the counter electrode comprising a counter electrode current collector and a counter electrode active material, the electrode and the counter electrode each extending in a longitudinal direction perpendicular to the stacking axis, the ends of the electrode current collectors extending longitudinally beyond the electrode active material and separator, and the ends of each electrode current collector bent toward the stacking axis in a direction different from the longitudinal direction of the electrode; An electrode busbar extending in a direction along the stacking axis, wherein its surface is adjacent to the end of each electrode current collector; and, An adhesive comprising a polymer material, wherein at least a portion of the end of each electrode current collector is bonded to the electrode busbar by the adhesive, (a) the polymer material is electrically resistant, (b) the polymer material comprises a conductive material suspended in the polymer material, (c) the electrode busbar is welded or soldered to the end of each electrode current collector, or (d) any combination of (a), (b), and (c); A device that includes this.

2. The device according to claim 1, wherein the polymer material is electrically resistant.

3. The device according to claim 1, wherein the polymer material comprises a conductive material suspended in the polymer material.

4. The device according to claim 3, wherein the conductive material includes a metal.

5. The device according to claim 3, wherein the conductive material includes carbon fiber.

6. The device according to claim 1, wherein the electrode busbars are welded or soldered to the ends of each electrode current collector.

7. The device according to claim 1, wherein the polymer material comprises an acid group.

8. The device according to claim 1, wherein the polymer material comprises a polymer blend.

9. The device according to claim 1, wherein the polymer material comprises a copolymer.

10. The device according to claim 1, wherein the adhesive comprises a film or sheet.

11. The device according to claim 1, wherein the electrode active material comprises silicon or graphite, and the electrode is an anode.

12. The device according to claim 1, wherein the electrode active material contains silicon and the electrode is an anode.

13. The device according to claim 1, wherein the electrode active material comprises silicon and carbon, and the electrode is an anode.

14. The device according to claim 1, wherein the electrode active material includes nanowires.

15. The device according to claim 1, wherein the normal operating temperature range of the device is -30 degrees Celsius (°C) to +80 degrees Celsius.

16. The device is the device according to claim 1, comprising zinc.

17. The device according to claim 1, wherein each of the electrode and the counter electrode has (A) a length of 5 mm to 500 mm, (B) a width of 0.01 mm to 2.5 mm, and (C) a height of 0.05 mm to 25 mm, and (II) the separator has a thickness of 4 micrometers to 50 micrometers.

18. The device according to claim 1, wherein each electrode and each counter electrode has a first length-to-width ratio of at least 5:1 or greater, a second length-to-height ratio of at least 5:1 or greater, and a third height-to-width ratio of at least 0.4:1 or greater.

19. The device according to claim 1, wherein the amount of conductive material loaded into the polymer material is 1% to 50%.

20. The device according to claim 1, comprising a secondary battery including a unit cell, wherein the secondary battery is a lithium-based battery.

21. A method for manufacturing a device according to any one of claims 1 to 20, comprising using one or more apparatus for manufacturing the device.

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