Electrode assembly structure, secondary battery, and manufacturing method

Abstract

A method is provided for manufacturing a structure comprising an electrode assembly having a porous electrically insulating material and first and second end plates. The electrode assembly comprises a group of unit cells stacked in succession in a stacking direction and first and second opposite longitudinal end faces separated along the stacking direction. The first and second end plates are separated in the stacking direction and overlie the first and second longitudinal end faces. According to an embodiment of the structure, (i) each unit cell comprises an electrode structure, a counter electrode structure, and an electrically insulating separator between the electrode structure and the counter electrode structure, (ii) the electrode structure, the counter electrode structure, and the electrically insulating separator in each unit cell have first and second opposite vertical end faces separated in a vertical direction, and (iii) the vertical direction is orthogonal to the stacking direction. The method includes providing the porous electrically insulating material to the electrode assembly using a stencil.

Description

[Technical Field]

[0001] Cross-reference of related applications This application claims the interests of U.S. Provisional Patent Application No. 63 / 293,272, filed December 23, 2021, U.S. Provisional Patent Application No. 63 / 293,391, filed December 23, 2021, U.S. Provisional Patent Application No. 63 / 168,638, filed March 31, 2021, and U.S. Provisional Patent Application No. 63 / 168,454, filed March 31, 2021, which are incorporated herein by reference in their entirety.

[0002] This disclosure generally relates to methods and structures such as electrode assemblies for use in energy storage devices such as secondary batteries, energy storage devices employing such structures, and methods for manufacturing such structures and energy devices. [Background technology]

[0003] A rocking chair battery, or inserted battery, is a type of energy storage device in which carrier ions, such as lithium ions, sodium ions, potassium ions, calcium ions, or magnesium ions, move between a positive electrode and a negative electrode via an electrolyte, such as a solid or liquid electrolyte. A battery comprises a single battery cell or two or more battery cells electrically coupled to form a battery, each battery cell may include a positive electrode, a negative electrode, an electrical isolation separator, and an electrolyte. In a solid-state battery, a single solid material can function as both the electrical isolation separator and the electrolyte.

[0004] In a rocking chair battery cell, both the positive and negative electrodes contain materials that allow carrier ions to be inserted and removed. When the cell is discharged, carrier ions are removed from the negative electrode and inserted into the positive electrode. When the cell is charged, the reverse process occurs, with carrier ions being removed from the positive electrode and inserted into the negative electrode.

[0005] However, as part of the carrier ion desorption and insertion processes that occur during the charging and / or discharging of secondary batteries, at least a portion of the carrier ions may be irreversibly lost in electrochemical reactions. For example, decomposition products containing lithium (or other carrier ions) and electrolyte components, known as the solid electrolyte interface phase (SEI), may form on the surface of the negative electrode. The formation of this SEI layer traps carrier ions, removing them from the circulation operation of the secondary battery and leading to irreversible capacity loss. Other chemical and electrochemical processes in the electrode assembly may also influence carrier ion loss. Such losses often occur during the initial charging step, performed as part of the secondary battery formation process, for example, due to the formation of the SEI layer in the initial charging step, resulting in significantly lower capacity compared to the amount of carrier ions included in the secondary battery preformation.

[0006] Methods for replenishing electrodes in secondary batteries are described (see, for example, U.S. Patent No. 10,770,760 by Castledine et al., which is incorporated herein by reference in its entirety). However, there remains a need for new methods and structures for effectively and efficiently supplying carrier ions to secondary batteries in order to replenish lost carrier ions.

[0007] Among the various embodiments of this disclosure are methods for manufacturing structures including electrode assemblies for energy storage devices such as secondary batteries, fuel cells, and electrochemical capacitors, which can restore capacity lost as a result of SEI formation and / or mechanical or electrical degradation of the negative and / or positive electrodes. Advantageously, energy storage devices according to embodiments of this disclosure offer increased cycle life, higher energy density, and / or increased discharge rate. [Overview of the project]

[0008] In short, one aspect of the present disclosure relates to a method for manufacturing a structure comprising an electrode assembly and first and second end plates, wherein the electrode assembly comprises a porous electrical insulating material. The electrode assembly comprises a group of unit cells stacked continuously in the stacking direction and first and second longitudinal end faces separated on opposite sides along the stacking direction, the first and second end plates separated in the stacking direction and overlapping the first and second longitudinal end faces, (i) each unit cell comprises an electrode structure, a counter electrode structure, and an electrical insulating separator between the electrode structure and the counter electrode structure, (ii) the electrode structure, counter electrode structure, and electrical insulating separator within each unit cell have first and second vertical end faces separated on opposite sides vertically, and (iii) the vertical direction is perpendicular to the stacking direction. The method comprises providing the porous electrical insulating material to the electrode assembly using a stencil.

[0009] A further aspect of the present disclosure relates to a structure comprising an electrode assembly and first and second end plates, wherein the electrode assembly comprises a porous electrical insulating material. The electrode assembly comprises a group of unit cells stacked in a continuous manner in the stacking direction and first and second longitudinal end faces separated on opposite sides along the stacking direction, the first and second end plates separated in the stacking direction and overlapping the first and second longitudinal end faces, (i) each unit cell comprises an electrode structure, a counter electrode structure, and an electrical insulating separator between the electrode structure and the counter electrode structure, (ii) the electrode structure, counter electrode structure, and electrical insulating separator within each unit cell have first and second vertical end faces separated on opposite sides vertically, and (iii) the vertical direction is perpendicular to the stacking direction. According to one aspect, the first and second vertical end faces are at least partially covered with the porous electrical insulating material using a stencil.

[0010] Other aspects, features, and embodiments of this disclosure will be discussed in part in the following description and drawings, and will be evident in part in the drawings. [Brief explanation of the drawing]

[0011] [Figure 1A] This is a perspective view of one embodiment of an electrode assembly having a set of electrode constraints. [Figure 1B] This is a schematic diagram of one embodiment of a three-dimensional electrode assembly for a secondary battery. [Figure 1C] Figure 1B is an inserted cross-sectional view of the electrode assembly. [Figure 1D] This is a cross-sectional view of the electrode assembly in Figure 1B, obtained along line D in Figure 1B. [Figure 2] An exploded view illustrating one embodiment of an energy storage device or secondary battery comprising an electrode assembly and a set of electrode constraints is provided. [Figure 3A] An example of a cross-section in the ZY plane of an electrode assembly embodiment having an auxiliary electrode is shown. [Figure 3B] An example of a top view in the XY plane of an embodiment of an electrode assembly having a set of electrode constraints with an internal opening is shown. [Figure 4] This is a cross-sectional view of one embodiment of an electrode assembly containing a porous electrical insulating material. [Figure 5] These are perspective and cross-sectional views of an embodiment of a secondary battery comprising a wound electrode assembly. [Figure 6A] This is a top view with insets of one embodiment of an electrode assembly, showing before (6A) and after (6B) providing porous electrical insulating material to the first and / or second vertical end faces of the electrode and / or counter electrode of the electrode assembly. [Figure 6B] This is a top view with insets of one embodiment of an electrode assembly, showing before (6A) and after (6B) providing porous electrical insulating material to the first and / or second vertical end faces of the electrode and / or counter electrode of the electrode assembly. [Figure 7A] A cross-section of an embodiment of an electrode assembly obtained along the line A-A' as shown in Figure 1A is illustrated, illustrating elements of embodiments of a primary growth constraint system and a secondary growth constraint system. [Figure 7B]A cross-section of one embodiment of an electrode assembly obtained along the line B-B' as shown in Figure 1A is illustrated, illustrating elements of embodiments of a primary growth constraint system and a secondary growth constraint system. [Figure 7C] A cross-section of one embodiment of an electrode assembly obtained along the line A-A' as shown in Figure 1A is illustrated, and elements of embodiments of a primary growth constraint system and a secondary growth constraint system are further illustrated. [Figure 8] This is a top view of one embodiment of an electrode assembly having a secondary growth constraint system and having a porous electrical insulating material on the first and / or second vertical end faces of the electrodes and / or opposing electrodes of the electrode assembly. [Figure 9] This is a schematic diagram illustrating part of the process of providing porous electrical insulating material to the first and / or second vertical end faces of the electrodes and / or counter electrodes of an electrode assembly. [Figure 10] This is a perspective view of one embodiment of a stencil on an electrode assembly. [Figure 11A] This is a cross-sectional view of one embodiment of an electrode assembly positioned between a set of bumpers. [Figure 11B] This is a side view of an end plate embodiment. [Figure 11C] This is a side view of an end plate embodiment. [Figure 12] This is a cross-sectional view of one embodiment of a section of an electrode assembly having a stencil covering the peripheral portion of the electrode assembly. [Figure 13] This is a cross-sectional view of another embodiment of a section of an electrode assembly having a stencil covering the peripheral portion of the electrode assembly. [Figure 14] This is a cross-sectional view of another embodiment of a section of an electrode assembly having a stencil covering the peripheral portion of the electrode assembly. [Figure 15] This is a side view of a section of one embodiment of an electrode assembly having an end plate with a curved profile. [Figure 16]This is another side view of a section of an electrode assembly having an end plate with a curved profile. [Modes for carrying out the invention]

[0012] Other aspects, embodiments, and features of the subject matter of the present invention will become apparent from the following detailed description, in conjunction with the accompanying drawings. The accompanying drawings are schematic and are not intended to be drawn to scale. For clarity, not every element or component is represented in every drawing, nor are every element or component of each embodiment of the subject matter of the present invention shown where the illustration is not necessary for those skilled in the art to understand the subject matter of the present invention.

[0013] definition As used herein, “a,” “an,” and “the” (i.e., singular) refer to multiple referents unless the context explicitly indicates otherwise. For example, in one instance, the reference to “electrode” includes both a single electrode and multiple similar electrodes.

[0014] 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 in the following specification 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.

[0015] As used herein in the context of the state of a secondary battery, “charged state” means a state in which a secondary battery is charged to at least 75% of its rated capacity. For example, a battery may be charged to at least 80% of its rated capacity, at least 90% of its rated capacity, and even to at least 95% of its rated capacity, such as 100% of its rated capacity.

[0016] As used herein, "C-rate" refers to a measure of the rate at which a secondary battery is discharged, and is defined as the discharge current divided by the theoretical current draw amount that the battery would deliver in one hour to its nominal rated capacity. For example, a C-rate of 1C represents the discharge current that discharges the battery in one hour, a rate of 2C represents the discharge current that discharges the battery in half an hour, a rate of C / 2 represents the discharge current that discharges the battery in two hours, and so on.

[0017] As used herein in the context of the state of a secondary battery, “discharge state” refers to a state in which a secondary battery has been discharged to less than 25% of its rated capacity. For example, a battery may be discharged to less than 20% of its rated capacity, such as less than 10% of its rated capacity, and even less than 5% of its rated capacity, such as 0% of its rated capacity.

[0018] As used herein in the context of cycles of 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 returning it to a discharged state to complete the cycle, as in a charging cycle. A single cycle may also include discharging the battery from a charged state to a discharged state, and then returning it to a charged state to complete the cycle, as in a discharge cycle.

[0019] With regard to the term "electrode" as used in "electrode structure" or "electrode active material," it should be understood that such structures and / or materials may, in certain embodiments, correspond to "negative electrodes," such as "negative electrode structure," "anode structure," "negative electrode active material," and "anode" as used in "anode active material." With regard to the term "counter electrode" as used in "counter electrode structure" or "counter electrode active material," it should be understood that such structures and / or materials may, in certain embodiments, correspond to "positive electrodes," such as "positive electrode structure," "cathode structure," "positive electrode active material," and "cathode active material." That is, where preferable, any embodiment described for an electrode and / or counter electrode may correspond to the same embodiment in which the electrode and / or counter electrode are specifically negative and / or positive electrodes, comprising the corresponding structures and materials, respectively.

[0020] 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. Therefore, the description of the elements of the subject matter of the present invention 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 of the present invention.

[0021] As used herein, “longitudinal,” “transverse,” and “vertical” refer to directions perpendicular to each other (i.e., each is orthogonal to the others). For example, as used herein, “longitudinal,” “transverse,” and “vertical” may generally be parallel to the longitudinal, transverse, and vertical axes of a Cartesian coordinate system used to define a three-dimensional aspect or orientation, respectively.

[0022] With respect to an electrode assembly, the “ferret diameter” as referred herein is defined as the distance between two parallel planes that restrict the electrode assembly, measured perpendicular to the two planes. For example, the ferret diameter of an electrode assembly in the longitudinal direction is the distance measured longitudinally between two parallel planes that restrict the electrode assembly perpendicular to the longitudinal direction. As another example, the ferret diameter of an electrode assembly in the transverse direction is the distance measured transversely between two parallel planes that restrict the electrode assembly perpendicular to the transverse direction. As yet another example, the ferret diameter of an electrode assembly in the vertical direction is the distance measured vertically between two parallel planes that restrict the electrode assembly perpendicular to the vertical direction.

[0023] As used herein with respect to an end plate, “maximum vertical range” is defined as a point on any vertical surface of the end plate that extends the maximum distance along the vertical axis in either vertical direction. For example, for an end plate having first and second vertical end faces separated vertically, the first maximum vertical range may be a point on the first vertical end face that extends the maximum distance along the vertical axis of the first vertical direction to any point on the first vertical end face, and the second maximum vertical range may be a point on the second vertical end face that extends the maximum distance along the vertical axis of the second vertical direction opposite to the first vertical direction to any point on the second vertical end face.

[0024] As used herein in the context of cycling between the charged and discharged states of a secondary battery, “repeated cycling” means cycling two or more times from a discharged state to a charged state, or from a charged state to a discharged state. For example, repeated cycling between a charged and discharged state may include at least two cyclings from a discharged state to a charged state, such as charging from a discharged state to a charged state, discharging back to a discharged state, recharging back to a charged state, and a final discharge back to a discharged state. Another example is repeated cycling between a charged and discharged state which may include at least two dischargings from a charged state to a discharged state, charging back to a charged state, recharging back to a discharged state, and a final charge back to a charged state. Further examples include repeated cycling between a charged and discharged state which may include cycling at least 25, 50, 100, 300, 500, and even 1000 times from a discharged state to a charged state.

[0025] As used herein in the context of secondary batteries, “rated capacity” refers to the capacity of a secondary battery to supply a specified current over a specified period, measured under standard temperature conditions (25°C). For example, rated capacity may be measured in ampere-hours by determining the current output for a specified time, or by determining the time for which a specified current can be output and taking the product of the current and time. For example, for a battery rated at 20 ampere-hours, if the current is specified at 2 amperes relative to the rating, the battery may be understood to be a battery that will provide a current output for 10 hours. Conversely, if the time is specified at 10 hours relative to the rating, the battery may be understood to be a battery that will output 2 amperes for 10 hours. In particular, the rated capacity of a secondary battery may also be given as the rated capacity at a specified discharge current, such as a C-rate, where the C-rate is a measure of the rate at which the battery is discharged relative to its capacity. For example, a C-rate of 1C indicates the discharge current at which the battery is discharged in 1 hour, 2C indicates the discharge current at which the battery is discharged in 1 / 2 hour, C / 2 indicates the discharge current at which the battery is discharged in 2 hours, and so on. Therefore, for example, if a battery is rated at 20 amp-hours with a C rate of 1C, a discharge current of 20 amps will be applied for 1 hour; if a battery is rated at 20 amp-hours with a C rate of 2C, a discharge current of 40 amps will be applied for 1 / 2 hour; and if a battery is rated at 20 amp-hours with a C / 2 C rate, a discharge current of 10 amps will be applied for 2 hours.

[0026] In the context of electrode assembly dimensions, the term "maximum width" (W) is used herein. EA This corresponds to the maximum width of the electrode assembly, measured longitudinally from a point opposite the longitudinal end face of the electrode assembly.

[0027] In the context of the dimensions of electrode assemblies, the term "maximum length" (L) is used herein. EA This corresponds to the maximum length of the electrode assembly measured laterally from a point on the opposite side of the lateral plane of the electrode assembly.

[0028] In the context of electrode assembly dimensions, "maximum height" (H) is used herein. EAThis corresponds to the maximum height of the electrode assembly, measured laterally from a point on the opposite side of the lateral plane of the electrode assembly.

[0029] Detailed explanation Generally, this disclosure relates to an energy storage device 100, such as a secondary battery 102, which cycles between a charged state and a discharged state, as shown, for example, in Figures 1A to 1D and Figure 2. The secondary battery 102 includes a battery housing 104, an electrode assembly 106, carrier ions, and a non-aqueous liquid electrolyte within the battery housing. In certain embodiments, the secondary battery 102 also includes a set of electrode constraints 108 that restrain the growth of the electrode assembly 106. The restricted growth of the electrode assembly 106 may be a macroscopic increase in one or more dimensions of the electrode assembly 106.

[0030] Embodiments of this disclosure provide a method for manufacturing an electrode assembly that facilitates the transfer of carrier ions from an auxiliary electrode 686 equipped with a carrier ion source to an electrode assembly 106, as shown, for example, in Figure 3A. As will be discussed in more detail herein, according to certain embodiments, the transfer of carrier ions is performed as part of an initial formation process performed to activate a secondary battery comprising the electrode assembly. According to other embodiments, the transfer of carrier ions is performed as part of a process to replenish carrier ions in the electrode assembly lost due to the formation of a solid electrolyte interface phase (SEI) during the initial formation process and / or during circulation between charged and discharged states. In certain embodiments, the method for manufacturing an electrode assembly may provide the application of a porous electrical insulating material to the electrode assembly, which enables the permeable transfer of carrier ions.

[0031] Referring again to Figures 1A to 1D, in one embodiment, the electrode assembly 106 includes a group of unit cells 504 stacked continuously in the stacking direction (i.e., stacking direction D in Figure 1B). Each constituent unit of the group of unit cells comprises an electrode structure 110, a counter electrode structure 112, and an electrical insulating separator 130 between the electrode structure and the counter electrode structure, electrically insulating the electrode structure 110 and the counter electrode structure 112 from each other. In one example, as shown in Figure 1B, the electrode assembly 106 includes a stacked continuous group of unit cells 504, each having an alternating arrangement of electrode structures 110 and counter electrode structures 112. Figure 1C is an inset showing a secondary battery 102 having the electrode assembly 106 of Figure 1B, and Figure 1D is a cross-section of the secondary battery having the electrode assembly 106 of Figure 1B. Other arrangements of the stacked continuous group of unit cells 504a, 504b can also be provided.

[0032] In one embodiment, the electrode structure 110 comprises an electrode active material layer 132 and an electrode current collector 136, as shown in Figures 1A to 1D, for example. For example, the electrode structure 110 may include an electrode current collector 136 disposed between one or more electrode active material layers 132. According to one embodiment, the electrode active material layer 132 includes an anode active material, and the electrode current collector 136 includes an anode current collector. Similarly, in one embodiment, the counter electrode structure 112 comprises a counter electrode active material layer 138 and a counter electrode current collector 140. For example, the counter electrode structure 112 may include a counter electrode current collector 140 disposed between one or more counter electrode active material layers 138. According to one embodiment, the counter electrode active material layer 138 includes a cathode active material, and the counter electrode current collector 140 includes a cathode current collector. Furthermore, it should be understood that the electrode structure 110 and the counter electrode structure 112 are not limited to the specific embodiments and structures described herein, and other configurations, structures, and / or materials not specifically described herein may also be provided for forming the electrode structure 110 and the counter electrode structure 112. According to a particular embodiment, each unit cell 504a, 504b in a group of unit cells comprises, in a stacked column, a unit cell portion of an electrode current collector 136, an electrode structure 110 comprising an electrode active material layer 132, an electrical insulating separator 130 between the electrode and the counter electrode active material layer, a counter electrode structure 112 comprising a counter electrode active material layer 138, and a unit cell portion of a counter electrode current collector 140. In certain embodiments, the order of the unit cell portions of the electrode current collector, electrode active material layer, separator, counter electrode active material layer, and counter electrode current collector is reversed with respect to adjacent unit cells in a stacked column, as shown, for example, in Figure 1C, so that portions of the electrode current collector and / or counter electrode current collector are shared between adjacent unit cells.

[0033] According to embodiments shown in Figures 1A to 1D, the constituent units of the electrode structure group 110 and the counter electrode structure group 112 are arranged in alternating arrangements having alternating arrangement directions corresponding to the stacking direction D. The electrode assembly 106 according to this embodiment further includes a longitudinal axis, a transverse axis, and a vertical axis perpendicular to each other, with the longitudinal axis A EAGenerally, the vertical axis A corresponds to or is parallel to the stacking direction D of the constituent units of the electrode structure group and the counter electrode structure group. As shown in the embodiment in Figure 1B, EA The horizontal axis is shown as corresponding to the Y-axis, the horizontal axis as corresponding to the X-axis, and the vertical axis as corresponding to the Z-axis.

[0034] According to embodiments disclosed herein, the electrode structure 110, counter electrode structure 112, and electrical insulation separator 130 within each unit cell 504 of the unit cell group have first and second vertical end faces that are separated on opposite sides in a vertical direction perpendicular to the stacking direction of the unit cell group. For example, referring to Figures 1C and 4, the electrode structure 110 in each component unit of the unit cell group may have a first vertical end face 500a and a second vertical end face 500b that are separated on opposite sides in a vertical direction, the counter electrode structure 110 in each component unit of the unit cell group may have a first vertical end face 501a and a second vertical end face 501b that are separated on opposite sides in a vertical direction, and the electrical insulation separator 130 may have a first vertical end face 502a and a second vertical end face 502b that are separated on opposite sides in a vertical direction. In another embodiment, the constituent units of the unit cell group have a first vertical edge 503a and a second vertical edge 503b within each unit cell constituent unit, which extend across and provide the first and second vertical end faces opposite the electrode structure 110, the electrical insulation separator 130, and the counter electrode structure 112. Referring to Figures 3A and 4, in yet another embodiment, the first vertical end faces 500a and 501a of the electrode structure 110 and the counter electrode structure 112 within the same unit cell group constituent unit are offset perpendicularly from each other to form a first recess 505a, and the second vertical end faces 500b and 501b of the electrode structure 110 and the counter electrode structure 112 within the same unit cell group constituent unit are offset perpendicularly from each other to form a second recess 505b. For example, the first and second vertical end faces of the counter electrode can be recessed inward and / or offset relative to the first and second vertical end faces of the respective electrodes within the same unit cell group constituent unit. Referring to Figure 3A, in one embodiment, the constituent unit of the unit cell group comprises a counter electrode active material layer 138 having a first vertical end face 501a and a second vertical end face 501b that are recessed inward relative to the first and second vertical end faces of the electrode active material layer 132 and / or the electrical insulating separator 130.

[0035] According to one embodiment, the electrode assembly 106 further comprises a porous electrical insulating material 508 covering the first vertical end faces 500a, 501a and / or second vertical end faces 500b, 501b of the electrode structure 110 and / or counter electrode structure 112 of the constituent units of the unit cell group 504. For example, as shown in Figures 3A and 4, the porous electrical insulating material 508 may be located in one or more of the first recesses 505a and second recesses 505b formed by the vertical offset of the electrode structure 110 and counter electrode structure 112 within the unit cell constituent unit. According to a particular embodiment, the porous electrical insulating material has a porosity in the range of 20% to 60% (percentage of pore volume per total volume of porous electrical insulating material). According to a particular embodiment, the porous electrical insulating material 508 can provide an ion conduction structure and can provide a pathway for carrier ions supplied to the constituent units of the unit cell group by the auxiliary electrode.

[0036] According to one embodiment of the present disclosure, a method is provided for manufacturing a structure 101 comprising an electrode assembly 106 and having a porous electrical insulating material 508, as shown, for example, in Figure 4. Referring to Figures 11-12, which will be discussed in more detail herein, according to a particular embodiment, the electrode assembly 106 comprises a group of unit cells 504 stacked continuously in the stacking direction, and a first longitudinal end face 116 and a second longitudinal end face 118 located on opposite sides separated along the stacking direction. According to a particular embodiment, the structure 101 further comprises a first end plate 180 and a second end plate 182 separated in the stacking direction and overlapping the first longitudinal end face 116 and the second longitudinal end face 118. According to a particular embodiment of this method and / or structure, (i) each unit cell 504 comprises an electrode structure 110, a counter electrode structure 112, and an electrical insulating separator 130 between the electrode structure 110 and the counter electrode structure 112; (ii) the electrode structure 110, the counter electrode structure 112, and the electrical insulating separator 130 within each unit cell 504 have first and second vertical end faces (500a, 500b), (501a, 501b), (502a, 502b) on opposite sides separated vertically; and (iii) the vertical direction is perpendicular to the stacking direction. According to a particular embodiment, this method includes using a stencil 700 to provide a porous electrical insulating material 508 to the electrode assembly 106.

[0037] Referring to Figures 11A to 11C and Figure 12, in one embodiment, the first end plate 180 and the second end plate 182 correspond to the first primary growth constraint 154 and the second primary growth constraint 156 of the primary growth constraint system, as further described herein. According to one embodiment, the first end plate 180 and the second end plate 182 each have a vertical thickness t of the cross-sectional area in a plane (e.g., the XZ plane) perpendicular to the stacking direction. EP The first vertical thickness t of the first cross-sectional area 1803 of each of the first end plates and the second end plates in the inner region 1801 of each of the first end plates and the second end plates adjacent to each of the stacked continuous unit cells EP1is greater than the second vertical thickness t of the second cross-sectional area 1804 in the second region 1802 of the first end plate and the second end plate that are outside each of the first regions in the stacking direction. In another embodiment, each of the first end plate 180 and the second end plate 182 has a cross-sectional area in a plane orthogonal to the stacking direction having a maximum vertical thickness t for each end plate, and each has a maximum vertical thickness t. In one embodiment, each of the first end plate 180 and the second end plate 182 also has a first and a second vertical end face region (1806a, 1806b) on the first and second vertical side faces (1850a, 1850b) that are on opposite sides of each of the first end plate 180 and the second end plate 182, which coincides with the respective maximum vertical thickness t. In another embodiment, each of the first and second end plates has a first and a second vertical end face region (1806a, 1806b) that coincides with the respective first and second maximum vertical ranges (1805a, 1805b) on the first and second vertical side faces (1850a, 1850b) that are on opposite sides of the first end plate 180 and the second end plate 182. In a particular embodiment, one or more of the first vertical end face region 1806a and the second vertical end face region 1806b of each end plate that coincides with the first and second maximum vertical ranges of that end plate may also coincide with the maximum vertical thickness t of that end plate at the same time. EP2 is greater than. In another embodiment, each of the first end plate 180 and the second end plate 182 has a cross-sectional area in a plane orthogonal to the stacking direction having a maximum vertical thickness t for each end plate, and each has a maximum vertical thickness t. EP In a plane orthogonal to the stacking direction having a maximum vertical thickness t for each end plate, each has a maximum vertical thickness t. EPMAX In one embodiment, each of the first end plate 180 and the second end plate 182 also has a first and a second vertical end face region (1806a, 1806b) on the first and second vertical side faces (1850a, 1850b) that are on opposite sides of each of the first end plate 180 and the second end plate 182, which coincides with the respective maximum vertical thickness t. EPMAX In one embodiment, each of the first end plate 180 and the second end plate 182 also has a first and a second vertical end face region (1806a, 1806b) on the first and second vertical side faces (1850a, 1850b) that are on opposite sides of each of the first end plate 180 and the second end plate 182, which coincides with the respective maximum vertical thickness t. EPMAX In a particular embodiment, one or more of the first vertical end face region 1806a and the second vertical end face region 1806b of each end plate that coincides with the first and second maximum vertical ranges of that end plate may also coincide with the maximum vertical thickness t of that end plate at the same time.

[0038] Referring to Figures 10 to 12, in one embodiment, the method includes (a) positioning a stencil 700, which comprises a stencil frame 701 defining a stencil opening 702 on a first end plate 180 and a second end plate 182, such that the stencil frame 701 covers at least a portion of the perimeter 1853 of the electrode assembly 106, so that the first vertical end faces 500a, 501a of the electrode structures 110 and counter electrode structures 112 of the constituent units of the group of unit cells 504 are exposed through the stencil opening 702. In another embodiment, the method includes (a) positioning a stencil 700, which comprises a stencil frame 701 defining a stencil opening 702 on a first end plate 180 and a second end plate 182, such that the upper surface 703 of the stencil frame 701 is the maximum vertical thickness t of each of the first end plate 180 and the second end plate 182 in the vertical direction. EPMAX The stencil 700 is positioned on the first end plate 180 and the second end plate 182 such that it does not exceed the first vertical end face region 1806a of each of the first and second end plates, which coincides with the first maximum vertical range 1805a of each of the first and second end plates. In another embodiment, this method includes (a) positioning the stencil 700 on the first end plate 180 and the second end plate 182, which includes a stencil frame 701 defining a stencil opening 702, such that the stencil is positioned on the first and second end plates such that the upper surface 703 of the stencil frame does not exceed the first vertical end face region 1806a of the first and second end plates, which coincides with the first maximum vertical range 1805a of each of the first and second end plates, which lies on the same vertical side surface of the electrode assembly as the upper surface of the stencil frame.

[0039] In one embodiment, the method further includes (b) coating the porous electrical insulating material 508 through the stencil opening 702 to at least partially and even completely cover the first vertical end faces 500a, 501a of the electrode structure 110 or counter electrode structure 112 of the constituent unit of the unit cell group. In another embodiment, the method includes (b) coating the porous electrical insulating material 508 through the stencil opening 702 to at least partially and even completely cover the first vertical end face 501a of the counter electrode structure 112 of the constituent unit of the unit cell group. In some embodiments, each electrode structure 110 of the constituent unit of the group of unit cells 504 comprises a layer of electrode active material 132, and each counter electrode structure 112 of the constituent unit of the unit cell group comprises a layer of counter electrode active material 138, and the method includes (b) coating the porous electrical insulating material 508 through the stencil opening 702 to cover the first vertical end face 507a of the layer of counter electrode active material of the constituent unit of the unit cell group.

[0040] In one embodiment, this method further includes (c) positioning the stencil 700 on the first end plate 180 and the second end plate 182 such that the second vertical end faces 500b, 501b of the electrode structure 110 and the counter electrode structure 112 of the constituent units of the unit cell group are exposed through the stencil opening 702. In one embodiment, the stencil 700 is positioned on the first end plate 180 and the second end plate 182 such that the upper surface 703 of the stencil frame 701 does not exceed the first vertical end face region 1806a of the first and second end plates, which coincide with the upper surface 703 of the stencil frame 701 and the respective second maximum vertical range 1805b of each of the first and second end plates that are on the same vertical side surface 1850a of the electrode assembly 106. In one embodiment, the upper surface 703 of the stencil frame 701 is within the maximum vertical thickness t of the first and second end plates. EPMAX The stencil 700 is positioned on the first end plate 180 and the second end plate 182 such that it does not exceed the second vertical end face region 1806b of the first end plate 180 and the second end plate 182, which coincide with the stencil 700.

[0041] In one embodiment, the method further includes (d) coating the porous electrical insulating material 508 through the stencil opening 702 to at least partially and even completely cover the second vertical end faces 500b, 501b of the electrode structure 110 or counter electrode structure 112 of the constituent units of the unit cell group. In another embodiment, the method includes (d) coating the porous electrical insulating material 508 through the stencil opening 702 to at least partially and even completely cover the second vertical end faces 501b of the counter electrode structures 110, 112 of the constituent units of the unit cell group. In some embodiments, each electrode structure 110 of the constituent units of the group of unit cells 504 comprises a layer of electrode active material 132, and each counter electrode structure 112 of the constituent units of the group of unit cells 504 comprises a layer of counter electrode active material 138, and the method includes (d) coating the porous electrical insulating material 508 through the stencil opening 702 to cover the second vertical end face 507b of the layer of counter electrode active material of the constituent units of the unit cell group.

[0042] In one embodiment, the method further includes applying a porous electrical insulating material 508 to the electrode assembly 106 and then rotating the electrode assembly 106 around a vertically perpendicular axis (e.g., the X-axis or Z-axis). In some embodiments, the electrode assembly is rotated following the application of the porous electrical insulating material to the first vertical end faces 500a, 501a of the electrode structure or counter electrode structure, and the method further includes applying the porous electrical insulating material to the second vertical end faces 500b, 501b of the electrode structure or counter electrode structure after rotation. According to the method disclosed herein, in one embodiment, the method includes rotating the electrode assembly 106 around a longitudinal axis in the stacking direction, or a transverse axis in the transverse direction perpendicular to the stacking direction and the vertical direction, thereby vertically reversing the positions of the first and second vertical end faces (500a, 500b), (501a, 501b) of the electrode structure and counter electrode structure.

[0043] According to the method disclosed herein, in one embodiment, the maximum vertical thickness of the electrode structure 110 and the counter electrode structure 112 in a cross-sectional area perpendicular to the stacking direction is the maximum vertical thickness t of the first end plate 180 and the second end plate 182 in the vertical direction.EPMAX It shall not exceed . In another embodiment, the maximum vertical thickness of the opposing electrode structure 112 in a cross-sectional area perpendicular to the stacking direction is the maximum vertical thickness t of the first end plate 180 and the second end plate 182 in the vertical direction. EPMAX It shall not exceed t. In one embodiment, the maximum vertical thickness of the layer 138 of the counter electrode active material of the counter electrode structure 112 in a cross-sectional area perpendicular to the stacking direction is equal to the respective maximum vertical thickness t of the first and second end plates in the vertical direction. EPMAX It does not exceed that.

[0044] In one embodiment, the first vertical end faces 500a, 501a of the electrode structure 110 and the counter electrode structure 112 do not exceed the first vertical end face region 1806a of the first end plate 180 and the second end plate 182, which coincide with the first vertical end faces 500a, 501a and the first maximum vertical range 1805a of the first and second end plates on the same vertical side surface 1850a of the electrode assembly. In one embodiment, the first vertical end face 501a of the counter electrode structure 112 does not exceed the first vertical end face region 1806a of the first and second end plates, which coincide with the first vertical end face 501a and the first maximum vertical range 1805a of the first and second end plates on the same vertical side surface 1850a of the electrode assembly. In another embodiment, the first vertical end face 507a of the layer 138 of the counter electrode active material of the counter electrode structure 112 does not exceed the first vertical end face region 1806a of the first and second end plates, which coincides with the first vertical end face 507a and the first maximum vertical range 1805a of the first and second end plates on the same vertical side surface 1850a of the electrode assembly.

[0045] In one embodiment, the second vertical end faces 500b, 501b of the electrode structure 110 and the counter electrode structure 112 do not exceed the second vertical end face region 1806b of the first end plate 180 and the second end plate 1182, which coincides with the second maximum vertical range 1805b of the first and second end plates on the same vertical side surface 1850b of the electrode assembly. In another embodiment, the second vertical end face 501b of the counter electrode structure 112 does not exceed the second vertical end face region 1806b of the first end plate 180 and the second end plate 182, which coincides with the second maximum vertical range 1805b of the first and second end plates on the same vertical side surface 1850b of the electrode assembly. In another embodiment, the second vertical end face 507b of the layer of counter electrode active material of the counter electrode structure 112 does not exceed the second vertical end face region 1806b of the first and second end plates, which coincides with the second maximum vertical range 1805b of the first end plate 180 and the second end plate 182 on the same vertical side surface 1850b of the electrode assembly.

[0046] In another embodiment, the first vertical end faces 500a, 501a of the electrode structure 110 and the counter electrode structure 112 are recessed relative to the first vertical end face region 1806a of the first end plate 180 and the second end plate 182, which coincide with the first vertical end faces 500a, 501a and the first maximum vertical range 1805a of the first and second end plates on the same vertical side surface 1850a of the electrode assembly. In yet another embodiment, the first vertical end face 501a of the counter electrode structure 112 is recessed relative to the first vertical end face 501a and the first maximum vertical range 1805a of the first and second end plates on the same vertical side surface 1850a of the electrode assembly. In some embodiments, each electrode structure 110 of the constituent units of the group of unit cells 504 comprises a layer 132 of electrode active material, and each counter electrode structure 112 of the constituent units of the group of unit cells 504 comprises a layer 138 of counter electrode active material, and the first vertical end face 507a of the counter electrode active material layer of the counter electrode structure 112 is recessed relative to the first vertical end face 507a and the first maximum vertical range 1805a of the first and second end plates on the same vertical side surface 1850a of the electrode assembly. In some other embodiments, each electrode structure 110 of the constituent units of the group of unit cells 504 comprises a layer 132 of electrode active material, and each counter electrode structure 112 of the constituent units of the group of unit cells comprises a layer 138 of counter electrode active material, and the maximum vertical thickness of the counter electrode active material layer of the counter electrode structure 112 in a plane perpendicular to the stacking direction is the respective maximum vertical thickness t of the first and second end plates in the vertical direction. EPMAX It does not exceed that.

[0047] In one embodiment, the second end faces 500b, 501b of the electrode structure 110 and the counter electrode structure 112 are recessed relative to the second maximum vertical range 1805b of the first and second end plates on the same vertical side surface 1850b of the electrode assembly as the second vertical end faces 500b, 501b. In another embodiment, the second end face 501b of the counter electrode structure 112 is recessed relative to the second vertical end face 501b and the second maximum vertical range 1805b of the first and second end plates on the same vertical side surface 1850b of the electrode assembly. In some embodiments, each electrode structure 110 of a constituent unit of a unit cell group comprises a layer 132 of electrode active material, and each counter electrode structure 112 of a constituent unit of a unit cell group comprises a layer 138 of counter electrode active material, wherein the second end face 507b of the counter electrode active material layer of the counter electrode structure 112 is recessed with respect to a second surface area 1806b of the first and second end plates, which coincides with the second end face and a second maximum vertical range 1805b of the first and second end plates on the same vertical side surface 1850b of the electrode assembly.

[0048] According to the method disclosed herein, in one embodiment, in (a), the stencil 700 is positioned such that the upper surface 703 of the stencil frame is spaced vertically above the first end faces 500a, 501a of the electrode structure 110 or counter electrode structure 112 in the electrode assembly 106. In another embodiment, in (a), the stencil 700 is positioned such that the upper surface 703 of the stencil frame is spaced vertically above the first end face 501a of the counter electrode structure 112 in the electrode assembly. In some embodiments, each electrode structure 110 of the constituent units of the unit cell group comprises a layer 132 of electrode active material, and each counter electrode structure 112 of the constituent units of the unit cell group comprises a layer 138 of counter electrode active material, and in (a), the stencil 700 is positioned such that the upper surface 703 of the stencil frame is spaced vertically above the first end face 507a of the layer of counter electrode active material of the counter electrode structure 112 in the electrode assembly.

[0049] In one embodiment, in (c), the stencil 700 is positioned such that the upper surface 703 of the stencil frame is spaced vertically above the second end faces 500b, 501b of the electrode structure 110 or the counter electrode structure 112. In another embodiment, in (c), the stencil 700 is positioned such that the upper surface 703 of the stencil frame is spaced vertically above the second end face 501b of the counter electrode structure 112 in the electrode assembly 106. In some embodiments, each electrode structure 110 of the constituent units of the group of unit cells 504 comprises a layer 132 of electrode active material, and each counter electrode structure 112 of the constituent units of the group of unit cells 504 comprises a layer 138 of counter electrode active material, and in (c), the stencil 700 is positioned such that the upper surface 703 of the stencil frame is spaced vertically above the second end face 507b of the layer of counter electrode active material of the counter electrode structure 112 in the electrode assembly.

[0050] In one embodiment, according to the method disclosed herein, in (a), the stencil 700 is positioned such that the upper surface 703 of the stencil frame does not exceed the first end faces 500a, 501a of the electrode structure 110 or the counter electrode structure 112 in the electrode assembly, or is positioned vertically below and spaced apart from them. In another embodiment, in (a), the stencil 700 is positioned such that the upper surface 703 of the stencil frame does not exceed the first end face 501a of the counter electrode structure 112 in the electrode assembly, or is positioned vertically below and spaced apart from them. In some embodiments, each electrode structure 110 of the constituent units of the group of unit cells 504 comprises a layer 132 of electrode active material, and each counter electrode structure 112 of the constituent units of the group of unit cells 504 comprises a layer 138 of counter electrode active material, and in (a), the stencil 700 is positioned such that the upper surface 703 of the stencil frame does not extend beyond the first end face 507a of the counter electrode active material layer of the counter electrode structure 112 in the electrode assembly, or is positioned vertically below and spaced apart from them.

[0051] In one embodiment, in (c), the stencil 700 is positioned such that the upper surface 703 of the stencil frame does not exceed the second end faces 500b, 501b of the electrode structure 110 or counter electrode structure 112 in the electrode assembly 106, or is positioned vertically below them. In another embodiment, in (c), the stencil 700 is positioned such that the upper surface 703 of the stencil frame does not exceed the second end face 501b of the counter electrode structure 112 in the electrode assembly, or is positioned vertically below them. In some embodiments, each electrode structure 110 of the constituent units of the unit cell group comprises a layer 132 of electrode active material, and each counter electrode structure 112 of the constituent units of the unit cell group comprises a layer 138 of counter electrode active material, and in (c), the stencil 700 is positioned such that the upper surface 703 of the stencil frame does not exceed the second end face 507b of the layer of counter electrode active material of the counter electrode structure 112 in the electrode assembly, or is positioned vertically below them. In one embodiment, in either (a) or (c), the stencil 700 is positioned around the first end plate 180 and the second end plate 182 in the stacking direction. In one embodiment, in one or more of (a) and (c), the stencil opening is positioned such that a first vertical end face region 1806a (in (a)) and / or a second vertical end face region 1806b (in (c)) that coincides with one or more of the maximum vertical range or maximum thickness of the end plate is exposed through the opening. In certain embodiments, by housing at least a portion of the end plates 180, 182 within the stencil opening, the end plates act as extensions of the stencil in the stacking direction.

[0052] According to the method disclosed herein, in one embodiment, in (a), the stencil frame 701 is received on the receiving surface area 1813a of the outer region 1802 of the first and second end plates, the outer region 1802 has a first vertical thickness t in the first cross-sectional area 1803 perpendicular to the stacking direction in the inner region 1801 adjacent to the stacked continuous unit cell 504 EP1The second vertical thickness t in the second cross-sectional area 1804, which is smaller than and perpendicular to the stacking direction. EP2 In another embodiment, in (c), the stencil frame 701 is received on the receiving surface area 1813b of the outer region 1802 of the first and second end plates, and the outer region 1802 has a first vertical thickness t in the first cross-sectional area 1803 perpendicular to the stacking direction in the inner region 1801 adjacent to the stacked continuous unit cell 504. EP1 The second vertical thickness t in the second cross-sectional area 1804, which is smaller than and perpendicular to the stacking direction. EP2 In one embodiment, in (a), the stencil frame 701 is received on a receiving surface area 1813a of the outer region 1802 of the first and second end plates, which does not exceed or fall below a first surface area 1806a of the first and second end plates, which coincides with a first maximum vertical range 1805a of the respective first and second end plates in the vertical direction. In another embodiment, in (c), the stencil frame 701 is received on a receiving surface area 1813b of the outer region 1802 of the first and second end plates, which does not exceed or fall below a second surface area 1806b of the first and second end plates, which coincides with a second maximum vertical range 1805b of the respective first and second end plates in the vertical direction.

[0053] In some embodiments, the first end plate 180 and the second end plate 182 each have a first end plate vertical end face 1870a and a second end plate vertical end face 1870b on the first vertical side surface 1850a and the second vertical side surface 1850b opposite to the first and second end plates, respectively, and at least one of the first and second vertical end faces includes an inner surface area 1807 in an inner region adjacent to a stacked continuous unit cell and an outer surface area 1808 in an outer region outside the inner surface area in the stacking direction, the outer surface area 1808 being offset vertically inward from the inner surface area 1807.

[0054] In some embodiments, each of the first end plate vertical end face 1870a and the second end plate vertical end face 1870b includes an inner region 1807a, 1807b on the opposite side, which is vertically separated by an inner region 1801 adjacent to a stacked continuous unit cell, and an outer region 1808a, 1808b on the opposite side, which is vertically separated by an outer region 1802 outside the inner region 1801 in the stacking direction, wherein the outer regions 1808a, 1808b on the opposite side of each of the first and second end plate vertical end faces are offset vertically inward from the inner regions 1807a, 1807b on the opposite side.

[0055] In one embodiment, the stencil frame 701 comprises a first opposite ledge 704a and a second opposite ledge 704b, and the stencil 700 is positioned on the electrode assembly 106 such that the first opposite ledge 704a and the second opposite ledge 704b of the stencil frame 701 are received by inwardly offset outer regions 1808a, 1808b of the first end plate 180 and the second end plate 182, which are located on the same vertical sides 1850a, 1850b of the stencil frame and the electrode assembly. In another embodiment, the stencil frame 701 comprises a first opposite ledge 704a and a second opposite ledge 704b, and in either (a) or (c), the upper frame surface 703 of the first opposite frame region 704a and the second opposite frame region 704b has a maximum vertical thickness t in the vertical direction. EPMAXThe stencil frame 701 is positioned such that it does not extend beyond the first surface area 1806a of the first and second end plates 180 and the second end plates 182, or is recessed relative to the first surface area 1806a, which coincides with the first maximum vertical range 1805a of the first and second end plates that lies on the same vertical side surface 1850a of the electrode assembly. In some embodiments, the stencil frame 701 comprises a first opposite ledge 704a and a second opposite ledge 704b, wherein the upper frame surface 703 of the first opposite frame area 704a and the second opposite frame area 704b is positioned such that it does not extend beyond the first surface area 1806a of the first and second end plates, or is recessed relative to the first surface area 1806a, which coincides with the first maximum vertical range 1805a of the first and second end plates that lies on the same vertical side surface 1850a of the electrode assembly. In some embodiments, the stencil frame 701 comprises a first opposite ledge 704a and a second opposite ledge 704b, and in (c), the upper frame surface 703 of the first opposite frame region 704a and the second opposite frame region 704b is positioned such that the upper frame surface 703 does not extend beyond the second surface region 1806b of the first and second end plates, or is recessed relative to the second surface region 1806b, such that the upper frame surface 703 of the first opposite frame region and the second opposite frame region coincides with the second maximum vertical range 1805b of the first and second end plates which are on the same vertical side surface 1850b of the electrode assembly.

[0056] Referring to Figures 11A-11C and 12-13, according to the method disclosed herein, in one embodiment, the electrode assembly 106 includes a longitudinal axis in the stacking direction (e.g., the Y-axis) and a vertical axis in the perpendicular direction (e.g., the Z-axis), and the first end plate 180 and the second end plate 182 each have a first opposite vertical end face 1870a and a second opposite vertical end face 1870b, respectively, having a cross-sectional profile in the plane of the vertical axis and longitudinal axis that is chamfered, inclined, stepped, or any combination thereof. In one embodiment, as shown in Figure 12, the cross-sectional profiles of the first end plate 180 and the second end plate 182 in the plane of the vertical axis and longitudinal axis each decrease monotonically from the inner region 1801 to the outer region 1802. In one embodiment, as shown in Figure 13, the cross-sectional profiles of the first end plate 180 and the second end plate 182 in the planes of the vertical and longitudinal axes are stepped in each of the first and second end plates from an inner region 1801 to an outer region 1802. In one embodiment, the outer regions 1802 of each of the first and second end plates include a stepped feature 1860 adapted to receive a stencil frame 701.

[0057] In one embodiment, according to the method disclosed herein, (b) includes using a blade 705 to apply a slurry of porous electrical insulating material 508 through a stencil opening 702 to at least partially and even completely cover the first vertical end faces 500a, 501a of the electrode structure 110 or counter electrode structure 112 of the constituent units of the unit cell group 504. In another embodiment, (b) includes using a blade to apply a slurry of porous electrical insulating material 508 through a stencil opening 702 to at least partially and even completely cover the first vertical end face 501a of the counter electrode structure 112 of the constituent units of the unit cell group 504. In some embodiments, each electrode structure 110 of a constituent unit of a group of unit cells 504 comprises a layer 132 of electrode active material, and each counter electrode structure 112 of a constituent unit of a group of unit cells 504 comprises a layer 138 of counter electrode active material, (b) including using a blade to apply a slurry of porous electrical insulating material 508 through a stencil opening 702 to at least partially and even completely cover the first vertical end face 507a of the counter electrode active material layer of the counter electrode structure 112 of the constituent unit of the group of unit cells 504.

[0058] In one embodiment, according to the method disclosed herein, (d) includes using a blade 705 to apply a slurry of porous electrical insulating material 508 through a stencil opening 702 to at least partially and even completely cover the second vertical end faces 500b, 501b of the electrode structure 110 or counter electrode structure 112 of the constituent units of the unit cell group 504. In another embodiment, (d) includes using a blade to apply a slurry of porous electrical insulating material 508 through a stencil opening 702 to at least partially and even completely cover the second vertical end face 501b of the counter electrode structure 112 of the constituent units of the unit cell group 504. In some embodiments, each electrode structure 110 of a constituent unit of a group of unit cells 504 comprises a layer 132 of electrode active material, and each counter electrode structure 112 of a constituent unit of a group of unit cells 504 comprises a layer 138 of counter electrode active material, (d) comprising using a blade to apply a slurry of porous electrical insulating material 508 through a stencil opening 702 to at least partially, and even completely, cover the second vertical end face 507b of the counter electrode active material layer of the counter electrode structure 112 of the constituent unit of the group of unit cells 504.

[0059] According to the method disclosed herein, in one embodiment, (b) includes running a blade along the first vertical end faces 1870a of the first and second end plates in a transverse direction perpendicular to the vertical and stacking directions to apply the porous electrical insulating material 508 to the first vertical end faces 500a, 501a of the electrode structure 110 or counter electrode structure 112 through the stencil opening 702. In another embodiment, the blade is applied to the respective maximum vertical thickness t in the vertical direction. EPMAXThe blade travels across the first vertical end face 1870a in the first surface area 1806a of the first and second end plates, which coincides with the first maximum extent 1805a of the first and second end plates in the vertical direction. In a particular embodiment, the blade travels across the first vertical end face 1870a in the first surface area 1806a of the first and second end plates, which coincides with the first maximum extent 1805a of the first and second end plates, respectively. In another embodiment, (b) includes traveling the blade across the first vertical end face 1870a of the first and second end plates in a transverse direction perpendicular to the stacking direction and the vertical direction. In some embodiments, in (b), the length of the blade extends across the electrode assembly 106 in the stacking direction from the first end plate 180 to the second end plate 182. In some embodiments, in (b), the porous electrical insulating material 508 is applied to either the blade or the surface of the electrode assembly 106, and the blade is run laterally along the first vertical end faces 1870a of the first and second end plates. In one embodiment, the blade is brought into contact with one or more of the first vertical end faces as it runs and / or sweeps across the first and second end plates.

[0060] According to the method disclosed herein, in one embodiment, (d) includes running a blade along the second vertical end faces 1870b of the first end plate 180 and the second end plate 182 in a transverse direction perpendicular to the vertical and stacking direction to apply the porous electrical insulating material 508 to the second end faces 500b, 501b of the electrode structure 110 or the counter electrode structure 112 through the stencil opening 702. In one embodiment, the blade is run along the respective maximum vertical thickness t in the vertical direction. EPMAXThe blade runs across the second vertical end faces 1870b of the first and second end plates in the second surface area 1806b of the first and second end plates, which coincides with the second maximum extent 1805b of the first and second end plates in the vertical direction. In certain embodiments, the blade runs across the second vertical end face 1870b of the second surface 1806b of the first and second end plates, which coincides with the second maximum extent 1805b of the first and second end plates, respectively. In other embodiments, the blade runs across the second vertical end faces 1870b of the first end plate 180 and the second end plate 182 in a transverse direction perpendicular to the stacking direction and the vertical direction. In some embodiments, in (b), the length of the blade extends across the electrode assembly 106 in the stacking direction from the first end plate 180 to the second end plate 182. In another embodiment, (d) includes running the blade along the second vertical end faces 1870b of the first and second end plates in a transverse direction perpendicular to the vertical and stacking directions to apply the porous electrical insulating material 508 to the second end faces 500b, 501b of the electrode structure 110 or counter electrode structure 112 through the stencil opening 702. In some embodiments, (d) includes applying the porous electrical insulating material 508 to either the surface of the blade or the electrode assembly 106 and running the blade transversely along the second vertical end faces 1870b of the first and second end plates. In one embodiment, the blade is brought into contact with one or more of the second vertical end faces as it runs and / or sweeps across the first and second end plates.

[0061] In one embodiment, according to the method disclosed herein, (a) includes positioning the stencil 700 such that at least a portion of the first vertical end faces 1870a of the first end plate 180 and the second end plate 182 adjacent to the stacked continuous unit cell 504 is exposed through the stencil opening 702. In another embodiment, (c) includes positioning the stencil 700 such that at least a portion of the second vertical end faces 1870b of the first end plate 180 and the second end plate 182 adjacent to the stacked continuous unit cell 504 is exposed through the stencil opening 702. For example, in a particular embodiment, the inner surfaces 1807a, 1807b located in the inner surface region 1801 of the first and second end plates adjacent to the stacked continuous unit cell can be exposed through the stencil opening in either (a) or (c).

[0062] According to the method disclosed herein, in one embodiment, (a) is the respective maximum vertical thickness t in the vertical direction. EPMAX In another embodiment, (a) includes positioning the stencil 700 such that a first surface area 1806a on the first vertical side surface 1850a of the first and second end plates, which coincides with the first vertical side surface 1805a, is exposed through the stencil opening 702.

[0063] According to the method disclosed herein, in one embodiment, (c) is the respective maximum vertical thickness t in the vertical direction. EPMAXIn another embodiment, (c) includes positioning the stencil 700 such that a second surface area 1806b on the second vertical side surface 1850b of the first and second end plates, which coincides with the second maximum vertical range 1805b, is exposed through the stencil opening 702.

[0064] According to the method disclosed herein, in one embodiment, in either (a) or (c), the stencil 700 is positioned such that the stencil frame 701 covers at least partially the periphery 1853 of the electrode assembly 106 in a transverse direction perpendicular to both the stacking direction and the vertical direction.

[0065] According to the method disclosed herein, with reference to Figure 14 in one embodiment, each unit cell 504 comprises an electrode current collector end section 512 and a counter electrode current collector end section 513 extending from their respective electrode structure 110 and counter electrode structure 112 in opposite lateral directions perpendicular to both the stacking direction and the vertical direction. In some embodiments, the end sections of the electrode current collector 136 and counter electrode current collector 140 are recessed perpendicular to the first and second vertical end faces (500a, 500b), (501a, 501b) of the electrode structure 110 and counter electrode structure 112. In some embodiments, in either (a) and (c), the stencil 700 is positioned such that the stencil frame 701 at least partially covers the end sections 512, 513 of the electrode current collector 136 and counter electrode current collector 140 around the electrode assembly 106 in a lateral direction perpendicular to the stacking direction and the vertical direction. In some embodiments, in either (a) or (c), the stencil 700 is positioned such that the end sections 512, 513 of the electrode current collector 136 and the counter electrode current collector 140 are recessed relative to the stencil frame 701. In some embodiments, in either (a) or (c), the stencil 700 is positioned such that the lateral ledges 704a, 704b on the opposite side of the stencil frame 701 are positioned on the end sections 512, 513 of the electrode current collector 136 and the counter electrode current collector 140. In one embodiment, the end sections 512, 513 may include both current collector connection areas 512a, 513a configured to connect to busbars, and may further include removable areas 512b, 513b located outside the lateral current collector connection areas and configured to be removed during the assembly of the structure 101 to expose the current collector connection areas 512a, 513a for connecting to the respective busbars. In the embodiment shown in Figure 14, the end sections 512, 513, which include removable regions 512b, 513b at the lateral ends of the end sections, and the stencil 700 are provided across both the current collector connection regions 512a, 513a and the removable regions 512b, 513b, thereby preventing the application of porous electrical insulating material to these regions.

[0066] According to the method disclosed herein, in one embodiment, the first and second vertical end faces (515a, 515b), (516a, 516b) of the end sections 512, 513 of the electrode current collector 136 and the counter electrode current collector 140 are (i) the first vertical end faces 500a and 500b of the electrode structure 110, (ii) the first vertical surface regions 1806a and 1806b of the first and second end plates, which coincide with the first and second maximum vertical ranges (1805a, 1805b) of the first and second end plates 180 and 182, and (iii) the respective maximum vertical thickness t of the first and second end plates in the vertical direction. EPMAX The first and second vertical surface regions 1806a and 1806b of the first and second end plates are recessed by at least 0.010 mm relative to either of them, which coincide with the first vertical surface region 1806a and 1806b of the first and second end plates. In some embodiments, the first and second vertical end faces (515a, 515b), (516a, 516b) of the end sections 512, 513 of the electrode current collector 136 and the counter electrode current collector 140 are (i) the first vertical end faces 500a and 500b of the electrode structure, (ii) the first surface regions 1806a and 1806b of the first and second end plates, which coincide with the first maximum vertical range 1805a and 2 maximum vertical range 1805b of the first end plate 180 and the second end plate 182, and (iii) the respective maximum vertical thickness t of the first and second end plates in the vertical direction. EPMAXThe first and second surface areas 1806a and 1806b of the first and second end plates are recessed by at least 0.025 mm relative to either of them, which coincide with the first surface area 1806a and 1806b of the first and second end plates. In some embodiments, the first and second vertical end faces (515a, 515b), (516a, 516b) of the end sections 512, 513 of the electrode current collector 136 and the counter electrode current collector 140 coincide with (i) the first vertical end face 500a and 500b of the electrode structure, (ii) the first surface areas 1806a and 1806b of the first and second end plates, which coincide with the first and second maximum vertical ranges (1805a, 1805b) of the first end plate 180 and the second end plate 182, and (iii) the respective maximum vertical thickness t of the first and second end plates in the vertical direction. EPMAX The first and second end plates are recessed by at least 0.050 mm relative to either the first surface area 1806a and the second surface area 1806b of the first and second end plates, which are consistent with the first and second end plates. In some embodiments, the first and second vertical end faces (515a, 515b), (516a, 516b) of the end sections 512, 513 of the electrode current collector 136 and the counter electrode current collector 140 are recessed to accommodate the stencil frame 701 in the vertical distance between the first and second vertical end faces (515a, 515b), (516a, 516b) of the end sections 512, 513 of the electrode current collector 136 and the counter electrode current collector 140 and the first and second vertical end faces (500a, 500b), (501a, 501b) of the electrode structure or counter electrode structure.

[0067] In one embodiment, according to the method disclosed herein, the method further includes positioning the electrode assembly 106 between a set of bumpers 800 located on opposite sides in the stacking direction, thereby applying pressure to the first end plate 180 and the second end plate 182 in the stacking direction via the bumpers. In one embodiment, the set of bumpers 800 located on opposite sides press against the first longitudinal end faces 1890a and the second longitudinal end faces 1890b of the end plates 180 and 182, applying compressive pressure thereto. In one embodiment, the electrode assembly 106 is positioned between the bumpers 800 such that a first surface area 1806a of the first and second end plates, coinciding with a first maximum vertical range 1805a of the first and second end plates, extends vertically past the first vertical end faces 801a and the second vertical end faces 801b of the bumpers. In some embodiments, the electrode assembly 106 is positioned between the bumpers 800 such that the first and second end plates have a maximum vertical thickness t in the vertical direction. EPMAX The first surface areas 1806a of the first end plate 180 and the second end plate 182, which coincide with the first end plate 180, are positioned between the bumpers 800 such that they extend vertically past the first vertical end faces 801a and the second vertical end faces 801b of the bumpers.

[0068] In some embodiments, the method further includes mounting at least a portion of the stencil frame 701 onto a set of bumpers 800 on the opposite side. In some embodiments, the first surface areas 1806a and 1806b of the first and second end plates, which coincide with the first maximum vertical ranges 1805a and 2 maximum vertical ranges 1805b of the first and second end plates, extend at least 0.010 mm past the first vertical end faces 801a and 2 vertical end faces 801b of the set of bumpers. In some embodiments, the maximum vertical thickness t of the first and second end plates in the vertical direction EPMAXThe first surface areas 1806a and 1806b of the first and second end plates, which coincide with the first and second maximum vertical ranges 1805a and 1805b of the first and second end plates, extend at least 0.010 mm past the first and second vertical end faces 801a and 801b of the bumper set. In some embodiments, the first surface areas 1806a and 1806b of the first and second end plates, which coincide with the first maximum vertical ranges 1805a and 1805b of the first and second end plates, extend at least 0.025 mm past the first and second vertical end faces 801a and 801b of the bumper set. In some embodiments, the maximum vertical thickness t of the first and second end plates in the vertical direction EPMAX The first surface areas 1806a and 1806b of the first and second end plates, which coincide with the first and second maximum vertical ranges 1805a and 1805b of the first and second end plates, extend at least 0.025 mm past the first and second vertical end faces 801a and 801b of the bumper set. In some embodiments, the first surface areas 1806a and 1806b of the first and second end plates, which coincide with the first maximum vertical ranges 1805a and 1805b of the first and second end plates, extend at least 0.050 mm past the first and second vertical end faces 801a and 801b of the bumper set. In some embodiments, the maximum vertical thickness t of the first and second end plates in the vertical direction EPMAX The first surface regions 1806a and 1806b of the first and second end plates, which coincide with the first and second end plates, extend by at least 0.050 mm past the first vertical end faces 801a and 801b of the bumper set.

[0069] According to embodiments disclosed herein, in one embodiment, the cross-sectional thickness t of each of the first end plate 180 and the second end plate 182 EP The area decreases in the stacking direction from the inner region 1801 of each first and second end plate adjacent to the stacked continuous unit cell to the outer region 1802 of each first and second end plate that is outside the first region in the stacking direction.

[0070] Referring to Figures 3A and 3B, a particular embodiment provides a method for transferring carrier ions from the auxiliary electrode 686 to the constituent units of the unit cell group 504 through a porous electrical insulating material 508. As discussed above, carrier ions can be transferred to supply carrier ions to the electrode structure 110 of the constituent units of the unit cell to compensate for carrier ion loss resulting from the formation of a solid electrolyte interface (SEI) layer that may be formed during the initial formation process, or from subsequent charging cycles of the secondary battery 102 having the electrode assembly 106. In a particular embodiment, a portion of the carrier ions introduced into the unit cell from the counter electrode structure are irreversibly bound in this SEI layer and are therefore removed from the cycling operation, i.e., from the capacity available to the user. As a result, during the initial discharge, fewer carrier ions are returned from the electrode structure to the counter electrode structure than were initially supplied by the cathode during the initial charging operation, leading to irreversible capacity loss. During each subsequent charge and discharge cycle of a secondary battery, capacity loss resulting from mechanical and / or electrical degradation of the electrode structure and / or counter electrode structure tends to be much less per cycle. However, even relatively small carrier ion losses per cycle significantly impact energy density and cycle life as the battery ages. In addition, chemical and electrochemical degradation also occurs in the electrode structure and counter electrode structure, which can cause capacity loss. Therefore, embodiments of the disclosure herein provide methods for activating an electrode assembly and / or a secondary battery, such as through an initial formation process that provides additional carrier ions from auxiliary electrodes to the constituent units of a unit cell, and / or during a replenishment process performed to replenish the carrier ion content lost during subsequent charge and / or discharge cycles of a secondary battery having an electrode assembly. According to certain embodiments, carrier ions are transported during the initial or subsequent charge cycle of the electrode assembly to compensate for carrier ion loss.

[0071] According to one embodiment, the auxiliary electrode 686 includes a carrier ion source such as lithium ions, sodium ions, potassium ions, calcium ions, magnesium ions, and aluminum ions. In the embodiment shown in Figure 3A, the auxiliary electrode 686 is positioned on the electrode structure, counter electrode structure, and vertical end face of the electrical insulating separator of the constituent unit of the unit cell, such as on the opening 176 in the first secondary growth constraint 158 ​​and / or the second secondary growth constraint 160. In one modification, one or more auxiliary electrodes 686 are positioned on both the first and second vertical end faces, and / or alternatively, the auxiliary electrode 686 may be positioned on only one of the first and second vertical end faces. For example, in one embodiment, the first auxiliary electrode 686a is positioned on the first vertical end face of the electrode structure 110 and / or the counter electrode structure 112, and the second auxiliary electrode 686b is positioned on the second vertical end face of the electrode structure and / or the counter electrode structure. The auxiliary electrode 686 may be selectively electrically connected or coupled to one or more of the electrode structures 110 and / or counter electrode structures 112 of the constituent units of the unit cell, for example, by a switch and / or control unit (not shown). According to a particular embodiment, the auxiliary electrode is electrolytically or otherwise coupled (e.g., through a separator) to the counter electrode structures and / or electrode structures of the constituent units of the unit cell group to provide a flow of carrier ions from the auxiliary electrode to the electrode structures and / or counter electrode structures. Electrolytic coupling means that carrier ions can be transferred through the electrolyte, such as from the auxiliary electrode to the electrode structures 110 and / or counter electrode structures 112, and between the electrode structures 110 and counter electrode structures 112. The auxiliary electrode 686 is also directly or indirectly coupled to the electrode structures and / or counter electrode structures, such as by a series of wires or other electrical connections.

[0072] In one embodiment, carrier ions are transported to a predetermined discharge voltage V at the end of the counter electrode structure. ces eod , and the discharge voltage V at the predetermined electrode structure end es,eod Achieve and / or restore the following, where, for a unit cell of the group, the discharge voltage V of the unit cell cell,eod =V es,eod-V ces,eod For example, in one embodiment, a secondary battery comprising a constituent unit of a unit cell and / or a constituent unit of a unit cell has a discharge voltage V at the cell end during the discharge cycle of the secondary battery (after the first charge and discharge cycle in which SEI is formed). cell,eod When it reaches this point, the discharge voltage V at the end of the electrode structure es,eod The voltage is less than 0.9V (vs. Li) and greater than 0.4V (vs. Li). Therefore, for example, in one such embodiment, the discharge voltage at the cell end of the secondary battery during the discharge cycle of the secondary battery (i.e., when the cell is under a discharge load) is V cell,eod When it reaches this point, the discharge voltage V at the electrode end es,eod This can be in the range of approximately 0.5V (v. Li) to approximately 0.8V (v. Li). As a further example, in one such embodiment, during the discharge cycle of the secondary battery (i.e., when the cell is under a discharge load), the discharge voltage V at the cell end cell,eod When it reaches this point, the discharge voltage V at the end of the electrode structure es,eod This can be in the range of approximately 0.6V (v. Li) to approximately 0.8V (v. Li). In one such embodiment, during the discharge cycle of the secondary battery (i.e., when the cell is under a discharge load), the discharge voltage V at the cell end cell,eod When it reaches this point, the discharge voltage V at the end of the electrode structure es,eod This can range from approximately 0.6V (relative to Li) to approximately 0.7V (relative to Li).

[0073] In another embodiment, V of a predetermined counter electrode structure ces,eod The value corresponds to the voltage at which the charge state of the counter electrode structure is at least 95% of the reversible chromium capacity of the counter electrode structure, V ces,eod The voltage is at least 0.4V (vs. Li) but less than 0.9V (vs. Li). For example, in one such embodiment, V cell,eod When this is reached, the counter electrode structure has a voltage corresponding to the charge state of the counter electrode structure where the charge state of the counter electrode structure is at least 96% of the reversible chron capacity of the counter electrode structure. ces,eod It has a value, V es,eod The voltage is at least 0.4V (vs. Li) but less than 0.9V (vs. Li). As a further example, in one such embodiment, V cell,eodWhen it reaches this point, the counter electrode structure has a voltage corresponding to the charge state of the counter electrode structure where the charge state of the counter electrode structure is at least 97% of the reversible chron capacity of the counter electrode structure. ces,eod It has a value, V es,eod The voltage is at least 0.4V (vs. Li) but less than 0.9V (vs. Li). As a further example, in one such embodiment, V cell,eod When it reaches this point, the counter electrode structure has a voltage corresponding to the charge state of the counter electrode structure where the charge state of the counter electrode structure is at least 98% of the reversible chron capacity of the counter electrode structure. ces,eod It has a value, V es,eod The voltage is at least 0.4V (vs. Li) but less than 0.9V (vs. Li). As a further example, in one such embodiment, V cell,eod When this is reached, the counter electrode structure has a voltage corresponding to the charge state of the counter electrode structure where the charge state of the counter electrode structure is at least 99% of the reversible chron capacity of the counter electrode structure. ces,eod It has a value, V es,eod The voltage is at least 0.4V (relative to Li) but less than 0.9V (relative to Li).

[0074] According to one embodiment, this method involves (i) transferring carrier ions from the counter electrode structure to the electrode structure in a unit cell group during an initial or subsequent charging cycle to at least partially charge the electrode assembly, and (ii) transferring carrier ions from the auxiliary electrode to the counter electrode structure and / or electrode structure through a porous electrical insulating material, the auxiliary electrode electrolytically coupling to the counter electrode structure and / or electrode structure of the constituent units of the unit cell group through a separator, thereby discharging a predetermined discharge voltage V at the end of the counter electrode structure to the electrode assembly. cos,eod And the discharge voltage V at the predetermined electrode structure end es,eodThe method includes providing and . According to one embodiment, the method further includes charging the electrode assembly by transferring carrier ions from the counter electrode structure of the constituent unit of the unit cell group to the electrode structure after (iii) and (ii). For example, carrier ions transferred from the auxiliary electrode to the counter electrode structure in (ii) may then be transferred from the counter electrode structure to the electrode structure in (iii). According to another embodiment, (ii) is performed simultaneously with (i). According to a particular embodiment, in (ii), a bias voltage is applied between the auxiliary electrode and the electrode structure and / or counter electrode structure of the constituent unit of the unit cell group to provide a flow of carrier ions through the porous electrical insulating material member to the electrode structure and / or counter electrode structure. Similarly, in (i) and (iii), a bias voltage can be applied between the electrode structure and the counter electrode structure of the constituent unit of the unit cell group to provide a flow of carrier ions from the counter electrode structure of the constituent unit to the electrode structure.

[0075] Referring again to Figure 4, according to one embodiment, the porous electrical insulating material 508 substantially fills the first and second recesses 505a and 505b of the constituent units of the unit cell group 504. According to another embodiment, at least a portion of the porous electrical insulating material 508 covering the first vertical end faces 500a, 501a and / or second vertical end faces 500b and 501b of the electrode structure 110 and / or counter electrode structure 112 in the constituent unit of the unit cell is arranged adjacent to the electrical insulating separator 130 of the unit cell. For example, in one embodiment, the porous electrical insulating material is disposed inward relative to the first vertical end faces 500a and the second vertical end faces 500b of the electrode structure 110 in the constituent unit of the unit cell group, and substantially fills the areas of the first recess 505a and the second recess 505b that abut against the first side surface 131a of the electrical insulating separator 130 facing the opposing electrode structure 110. According to a particular embodiment, the porous electrical insulating material fills at least a portion of the first recess 505a and / or the second recess 505b that recess inward from the first vertical end face 502a and the second vertical end face 502b of the electrical insulating separator 130, thereby providing structural support to the electrical insulating separator 130. For example, in certain embodiments, a porous electrical insulating material can provide a rigid material that abuts the first vertical end 133a and the second vertical end 133b of the electrical insulating separator 130, thereby maintaining the upright position of the vertical end relative to the first and second vertical end faces of the counter electrode structure 112. Maintaining the positions of the vertical ends 133a and 133b of the electrical insulating separator 130 can, in certain embodiments, reduce the possibility of electrical short circuits between the electrode structure and the counter electrode structure, and other undesirable effects. In certain embodiments, a porous electrical insulating material can also reduce undesirable electrical edge effects at the portions of the first and second vertical end faces of the cathode structure.

[0076] According to one embodiment, the electrode structure 110 of the constituent unit of the unit cell group comprises an electrode active material layer 132 and an electrode current collector layer 136, the counter electrode structure 112 of the constituent unit of the unit cell group comprises a counter electrode active material layer 138 and a counter electrode current collector layer 140, and the porous electrical insulating material 508 covers the counter electrode active material layer of the constituent unit of the unit cell group, with the first vertical end face 507a and the second vertical end face 507b. In the embodiments shown in Figures 3A and 4, the porous electrical insulating material extends in the stacking direction across the first vertical end faces 501a and the second vertical end faces 501b of the counter electrode structure 112, covering them, including traversing one or more of the first vertical end faces 507a and the second vertical end faces 507b of the counter electrode active material layer 138 in adjacent unit cells 504a and 504b, and, in certain embodiments, traversing the first vertical end faces 509a and the second vertical end faces 509b of the counter electrode current collector 140 shared by adjacent unit cells 504. The porous electrical insulating material extending across portions of adjacent unit cells can, in this embodiment, abut against and provide structural support to the vertical ends 133a and 133b of the electrical insulating separator 130 in adjacent unit cells. In further embodiments, the porous electrical insulating material 508 can be provided on the first and second vertical end faces of the electrode structure 110, such as on the first vertical end faces 511a and second vertical end faces 511b of the electrode active material layer 132 in adjacent unit cells 504a and 504b, and across the first vertical end faces 510a and second vertical end faces 510b of the electrode current collector 136 shared by adjacent unit cells 504.

[0077] In further embodiments, the porous electrical insulating material 508 is provided on portions of the first and second vertical end faces of the electrode structure and the counter electrode structure, thereby providing pathways for the flow of carrier ions from the auxiliary electrode to the constituent units of the unit cell group. For example, in an embodiment where the flow of carrier ions from the auxiliary electrode 686 to the counter electrode structure 112 is provided, the porous electrical insulating material 508 is disposed on the first and second vertical end faces of the counter electrode structure to provide pathways for carrier ions to the counter electrode structure. In another example, in an embodiment where the flow of carrier ions from the auxiliary electrode to the electrode structure 110 is provided, the porous electrical insulating material 508 is disposed on the first and second vertical end faces of the electrode structure to provide pathways for carrier ions to the electrode structure.

[0078] According to certain embodiments, the porosity of the electrical insulating material can be selected to provide a predetermined conductivity for carrier ions passing through the material. In certain embodiments, the porous electrical insulating material includes porosity of at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, and / or at least 55%. Furthermore, in certain embodiments, the porous electrical insulating material includes porosity of 55% or less, 50% or less, 45% or less, 40% or less, and / or 35% or less. In yet another embodiment, the porous electrical insulating material 508 includes a ratio of porosity to the porosity of the electrical insulating separator 130 between the electrode structure and the counter electrode structure within the constituent unit of the unit cell group, in the range of 1:0.75 to 1:1.5.

[0079] In one embodiment, the porous electrical insulating material 508 includes a particulate material dispersed in a binder material. For example, certain materials may include stable metal oxides and / or ceramics, such as one or more of alumina, boron nitride, titania, silica, zirconia, magnesium oxide, and calcium oxide. In another embodiment, the particulate material includes particles having a d50 particle size (median particle size) of at least 0.35 microns, at least 0.45 microns, at least 0.5 microns, and / or at least 0.75 microns. In yet another embodiment, the particulate material includes particles having a d50 particle size (median particle size) of 40 microns or less, 35 microns or less, 25 microns or less, and / or 20 microns or less. In one embodiment, at least 80% by weight, at least 85% by weight, at least 90% by weight, and / or at least 95% by weight of the particles have particle sizes of at least 0.35 microns, at least 0.45 microns, at least 0.5 microns, and / or at least 0.75 microns, and 40 microns or less, 35 microns or less, 25 microns or less, and / or 20 microns or less. Furthermore, in one embodiment, the particle material comprises at least 70% by weight, at least 75% by weight, at least 80% by weight, and / or at least 85% by weight of porous electrical insulating material. In further embodiments, the particle material comprises 99.5% by weight or less, 97% by weight or less, 95% by weight or less, and / or 90% by weight or less of porous electrical insulating material. In one embodiment, the binder material comprises a polymer material selected from the group consisting of polyvinylidene fluoride (PVDF), polyethylene, polypropylene, ethylene acrylic acid (EAA), ethylene methacrylic acid (EMAA), and copolymers thereof.

[0080] Referring to Figures 1A to 1D, according to one embodiment, the electrode assembly 106 has mutually perpendicular horizontal, vertical, and vertical axes corresponding to the x, y, and z axes of a virtual three-dimensional Cartesian coordinate system, a first vertical end face 116 and a second vertical end face 118 separated from each other in the vertical direction, and the electrode assembly vertical axis A EAIt has a lateral surface 142 that surrounds and connects the first longitudinal end face 116 and the second longitudinal end face 118. The lateral surface 142 includes first and second regions separated on both sides of the longitudinal axis in a first direction perpendicular to the longitudinal axis. For example, the lateral surface 142 may include surface regions 144, 146 on opposite sides in the X direction (i.e., the sides of the rectangular column) and surface regions 148, 150 on opposite sides in the Z direction. In another embodiment, the lateral surface may include a cylindrical shape. The electrode assembly 106 has a maximum width W measured in the longitudinal direction. EA The boundary is defined by the lateral plane, and the maximum length L is measured laterally. EA The boundary is defined by the lateral plane, and the maximum height H is measured vertically. EA And, it may further include. In one embodiment, the maximum length L EA and maximum height H EA The ratio to can be at least 2:1. As a further example, in one embodiment, the maximum length L EA and maximum height H EA The ratio can be at least 5:1. As a further example, in one embodiment, the maximum length L EA and maximum height H EA The ratio can be at least 10:1. As a further example, in one embodiment, the maximum length L EA and maximum height H EA The ratio can be at least 15:1. As a further example, in one embodiment, the maximum length L EA and maximum height H EA The ratio can be at least 20:1. The ratio of various dimensions allows for an optimal configuration within the energy storage device, maximizing the amount of active material and thereby increasing the energy density.

[0081] In some embodiments, the maximum width W EA The maximum height H EA It may be selected to provide a width for the electrode assembly 106 that is greater than the maximum width W. EA and maximum height H EA The ratio to can be at least 2:1. As a further example, in one embodiment, the maximum width WEA and the maximum height H EA The ratio to can be at least 5:1. As a further example, in one embodiment, the maximum width W EA and the maximum height H EA The ratio to can be at least 10:1. As a further example, in one embodiment, the maximum width W EA and the maximum height H EA The ratio to can be at least 15:1. As a further example, in one embodiment, the maximum width W EA and the maximum height H EA The ratio to can be at least 20:1.

[0082] According to one embodiment, the maximum width W EA and the maximum length L EA The ratio to can be selected to be within a predetermined range that provides an optimal configuration. For example, in one embodiment, the maximum width W EA and the maximum length L EA The ratio to can be in the range of 1:5 to 5:1. As a further example, in one embodiment, the maximum width W EA and the maximum length L EA The ratio to can be in the range of 1:3 to 3:1. As yet another example, in one embodiment, the maximum width W EA and the maximum length L EA ]>The ratio to can be in the range of 1:2 to 2:1.

[0083] ` According to an embodiment of the present disclosure, each electrode structure 110 of the constituent unit of the unit cell group includes a length L measured in the horizontal direction between the horizontal end face 601a on the first opposite side of the electrode structure 110 and the horizontal end face 601b on the second opposite side, E a height H measured in the vertical direction between the vertical end face 500a on the first opposite side of the electrode structure and the vertical end face 500b on the second opposite side, E and a width W measured in the longitudinal direction between the surface 603a on the first opposite side of the electrode structure and the surface 603b on the second opposite side. Each pair of opposing electrode structures of the constituent unit of the electrode structure includes a length L measured in the horizontal direction between the horizontal end face 602a on the first opposite side of the opposing electrode structure and the horizontal end face 602b on the second opposite side, E and, Each pair of opposing electrode structures of the constituent unit of the electrode structure includes a length L measured in the horizontal direction between the horizontal end face ..... CEThe height H measured vertically between the first opposite vertical end face 501a and the second opposite vertical end face 501b of the opposing electrode structure. CE The width W measured longitudinally between the first opposite surface 604a and the second opposite surface 604b of the counter electrode structure. CE This includes,

[0084] According to one embodiment, the electrode structure 110 of the constituent unit of the unit cell group is L E and W E and H E The ratio of each to is at least 5:1, and H E and W E The ratio is in the range of approximately 2:1 to approximately 100:1, and for the counter electrode structure 112 of the constituent unit of the unit cell group, L CE and W CE and H CE The ratio of each to is at least 5:1, and H CE and W CE The ratio is in the range of approximately 2:1 to approximately 100:1. As a further example, in one embodiment, L E and W E and H E The ratio of each to L is at least 10:1. CE and W CE and H CE 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 L is at least 15:1. CE and W CE and H CE The ratio of each to is at least 15:1. As a further example, in one embodiment, L E and W E and H E The ratio of each to L is at least 20:1. CE and W CE and H CE The ratio of each to the others is at least 20:1.

[0085] In one embodiment, the height (H) of the electrode structure 110E ) and width (W E The ratios of ) to each other are at least 0.4:1. For example, in one embodiment, for each electrode structure 110 of the constituent units of the unit cell group, H E and W E The ratios to each will be at least 2:1. As a further example, in one embodiment, H E and W E The ratios to each will be at least 10:1. As a further example, in one embodiment, H E and W E The ratios to each will be at least 20:1. However, typically, H E and W E The ratios to each will generally be less than 1,000:1. For example, in one embodiment, H E and W E The ratios to each will be less than 500:1. As a further example, in one embodiment, H E and W E The ratios to each will be less than 100:1. As a further example, in one embodiment, H E and W E The ratios to each will be less than 10:1. As a further example, in one embodiment, for each electrode structure of the constituent unit of the unit cell group, H E and W E The ratios to each will likely be in the range of approximately 2:1 to 100:1.

[0086] In one embodiment, the height (H) of the counter electrode structure 112 CE ) and width (W CE The ratios of ) to each other are at least 0.4:1. For example, in one embodiment, for each opposing electrode structure 112 of the constituent units of the unit cell group, H CE and W CE The ratios to each will be at least 2:1. As a further example, in one embodiment, H CE and W CE The ratios to each will be at least 10:1. As a further example, in one embodiment, H CE and W CEThe ratios to each will be at least 20:1. However, typically, H CE and W CE The ratios to each will generally be less than 1,000:1. For example, in one embodiment, H CE and W CE The ratios to each will be less than 500:1. As a further example, in one embodiment, H CE and W CE The ratios to each will be less than 100:1. As a further example, in one embodiment, H CE and W CE The ratios to each will be less than 10:1. As a further example, in one embodiment, for each counter electrode structure of the constituent unit of the unit cell group, H CE and W CE The ratios to each other will likely be in the range of approximately 2:1 to 100:1.

[0087] In one embodiment, the unit cell group may include an alternating array of electrode structures 110 and counter electrode structures 112, and may include any number of constituent units depending on the energy storage device 100 and its intended use. As a further example, in one embodiment, more generally, the group of electrode structures 110 and the group of counter electrode structures 112 each have N constituent units, where each of the N-1 constituent units 110 of the electrode structures lies between two constituent units 112 of the counter electrode structures, and each of the N-1 constituent units 112 of the counter electrode structures lies between two constituent units 110 of the electrode structures, where N is at least 2. As a further example, in one embodiment, N is at least 4. As a further example, in one embodiment, N is at least 5. As a further example, in one embodiment, N is at least 10. As a further example, in one embodiment, N is at least 25. As a further example, in one embodiment, N is at least 50. As a further example, in one embodiment, N is at least 100 or more.

[0088] Referring to Figure 5, in one embodiment, the electrode assembly 106 includes a wound electrode assembly having a plurality of windings 205a, 205b of electrode structures 110 and counter electrode structures 112 that constitute a unit of a group of unit cells around the central axis C of the wound electrode assembly, the vertical direction of the wound electrode assembly is parallel to the central axis (z direction), and furthermore, the electrode structures and counter electrode structures of the unit of the group of unit cells each extend along a length L from a first end 121a of the counter electrode structure in the central region 200 of the wound electrode assembly and along each winding to a second end 121b of the counter electrode structure in the outer region 202 of the electrode assembly E and L CE This includes the following. In the embodiments shown, the wound electrode assembly generally includes a cylindrical shape.

[0089] According to one embodiment, the porous electrical insulating material has a length L of the counter electrode structure of the constituent unit of the unit cell group. CE Extending by at least 50%, at least 60%, at least 75%, at least 85%, and / or at least 90%, and / or the length L of the electrode structure of the constituent unit of the unit cell group. E It extends for at least 50%, at least 60%, at least 75%, at least 85%, and / or at least 90% of the length. Referring to Figures 6A and 6B, embodiments include an electrode assembly without the porous electrical insulating material 508 (Figure 6A) and an electrode assembly with the porous electrical insulating material 508 extending for at least 50%, at least 60%, at least 75%, at least 85%, and / or at least 90% of the length L of the counter electrode structure (Figure 6B). CE A top view is shown of an electrode assembly provided to fill recesses 505a and 505b, which are grooves extending along the electrode. In the embodiment shown in Figure 6B, the porous electrical insulating material 508 covers the counter electrode active material layer 138 and the counter electrode current collector 140. In addition to covering the first vertical end faces 501a and the second vertical end faces 501b of the cathode structure, the embodiment shown in Figure 6B further includes the porous electrical insulating material covering the length of the electrode active material layer 132 of the electrode structure 110 such that only the electrode current collector 136 remains exposed.

[0090] In one embodiment, the electrode assembly 106 is enclosed within a volume V defined by a set of electrode constraints 108 that suppresses the overall macroscopic growth of the electrode assembly 106, as illustrated, for example, in Figure 1A. The set of electrode constraints 108 may be capable of suppressing the growth of the electrode assembly 106 along one or more dimensions to reduce swelling and deformation of the electrode assembly 106 and thereby improve the reliability and cycling life of the energy storage device 100 having the set of electrode constraints 108. Although not limited to any one specific theory, it is conceivable that carrier ions moving between the electrode structure 110 and the counter electrode structure 112 during charging and / or discharging of the secondary battery 102 and / or electrode assembly may be inserted into the electrode active material and cause the electrode active material and / or electrode structure 110 to expand. This expansion of the electrode structure 110 may deform and swell the electrode and / or electrode assembly 106, thereby impairing the structural integrity of the electrode assembly 106 and / or increasing the possibility of electrical short circuits or other failures. In one example, excessive swelling and / or expansion and contraction of the electrode active material layer 132 during cycling of the energy storage device 100 may cause fragments of the electrode active material to peel off from the electrode active material layer 132 and / or tear thinly, thereby impairing the efficiency and cycling life of the energy storage device 100. In another example, excessive swelling and / or expansion and contraction of the electrode active material layer 132 may cause the electrode active material to break through the electrically insulating microporous separator 130, thereby causing an electrical short circuit and other failures in the electrode assembly 106. Therefore, the set of electrode constraints 108 prevents this swelling or growth from occurring during cycling between the charged and discharged states, thereby improving the reliability, efficiency, and / or cycling life of the energy storage device 100.

[0091] In one embodiment, a set of electrode constraints 108 comprising a primary growth constraint system 151 is provided to mitigate and / or reduce at least one of growth, expansion, and / or swelling of the electrode assembly 106 in the longitudinal direction (i.e., in the direction parallel to the Y-axis), as shown, for example, in Figure 1A. For example, the primary growth constraint system 151 may include a structure configured to restrict growth by opposing expansion at the longitudinal end faces 116, 118 of the electrode assembly 106. In one embodiment, the primary growth constraint system 151 comprises a first primary growth constraint 154 and a second primary growth constraint 156 that are separated from each other in the longitudinal direction (stack direction) and can work in conjunction with at least one primary connecting member 162 that connects the first primary growth constraint 154 and the second primary growth constraint 156 together to suppress growth in the electrode assembly 106 in the stack direction. For example, the first primary growth constraint 154 and the second primary growth constraint 156 can at least partially cover the first longitudinal end face 116 and the second longitudinal end face 118 of the electrode assembly 106, and can work in conjunction with connecting members 162 and 164 that connect the primary growth constraints 154 and 156 to each other to prevent and suppress any growth in the electrode assembly 106 that occurs during repeated charging and / or discharging cycles.

[0092] In addition, the repeated charging and discharging processes in the secondary battery 102 can induce growth and strain not only in the longitudinal direction (e.g., the Y-axis in Figure 1A) of the electrode assembly 106, but also in the transverse and vertical directions (e.g., the X-axis and Z-axis in Figure 1A, respectively), as discussed above, which are orthogonal to the longitudinal direction. Furthermore, in certain embodiments, the incorporation of a primary growth constraint system 151 to inhibit growth in one direction may even exacerbate growth and / or swelling in one or more other directions. For example, if a primary growth constraint system 151 is provided to suppress longitudinal growth of the electrode assembly 106, the intercalation of carrier ions during the charging and discharging cycle, and the resulting swelling of the electrode structure, may induce strain in one or more other directions. In particular, in one embodiment, the strain generated by the combination of electrode growth / swelling and longitudinal growth constraint can lead to buckling or other failures of the electrode assembly 106 in the vertical direction (e.g., the Z-axis shown in Figure 1A) or even in the lateral direction (e.g., the X-axis shown in Figure 1A). Therefore, in one embodiment of the present disclosure, a secondary growth constraint system 152 is provided that can operate in conjunction with a primary growth constraint system 151 to suppress the growth of the electrode assembly 106 along multiple axes of the electrode assembly 106. For example, in one embodiment, the secondary growth constraint system 152 may be configured to operate in conjunction with the primary growth constraint system 151 or synergistically with the primary growth constraint system 151 in a different manner, thereby suppressing the overall growth of the electrode assembly 106 and resulting in improved performance and reduced failure occurrence for the secondary battery having the electrode assembly 106 and the primary and secondary growth constraint systems 151 and 152, respectively.

[0093] Referring to Figures 7A to 7C, embodiments of a set of electrode constraints 108 having a primary growth constraint system 151 and a secondary growth constraint system 152 for an electrode assembly 106 are shown. Figure 7A shows a cross-section of the electrode assembly 106 in Figure 1A obtained along the longitudinal axis (Y-axis), such that the resulting 2D cross-sections are illustrated in the vertical axis (Z-axis) and the longitudinal axis (Y-axis). Figure 7B shows a cross-section of the electrode assembly 106 in Figure 1A obtained along the transverse axis (X-axis), such that the resulting 2D cross-sections are illustrated in the vertical axis (Z-axis) and the transverse axis (X-axis). As shown in Figure 7A, the primary growth constraint system 151 may generally comprise a first primary growth constraint 154 and a second primary growth constraint 156, respectively, separated from each other along the longitudinal axis (Y-axis). For example, in one embodiment, the first primary growth constraint 154 and the second primary growth constraint 156 each include the first primary growth constraint 154 which at least partially, or even completely, covers the first longitudinal end face 116 of the electrode assembly 106, and the second primary growth constraint 156 which at least partially, or even completely, covers the second longitudinal end face 118 of the electrode assembly 106. In another version, one or more of the first primary growth constraint 154 and the second primary growth constraint 156 may be located inside the longitudinal end faces 116, 118 of the electrode assembly 106, for example, when one or more of the primary growth constraints include the internal structure of the electrode assembly 106. The primary growth constraint system 151 may further include at least one primary connecting member 162 which connects the first primary growth constraint 154 and the second primary growth constraint 156 and may have a principal axis parallel to the longitudinal direction. For example, the primary growth constraint system 151 may include a first primary connecting member 162 and a second primary connecting member 164, respectively, separated from each other along an axis perpendicular to the longitudinal axis, such as along the vertical axis (Z-axis) as depicted in the embodiment. The first primary connecting member 162 and the second primary connecting member 164 can function to suppress growth of the electrode assembly 106 along the longitudinal axis by connecting the first primary growth constraint 154 and the second primary growth constraint 156 to each other and maintaining tension between them.

[0094] As further shown in Figures 7A to 7C, the electrode constraint set 108 may further include a secondary growth constraint system 152, which may generally comprise a first secondary growth constraint 158 ​​and a second secondary growth constraint 160 separated from each other along a second direction perpendicular to the longitudinal direction, such as along the vertical axis (Z-axis) in the shown embodiments. For example, in one embodiment, the first secondary growth constraint 158 ​​extends at least partially across a first region 148 of the lateral surface 142 of the electrode assembly 106, and the second secondary growth constraint 160 extends at least partially across a second region 150 of the lateral surface 142 of the electrode assembly 106, opposite to the first region 148. In another version, one or more of the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 may be located inside the lateral surface 142 of the electrode assembly 106, for example, when one or more of the secondary growth constraints include the internal structure of the electrode assembly 106. In one embodiment, the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 are connected by at least one secondary connecting member 166, each having a principal axis parallel to a second direction, such as the vertical axis. The secondary connecting member 166 may function to connect and hold the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 to each other with tension, such as suppressing growth of the electrode assembly 106 along a direction perpendicular to the longitudinal direction, such as suppressing growth in the vertical direction (e.g., along the Z-axis). In the embodiment shown in Figure 7A, at least one secondary connecting member 166 may correspond to at least one of the first primary growth constraint 154 and the second primary growth constraint 156. However, the secondary connecting member 166 is not limited to that, and may alternatively and / or in addition, have other structures and / or configurations.

[0095] In one embodiment, the primary growth constraint system 151 and the secondary growth constraint system 152 are configured to operate cooperatively such that a portion of the primary growth constraint system 151 functions cooperatively as part of the secondary growth constraint system 152, and / or a portion of the secondary growth constraint system 152 functions cooperatively as part of the primary growth constraint system 151. For example, in the embodiments shown in Figures 7A and 7B, the first primary connecting member 162 and the second primary connecting member 164 of the primary growth constraint system 151 can function as at least a portion, or even the entire structure, of the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 that constrain growth in a second direction perpendicular to the longitudinal direction. In another embodiment, as described above, one or more of the first primary growth constraint 154 and the second primary growth constraint 156 can function as one or more secondary connecting members 166 for connecting the first secondary growth constraint 158 ​​and the second secondary growth constraint 160, respectively. Conversely, at least a portion of the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 can each act as the first primary connecting member 162 and the second primary connecting member 164 of the primary growth constraint system 151, respectively, and at least one secondary connecting member 166 of the secondary growth constraint system 152 can, in one embodiment, each act as one or more of the first primary growth constraint 154 and the second primary growth constraint 156, respectively. Thus, the primary growth constraint system 151 and the secondary growth constraint system 152 can each share components and / or structures for inhibiting the growth of the electrode assembly 106.

[0096] In one embodiment, the set of electrode constraints 108 may comprise structures such as primary and secondary growth constraints, and primary and secondary connecting members, which may be structures located outside and / or inside the battery housing 104, or may be part of the battery housing 104 itself. In a particular embodiment, the battery housing 104 may be a sealed housing, for example, to seal a liquid electrolyte inside and / or to seal the electrode assembly 106 from the external environment. In one embodiment, the set of electrode constraints 108 may comprise a combination of structures including the battery housing 104 and other structural components. In one such embodiment, the battery housing 104 may be a component of the primary growth constraint system 151 and / or the secondary growth constraint system 152, or in other words, in one embodiment, the battery housing 104, alone or in combination with one or more other structures (inside and / or outside the battery housing 104, e.g., the primary growth constraint system 151 and / or the secondary growth constraint system 152), suppresses the growth of the electrode assembly 106 in the electrode stacking direction D and / or in a second direction perpendicular to the stacking direction D. In one embodiment, one or more of the primary growth constraints 154, 156 and the secondary growth constraints 158, 160 may include a structure located inside the electrode assembly. In another embodiment, the primary growth constraint system 151 and / or the secondary growth constraint system 152 do not form any part of the battery housing 104, but instead one or more separate structures other than the battery housing 104 (inside and / or outside the battery housing 104) suppress the growth of the electrode assembly 106 in the electrode stacking direction D and / or in a second direction perpendicular to the stacking direction D. In another embodiment, the primary growth constraint system 151 and the secondary growth constraint system 152 are located inside the battery housing 104, which may be a sealed battery housing such as a hermetically sealed battery housing. The electrode assembly 106 can be suppressed by a set of electrode constraints 108 at a pressure greater than the pressure exerted by the growth and / or swelling of the electrode assembly 106 during repeated cycling of the energy storage device 100 or secondary battery 102 having the electrode assembly 106.

[0097] In one exemplary embodiment, the primary growth constraint system 151 includes one or more separate structures within the battery housing 104 that suppress the growth of the electrode structure 110 in the stacking direction D by applying a pressure in the stacking direction D that exceeds the pressure generated by the electrode structure 110 during repeated cycling of the secondary battery 102 having the electrode structure 110 as part of the electrode assembly 106. In another exemplary embodiment, the primary growth constraint system 151 includes one or more separate structures within the battery housing 104 that suppress the growth of the counter electrode structure 112 in the stacking direction D by applying a pressure in the stacking direction D that exceeds the pressure generated by the counter electrode structure 112 during repeated cycling of the secondary battery 102 having the counter electrode structure 112 as part of the electrode assembly 106. The secondary growth constraint system 152 may also include one or more separate structures within the battery housing 104 that, during repeated cycling of the secondary battery 102 each having an electrode structure 110 or a counter electrode structure 112, suppress the growth of at least one of the electrode structure 110 and the counter electrode structure 112 in a second direction perpendicular to the stacking direction D, such as along the vertical axis (Z-axis), by applying a pressure in a second direction that exceeds the pressure generated by the electrode structure 110 or the counter electrode structure 112, respectively.

[0098] In another embodiment, the first primary growth constraint 154 and the second primary growth constraint 156 of the primary growth constraint system 151 suppress the growth of the electrode assembly 106 by applying pressure longitudinally to the first longitudinal end face 116 and the second longitudinal end face 118 of the electrode assembly 106, respectively, that is, to other surfaces of the electrode assembly 106 that would be in a direction perpendicular to the longitudinal direction, such as the first and second regions of the lateral surface 142 of the electrode assembly 106 that are opposite each other along the transverse and / or vertical axes, by applying pressure longitudinally that exceeds the pressure applied by the first primary growth constraint 154 and the second primary growth constraint 156. That is, the first primary growth constraint 154 and the second primary growth constraint 156 may apply pressure longitudinally (Y-axis) that exceeds the pressure generated by the first primary growth constraint 154 and the second primary growth constraint 156 in directions perpendicular to the longitudinal direction, such as the transverse (X-axis) and vertical (Z-axis) directions. For example, in one such embodiment, the primary growth constraint system 151 suppresses the growth of the electrode assembly 106 by a pressure on the first longitudinal end face 116 and the second longitudinal end face 118 (i.e., in the stacking direction D) that exceeds the pressure maintained on the electrode assembly 106 by the primary growth constraint system 151 in at least one or more of two directions perpendicular to the stacking direction D. In another embodiment, the primary growth constraint system 151 suppresses the growth of the electrode assembly 106 by a pressure on the first longitudinal end face 116 and the second longitudinal end face 118 (i.e., in the stacking direction D) that exceeds at least twice the pressure maintained on the electrode assembly 106 by the primary growth constraint system 151 in at least one or more of two directions perpendicular to the stacking direction D. For example, in one such embodiment, the primary growth constraint system 151 suppresses the growth of the electrode assembly 106 by a pressure on the first longitudinal end face 116 and the second longitudinal end face 118 (i.e., in the stacking direction D) that is at least three times the pressure maintained on the electrode assembly 106 by the primary growth constraint system 151 in at least one or both of two directions perpendicular to the stacking direction D.As a further example, in one such embodiment, the primary growth constraint system 151 suppresses the growth of the electrode assembly 106 by a pressure on the first longitudinal end face 116 and the second longitudinal end face 118 (i.e., in the stacking direction D) that is at least four times the pressure maintained on the electrode assembly 106 by the primary growth constraint system 151 in at least one or both of two directions perpendicular to the stacking direction D. As a further example, in one such embodiment, the primary growth constraint system 151 suppresses the growth of the electrode assembly 106 by a pressure on the first longitudinal end face 116 and the second longitudinal end face 118 (i.e., in the stacking direction D) that is at least five times the pressure maintained on the electrode assembly 106 in at least one or both of two directions perpendicular to the stacking direction D.

[0099] Referring here to Figure 7C, an embodiment of an electrode assembly 106 having a set of electrode constraints 108 is shown along with a cross-section obtained along the line A-A' shown in Figure 1A. In the embodiment shown in Figure 7C, the primary growth constraint system 151 may comprise a first primary growth constraint 154 and a second primary growth constraint 156 on the longitudinal end faces 116, 118 of the electrode assembly 106, respectively, and the secondary growth constraint system 152 may comprise a first secondary growth constraint 158 ​​and a second secondary growth constraint 160 on the opposite first surface region 148 and second surface region 150 of the lateral surface 142 of the electrode assembly 106. According to this embodiment, the first primary growth constraint 154 and the second primary growth constraint 156 may function as at least one secondary connecting member 166 to connect the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 and to maintain the growth constraints tensilely relative to each other in a second direction (e.g., vertical) perpendicular to the longitudinal direction. However, additionally and / or alternatively, the secondary growth constraint system 152 may include at least one secondary connecting member 166 located in a region other than the longitudinal end faces 116, 118 of the electrode assembly 106. It can also be understood that at least one secondary connecting member 166 may act as at least one of the first primary growth constraint 154 and the second primary growth constraint 156 located inside the longitudinal ends 116, 118 of the electrode assembly, and may work in conjunction with any other internal primary growth constraint and / or primary growth constraint at the longitudinal ends 116, 118 of the electrode assembly 106 to suppress growth. Referring to the embodiment shown in Figure 7C, secondary connecting members 166 may be provided that are spaced apart along the longitudinal axis from the first longitudinal end faces 116 and the second longitudinal end faces 118 of the electrode assembly 106, respectively, such as toward the central region of the electrode assembly 106. The secondary connecting member 166 can connect the first secondary growth constraint 158 ​​and the second secondary growth constraint 160, respectively, at internal positions from the electrode assembly end faces 116 and 118, and can receive the tension between the secondary growth constraints 158 and 160 at those positions.In one embodiment, secondary connecting members 166 connecting the secondary growth constraints 158, 160 at internal positions from the end faces 116, 118 are provided in addition to one or more secondary connecting members 166 provided to the electrode assembly end faces 116, 118, such as secondary connecting members 166 that also function as primary growth constraints 154, 156 at the longitudinal end faces 116, 118. In another embodiment, the secondary growth constraint system 152 comprises one or more secondary connecting members 166 that connect to a first secondary growth constraint 158 ​​and a second secondary growth constraint 160 at internal positions spaced apart from the longitudinal end faces 116, 118, with or without the presence of secondary connecting members 166 at the longitudinal end faces 116, 118. The internal secondary connecting members 166 may also be understood to act as a first primary growth constraint 154 and a second primary growth constraint 156 according to one embodiment. For example, in one embodiment, at least one of the internal secondary connecting members 166 may include at least a portion of the electrode structure 110 or the counter electrode structure 112, as will be described in more detail below.

[0100] More specifically, with respect to the embodiment shown in Figure 7C, the secondary growth constraint system 152 may include a first secondary growth constraint 158 ​​overlapping a first region 148 of the lateral surface 142 of the electrode assembly 106, and a second secondary growth constraint 160 on the opposite side overlapping a second region 150 of the lateral surface 142 of the electrode assembly 106, wherein the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 are separated from each other in the vertical direction (i.e., along the Z-axis). Additionally, the secondary growth constraint system 152 may further include at least one internal secondary connecting member 166 spaced apart from the longitudinal end faces 116, 118 of the electrode assembly 106. The internal secondary connecting member 166 may be aligned parallel to the Z-axis and connect the first secondary growth constraint 158 ​​and the second secondary growth constraint 160, respectively, to maintain the growth constraints relative to each other in tension, forming at least a portion of the secondary growth constraint system 152. In one embodiment, at least one internal secondary connecting member 166, either alone or in conjunction with secondary connecting members 166 located at the longitudinal end faces 116, 118 of the electrode assembly 106, can reduce vertical growth of the electrode assembly 106 during repeated charging and / or discharging of the energy storage device 100 and / or secondary battery 102 having the electrode assembly 106, by being subjected to tension between first and secondary growth constraints 158, 160. Furthermore, in the embodiment shown in Figure 7C, the set of electrode constraints 108 further comprises a primary growth constraint system 151 having a first primary growth constraint 154 and a second primary growth constraint 156 at the longitudinal ends 116, 118 of the electrode assembly 106, which are connected to a first lateral surface region 148 and a second lateral surface region 150 of the electrode assembly 106 by a first primary connecting member 162 and a second primary connecting member 164, respectively. In one embodiment, the secondary internal connecting member 166 can be understood to act in coordination with one or more of the first primary growth constraints 154 and the second primary growth constraints 156, respectively, and exert constraint pressure on the portions of the electrode assembly 106 that exist longitudinally between the secondary internal connecting member 166 and the longitudinal ends 116, 118 of the electrode assembly 106, where the first primary growth constraints 154 and the second primary growth constraints 156 may be located, respectively.

[0101] According to one embodiment, the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 are each connected to a secondary connecting member 166 which includes at least a portion of the electrode structure 110 or counter electrode structure 112 of the electrode assembly 106, or other internal structure. In one embodiment, the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 may each be connected to the first and / or second vertical end faces of the counter electrode structure 112 and / or electrode structure 110, or other internal structure that form the secondary connecting member 166. In one embodiment, the first secondary growth constraint 158 ​​is connected to the first vertical end faces 500a, 501a of the electrode structure 110 and / or counter electrode structure 112 of the constituent unit of the unit cell group 504. In another embodiment, the second secondary growth constraint 160 is connected to the second vertical end faces 500b, 501b of the electrode structure 110 or counter electrode structure 112 of the constituent unit of the unit cell group 504. The constituent units of the unit cells connected at the first vertical end face may be the same as or different from the constituent units of the unit cells connected at the second vertical end face. The first secondary growth constraint and / or the second secondary growth constraint may be connected to the first and / or second vertical end faces away from the electrode structure and / or counter electrode structure, which includes one or more of the electrode current collector, electrode active material layer, counter electrode current collector, and counter electrode active material layer in the constituent units of the unit cell group. In another example, the first and second secondary growth constraints may be connected to the first and / or second vertical end faces of the electrical insulation separator. Thus, in a particular embodiment, the secondary connecting member 166 may comprise one or more of the electrode structures and / or counter electrode structures, which include one or more of the electrode current collector, electrode active material layer, counter electrode current collector, and counter electrode active material layer in the constituent units of the unit cell group. Referring to Figures 3A and 3B, an embodiment is shown in which the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 are connected to a secondary connecting member 166 that includes an electrode current collector 136 in the constituent unit of the unit cell group. In Figure 4, the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 are connected to a secondary connecting member 166 that includes an electrode structure 110 that includes an electrode current collector 136.Furthermore, in one embodiment, the first primary connecting member is the first secondary growth constraint, the second primary connecting member is the second secondary growth constraint, and the first primary growth constraint or the second primary growth constraint is the first secondary connecting member.

[0102] Referring to Figures 15 and 16, in one embodiment, the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 are connected to the first end plate 180 and the second end plate 182, which correspond to the first primary growth constraint 154 and the second primary growth constraint 156. In one embodiment, the end segments 1880 of the first and secondary growth constraints 158 and 160 at the longitudinal ends opposite the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 wrap around at least a portion of the first vertical end face 1870a and the second vertical end face 1870b of the first and second end plates, respectively. In one embodiment, the end segments 1880 of the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 wrap around at least a portion of the first vertical end face 1870a and the second vertical end face 1870b of the first end plate 180 and the second end plate 182, respectively, and connect to the outer longitudinal end faces of the first and second end plates. According to some embodiments, the end segments of the first and second secondary growth constraints are connected to the outer longitudinal end faces of the first and second end plates by one or more of the following methods: adhesion, bonding, welding, joining, soldering, sintering, crimping, brazing, thermal spray joining, clamping, wire joining, ribbon joining, ultrasonic joining, ultrasonic welding, resistance welding, laser beam welding, electron beam welding, induction welding, cold welding, plasma spraying, flame spraying, and arc spraying. According to one embodiment, the end segments of the first and second secondary growth constraints wrap around at least a portion of the first and second vertical end faces of the first and second end plates, respectively, to provide a curved profile of the end segments in a plane formed by a vertical axis and a longitudinal axis parallel to the stacking direction. In one embodiment, the end segments of the first and second growth constraints are curved around the first and second vertical end faces of the first and second end plates.

[0103] According to embodiments of this specification, the primary growth constraint system 151 suppresses the growth of the electrode assembly 106 in the longitudinal direction such that the increase in the ferret diameter of the electrode assembly 106 that may occur after 20 consecutive cycles (cycles between the charging and discharging states) of the secondary battery 102 is less than 20%, or less than 10% after 10 consecutive cycles of the secondary battery, or less than 1% after 5 consecutive cycles, or less than 1% per cycle of the battery. In one embodiment, the increase in the ferret diameter of the electrode assembly in the stacking direction that may occur after 20 and / or 50 consecutive cycles of the secondary battery is less than 3% and / or less than 2%. According to further embodiments of this specification, a secondary growth constraint system 152 comprising a first connecting member 158 and a second connecting member 160 suppresses the growth of the electrode assembly 106 in the vertical direction such that the increase in the ferret diameter of the electrode assembly in the vertical direction that may occur after 20 consecutive cycles of the secondary battery is less than 20%, or less than 10% after 10 consecutive cycles of the secondary battery, or less than 1% after 5 consecutive cycles, or less than 1% per cycle of the battery. In one embodiment, the increase in the ferret diameter of the electrode assembly in the vertical direction that may occur after 20 and / or 50 consecutive cycles of the secondary battery is less than 3% and / or less than 2%.

[0104] In one embodiment, the first primary growth constraint 154 and the second primary growth constraint 156 include, respectively, the first primary growth constraint 154 which covers at least partially or completely the first longitudinal end face 116 of the electrode assembly 106, and the second primary growth constraint 156 which covers at least partially or completely the second longitudinal end face 118 of the electrode assembly 106. In one embodiment, the electrode assembly 106 is configured such that the surface area of ​​the projection of the electrode assembly 106 into a plane perpendicular to the stacking direction (i.e., the longitudinal direction) is smaller than the surface area of ​​the projection of the electrode assembly 106 into another orthogonal plane. For example, referring to the embodiment of the electrode assembly 106 shown in Figure 1 (e.g., a rectangular prism), the surface area of ​​the projection of the electrode assembly 106 into a plane perpendicular to the stacking direction (i.e., the XZ plane) is LEA ×H EA It can be seen that this corresponds to. Similarly, the projection of electrode assembly 106 into the ZY plane is W EA ×H EA Corresponding to this, the projection of the electrode assembly 106 into the XY plane is L EA ×W EA Corresponds to H. Therefore, the electrode assembly 106 is configured such that the stacking direction intersects with the plane in which the projection with the smallest surface area exists. Thus, in the embodiment shown in Figure 2A, the electrode assembly 106 is configured such that the stacking direction is H EA ×L EA It is positioned so as to intersect the XZ plane where the projection of the smallest surface area corresponding to exists. That is, the electrode assembly is positioned so as to intersect the XZ plane where the projection of the smallest surface area corresponding to H EA ×L EA The projection having ) is positioned so as to be perpendicular to the stacking direction (for example, the longitudinal end face).

[0105] In one embodiment, the surface areas of the first longitudinal end face 116 and the second longitudinal end face 118 are less than 33% of the surface area of ​​the electrode assembly 106. For example, in such an embodiment, the combined surface areas of the first longitudinal end face 116 and the second longitudinal end face 118 are each less than 25% of the total surface area of ​​the electrode assembly 106. As a further example, in one embodiment, the combined surface areas of the first longitudinal end face 116 and the second longitudinal end face 118 are each less than 20% of the total surface area of ​​the electrode assembly. As a further example, in one embodiment, the combined surface areas of the first longitudinal end face 116 and the second longitudinal end face 118 are each less than 15% of the total surface area of ​​the electrode assembly. As a further example, in one embodiment, the combined surface areas of the first longitudinal end face 116 and the second longitudinal end face 118 are each less than 10% of the total surface area of ​​the electrode assembly.

[0106] In one embodiment, each of the first and second longitudinal end faces of the electrode assembly is subjected to a compressive load of at least 100 psi. For example, in one embodiment, each of the first and second longitudinal end faces is subjected to a compressive load of at least 200 psi. As a further example, in one embodiment, each of the first and second longitudinal end faces is subjected to a compressive load of at least 300 psi. As a further example, in one embodiment, each of the first and second longitudinal end faces is subjected to a compressive load of at least 400 psi. As yet another example, in one embodiment, each of the first and second longitudinal end faces is subjected to a compressive load of at least 500 psi. As yet another example, in one embodiment, each of the first and second longitudinal end faces is subjected to a compressive load of at least 600 psi. As yet another example, in one embodiment, each of the first and second longitudinal end faces is subjected to a compressive load of at least 700 psi. As yet another example, in one embodiment, each of the first and second longitudinal end faces is subjected to a compressive load of at least 800 psi. As a further example, in one embodiment, each of the first and second longitudinal end faces is subjected to a compressive load of at least 900 psi. In another example, each of the first and second longitudinal end faces is subjected to a compressive load of at least 1000 psi. In one embodiment, the first and second secondary growth constraints are connected to at least one secondary connecting member by one or more of the following methods: adhesion, bonding, welding, joining, soldering, sintering, crimping, brazing, thermal spray joining, clamping, wire joining, ribbon joining, ultrasonic joining, ultrasonic welding, resistance welding, laser beam welding, electron beam welding, induction welding, cold welding, plasma spraying, flame spraying, and arc spraying.

[0107] In one embodiment, the regions of the longitudinal end faces 122, 124 of the electrode assembly that coincide with the projection of the constituent units of the electrode group and the counter electrode group onto the longitudinal end faces 162, 164 (i.e., the “projected surface region”) will each be subjected to a significant compressive load imposed by constraint 130. For example, in one embodiment, the regions of the longitudinal end faces of the electrode assembly that coincide with the projection of the constituent units of the electrode group and the counter electrode group onto the longitudinal end faces will each be subjected to a compressive load of at least 0.7 MPa (averaged over each of the surface regions of the first and second projected surface regions). As a further example, in such an embodiment, the regions of the longitudinal end faces of the electrode assembly that coincide with the projection of the constituent units of the electrode group and the counter electrode group onto the longitudinal end faces will each be subjected to a compressive load of at least 1.75 MPa (averaged over each of the surface regions of the first and second projected surface regions). As a further example, in one such embodiment, the regions of the longitudinal end face of the electrode assembly that coincide with the projection of the constituent units of the electrode group and the counter electrode group onto the longitudinal end face will each be subjected to a compressive load of at least 2.8 MPa (averaged over each of the surface regions of the first and second projected surface regions, respectively). As a further example, in one such embodiment, the regions of the longitudinal end face of the electrode assembly that coincide with the projection of the constituent units of the electrode group and the counter electrode group onto the longitudinal end face will each be subjected to a compressive load of at least 3.5 MPa (averaged over each of the surface regions of the first and second projected surface regions, respectively). As a further example, in one such embodiment, the regions of the longitudinal end face of the electrode assembly that coincide with the projection of the constituent units of the electrode group and the counter electrode group onto the longitudinal end face will each be subjected to a compressive load of at least 5.25 MPa (averaged over each of the surface regions of the first and second projected surface regions, respectively). As a further example, in one such embodiment, the longitudinal end face regions of the electrode assembly that coincide with the projection of the constituent units of the electrode group and the opposing electrode group onto the longitudinal end face are each subjected to a compressive load of at least 7 MPa (averaged over the respective surface regions of the first and second projected surface regions).As a further example, in one such embodiment, the longitudinal end face regions of the electrode assembly that coincide with the projections of the constituent units of the electrode group and the counter electrode group onto the longitudinal end face will each experience a compressive load of at least 8.75 MPa (averaged over each of the first and second projected surface regions, respectively). However, generally, the longitudinal end face regions of the electrode assembly that coincide with the projections of the constituent units of the electrode group and the counter electrode group onto the longitudinal end face will each experience a compressive load of about 10 MPa or less (averaged over each of the first and second projected surface regions, respectively). In each of the exemplary embodiments described above, the longitudinal end face of the secondary battery of the present disclosure will experience such a compressive load when the battery is charged to at least about 80% of its rated capacity.

[0108] Referring to Figures 3A and 3B, in one embodiment, the first secondary growth constraint 158 ​​and / or the second secondary growth constraint 160 are their respective vertical thickness T CThe electrode assembly includes an opening 176 formed through the first secondary growth constraint 158 ​​and / or the second secondary growth constraint 160. According to embodiments herein, the opening 176 can provide a passage for the flow of carrier ions from the auxiliary electrode 686 through the first secondary growth constraint 158 ​​and / or the second secondary growth constraint 160 to the constituent units of the unit cell group. For example, for an auxiliary electrode 686 located outside the volume V enclosed by the set of electrode constraints 108, for example, outside the first secondary growth constraint 158 ​​and / or the second secondary growth constraint 160, carrier ions supplied from the auxiliary electrode 686 can access the constituent units of the unit cells of the electrode assembly inside the constraints, via a passage through the opening 176. In the embodiment shown in Figure 8, which draws a top view of the electrode assembly 106 showing the first secondary growth constraint 158, the opening 176 includes a slot shape having elongated dimensions oriented in the longitudinal and / or stacking direction (Y direction) and extending across the constituent units of the multiple unit cells. Other shapes and / or configurations of the opening 176 may also be provided. According to certain embodiments, at least a portion of the opening 176 is vertically aligned on the porous electrical insulating material 508, so that carrier ions entering the electrode assembly 106 through the opening 176 pass through the porous electrical insulating material 508 to the constituent units of the unit cell group. The process for transferring carrier ions from the auxiliary electrode 686 to the constituent units of the unit cell, according to certain embodiments, may include transferring carrier ions from the auxiliary electrode 686 through the opening 176 and through the porous electrical insulating material 508 to one or more of the electrode structure 110 and counter electrode structure 112. In the embodiment shown in Figure 8, the porous electrical insulating material 508 extends on the first and second vertical end faces of the electrode structure and counter electrode structure, within the limits of first and second secondary growth constraints, while the first and second vertical end faces of the electrode current collector 136 remain exposed.

[0109] Further embodiments of the present disclosure provide a method for manufacturing an electrode assembly and / or a secondary battery. According to one embodiment, the manufacturing method comprises providing a group of unit cells stacked in a continuous stacking direction, wherein (i) each unit cell comprises an electrode structure, a counter electrode structure, and an electrical insulating separator between the electrode structure and the counter electrode structure, (ii) the electrode structure, counter electrode structure, and electrical insulating separator within each unit cell have first and second vertical end faces that are separated vertically and are opposite each other, and (iii) the vertical direction is perpendicular to the stacking direction. The manufacturing method further comprises providing a porous electrical insulating material that covers the first and / or second vertical end faces of the electrode structure or counter electrode structure of a constituent unit of the group of unit cells, wherein the porous electrical insulating material has a porosity in the range of 20% to 60%. According to one embodiment, a porous electrical insulating material is provided by coating a first vertical end face and / or a second vertical end face with a slurry or paste containing a particulate material binder material in a solvent, and then evaporating the solvent to leave the particulate material dispersed in the binder material on the first vertical end face and / or the second vertical end face. For example, in the embodiment shown in Figure 9, the slurry and / or paste 900 is applied to the first vertical end faces 500a, 501a and / or the second vertical end faces 500b, 501b of the electrode structure 110 and / or the counter electrode structure 112.

[0110] In one embodiment, the binder material is soluble in a solvent, and the solvent is evaporated by heating and / or drying the solvent by a gas flow. For example, the solvent may include N-methyl-2-pyrrolidone (NMP), heptane, octane, toluene, xylene, or a mixed hydrocarbon solvent. Furthermore, according to a particular embodiment, the slurry and / or paste comprises at least 50% by weight, at least 55% by weight, at least 60% by weight, at least 65% by weight, at least 70% by weight, at least 75% by weight, and / or at least 80% by weight of particulate material, and 90% by weight or less, 85% by weight or less, 80% by weight or less, and / or 75% by weight or less of particulate material. According to one embodiment, the density of the porous electrical insulating material provided per unit surface area of ​​the first and second vertical end faces of the counter electrode structure is 15 mg / cm³. 2 ~25 mg / cm³ 2 It is within the range.

[0111] According to one embodiment, the manufacturing method further includes connecting vertically separated first and second secondary growth constraints to the electrode current collectors of the constituent units of the electrode structure, the first and second secondary growth constraints having openings formed through their respective vertical thicknesses, and the secondary growth constraint system at least partially suppresses the vertical growth of the electrode assembly during the cycling of the electrode assembly. For example, the growth constraints can be connected to the exposed first and second vertical end faces of the electrode current collectors after a porous electrical insulating material has been applied to the first and / or second vertical end faces of the electrode structure 110 and / or the counter electrode structure 112, as shown in Figure 8.

[0112] In another embodiment, a method for manufacturing an electrode assembly and / or secondary battery includes (1) providing an auxiliary electrode including a carrier ion source outside of a porous electrical insulating material, and (2) applying a bias voltage between the auxiliary electrode and a constituent unit of an electrode group or a constituent unit of a counter electrode group to provide a flow of carrier ions to the electrode group and / or counter electrode structure of the constituent unit of a unit cell group through openings in first and second secondary growth constraints and through the porous electrical insulating material. For example, the manufacturing method may include a process for forming a secondary battery, which includes an initial charging process for charging the secondary battery and / or the electrode structure, and a process for replenishing carriers lost in the initial charging process. According to a particular embodiment, a method for manufacturing an electrode assembly and / or secondary battery may include any of the methods for providing carrier ions to the constituent units of a unit cell group described herein. According to a further embodiment, a method for transferring carrier ions from an auxiliary electrode including a carrier ion source to an electrode assembly may be performed during an initial or subsequent charging cycle of the secondary battery and / or electrode assembly.

[0113] In one embodiment, a method is provided for preparing an electrode assembly 106 comprising a set of electrode constraints 108, the electrode assembly 106 which can be used as part of a secondary battery configured to cycle between a charged state and a discharged state. The method generally includes forming a sheet structure, cutting the sheet structure into fragments (and / or pieces), stacking the fragments, and applying the set of constraints. It is understood that by strip, fragments other than those in the shape of a strip can be used. These fragments include an electrode active material layer, an electrode current collector, a counter electrode active material layer, a counter electrode current collector, and a separator, and can be stacked to provide an alternating arrangement of electrode active material and / or counter electrode active material. The sheet can include, for example, a unit cell 504 and / or at least one of the components of a unit cell 504. For example, the sheet can include a group of unit cells which can be cut to a predetermined size (such as a size suitable for a 3D battery), and the sheets of unit cells can then be stacked to form the electrode assembly 106. In another example, the sheet may include one or more components of a unit cell, such as at least one of the following: an electrode current collector 136, an electrode active material layer 132, a separator 130, a counter electrode active material layer 138, and a counter electrode current collector 140. The sheet of components can be cut to a predetermined size to form fragments (such as a size suitable for a 3D battery), which can then be stacked to form an alternating arrangement of electrode active material layer components and counter electrode active material layer components.

[0114] In another embodiment, the set of electrode constraints 108 to be applied may correspond to any of those described herein, such as a set of constraints including a primary growth constraint system comprising, for example, first and second primary growth constraints, at least one primary connecting member, first and second primary growth constraints separated from each other in the longitudinal direction, and at least one primary connecting member connecting the first and second primary growth constraints. Furthermore, the set of electrode constraints may include a secondary growth constraint system comprising first and second secondary growth constraints separated in a direction orthogonal to the longitudinal direction (such as vertical or transverse direction) and connected by at least one secondary connecting member, the secondary growth constraint system at least partially suppressing the growth of the electrode assembly in the vertical direction during the cycling of the secondary battery. At least one of the primary connecting member, or the first primary growth constraint and / or second primary growth constraint of the primary growth constraint system, and the secondary connecting member, or the first secondary growth constraint and / or second secondary growth constraint of the secondary growth constraint system, may be one or more assembly components constituting the fragment, such as at least one of an electrode active material layer, an electrode current collector, a counter electrode active material layer, a counter electrode current collector, and a separator. For example, in one embodiment, the primary connecting member of the primary growth constraint system may be one or more assembly components constituting the fragment, such as at least one of an electrode active material layer, an electrode current collector, a counter electrode active material layer, a counter electrode current collector, and a separator. That is, the application of constraints may include applying the first and second primary growth constraints to a primary structural unit connecting member, which is one of the structures in the stacking of fragments.

[0115] Referring here to Figure 2, an exploded view illustrating one embodiment of a secondary battery 102 having the set of electrode constraints 108 of the present disclosure is illustrated. The secondary battery 102 includes, as described above, a battery housing 104 and an electrode assembly within the battery housing 104, the electrode assembly 106 having a first longitudinal end face 116 and a second longitudinal end face 118 on the opposite side (i.e., separated from the first longitudinal end face 116 along the indicated Y-axis Cartesian coordinate system). Alternatively, the secondary battery 102 may comprise a plurality of electrode assemblies 106 having the set of electrode constraints 108 provided within the housing. The electrode assembly 106 includes a group of electrode structures 110 and a group of counter electrode structures 112 stacked relative to each other in the stacking direction D within each electrode assembly 106, or in other words, the groups of electrode structures 110 and counter electrode structures 112 are arranged alternately and continuously, and this continuity progresses in the stacking direction D between a first longitudinal end face 116 and a second longitudinal end face 118, respectively.

[0116] According to the embodiment shown in Figure 2, tabs 190 and 192 protrude outward from the battery housing 104 and provide an electrical connection between the electrode assembly 106 and an energy source or consumer (not shown). More specifically, in this embodiment, tab 190 is electrically connected (e.g., using conductive adhesive) to a tab extension 191, which is electrically connected to an electrode structure 110 of the electrode assembly 106. Similarly, tab 192 is electrically connected (e.g., using conductive adhesive) to a tab extension 193, which is electrically connected to a counter electrode structure 112 of the electrode assembly 106. The tab extensions 191 and 193 can also function as busbars that pool current from each of the respective electrode and counter electrode structures to which the tab extensions 191 and 193 are electrically connected.

[0117] In the embodiment illustrated in Figure 2, the electrode assembly 106 has an associated primary growth constraint system 151 to suppress growth in the longitudinal direction (i.e., the stacking direction D). Alternatively, in one embodiment, multiple electrode assemblies 106 may share at least a portion of the primary growth constraint system 151. In the shown embodiment, each primary growth constraint system 151 includes, as described above, a first primary growth constraint 154 and a second primary growth constraint 156 that may overlap the first longitudinal end face 116 and the second longitudinal end face 118, respectively, and a first primary connecting member 162 and a second primary connecting member 164 on the opposite side that may overlap the lateral surface 142, respectively. The first primary connecting member 162 and the second primary connecting member 164 on opposite sides can pull the first primary growth constraint 154 and the second primary growth constraint 156 toward each other, or, alternatively, can help suppress the longitudinal growth of the electrode assembly 106, and the primary growth constraints 154 and 156 can apply compressive or restrictive forces to the first longitudinal end face 116 and the second longitudinal end face 118 on opposite sides, respectively. As a result, expansion of the electrode assembly 106 in the longitudinal direction is prevented during the formation and / or cycling of the battery 102 between the charged and discharged states. Additionally, the primary growth constraint system 151 exerts a pressure on the electrode assembly 106 in the longitudinal direction (i.e., the stacking direction D) that exceeds the pressure maintained on the electrode assembly 106 in either of two directions that are mutually perpendicular and perpendicular to each other in the longitudinal direction (for example, as illustrated, the longitudinal direction corresponds to the direction of the Y axis, and the two directions that are mutually and perpendicular to each other in the longitudinal direction correspond to the directions of the X axis and Z axis, respectively, of the illustrated Cartesian coordinate system).

[0118] Furthermore, the electrode assembly 106 in the embodiment illustrated in Figure 2 has an associated secondary growth constraint system 152 for suppressing vertical growth (i.e., expansion of the electrode assembly 106, electrode structure 110, and / or counter electrode structure 112 in the vertical direction (i.e., along the Z-axis of the Cartesian coordinate system)). Alternatively, in one embodiment, multiple electrode assemblies 106 share at least a portion of the secondary growth constraint system 152. Each secondary growth constraint system 152 includes, respectively, a first secondary growth constraint 158 ​​and a second secondary growth constraint 160 that may overlap the lateral plane 142, and at least one secondary connecting member 166, each of which is described in more detail above. The secondary connecting member 166 can pull the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 toward each other, or, alternatively, can help suppress the growth of the electrode assembly 106 in the vertical direction, and the first secondary growth constraint 158 ​​and the second secondary growth constraint 160 can apply compressive or restrictive forces to the lateral plane 142, each of which is described in more detail above. As a result, expansion of the electrode assembly 106 in the vertical direction is prevented during the formation and / or cycling of the battery 102 between the charged and discharged states. Additionally, the secondary growth constraint system 152 exerts a pressure on the electrode assembly 106 in the vertical direction (i.e., parallel to the Z-axis of the Cartesian coordinate system) that exceeds the pressure maintained on the electrode assembly 106 in either of two directions that are mutually perpendicular and perpendicular to each other (for example, as illustrated, the vertical direction corresponds to the direction of the Z-axis, and the two directions that are mutually and perpendicular to each other correspond to the X-axis and Y-axis directions of the illustrated Cartesian coordinate system, respectively).

[0119] According to a particular embodiment, to complete the assembly of the secondary battery 102, the battery housing 104 can be filled with a non-aqueous electrolyte (not shown), and the lid 104a can be folded back (along the fold line, FL) and sealed against the upper surface 104b. When fully assembled, the sealed secondary battery 102 occupies a volume (i.e., displacement volume) bounded by the outer surface of the secondary battery 102, the secondary battery housing 104 occupies a volume corresponding to the displacement volume of the battery (including the lid 104A) which is less than the internal volume of the battery (i.e., the volume of the prism bounded by the inner surfaces 104c, 104d, 104e, 104f, 104g, and lid 104a), and each of the primary growth constraint system 151 and secondary growth constraint system 152 of set 106a occupies a volume corresponding to its respective displacement volume. Therefore, in combination, the battery housing 104, the primary growth constraint system 151, and the secondary growth constraint system 152 occupy 75% or less of the volume bounded by the outer surface of the battery housing 104 (i.e., the displacement volume of the battery). For example, in one such embodiment, the primary growth constraint system 151, the secondary growth constraint system 152, and the battery housing 104 occupy 60% or less of the volume bounded by the outer surface of the battery housing 104 in combination. As a further example, in one such embodiment, the primary growth constraint system 151, the secondary growth constraint system 152, and the battery housing 104 occupy 45% or less of the volume bounded by the outer surface of the battery housing 104 in combination. As a further example, in one such embodiment, the primary growth constraint system 151, the secondary growth constraint system 152, and the battery housing 104 occupy 30% or less of the volume bounded by the outer surface of the battery housing 104 in combination. As a further example, in one such embodiment, the primary growth constraint system 151 and the secondary growth constraint system 152, along with the battery housing 104, together occupy 20% or less of the volume bounded by the outer surface of the battery housing.

[0120] Generally, the primary growth constraint system 151 and / or the secondary growth constraint system 152 would typically include a material having a tensile strength of at least 10,000 psi (greater than 70 MPa), comparable to that of the battery electrolyte, and which does not corrode significantly at the stray potential or anode potential of the battery 102, and does not react significantly up to 45°C and even 70°C, and does not lose mechanical strength. In one embodiment, at least one of the first primary growth constraint, the second primary growth constraint, the first secondary growth constraint, and the second secondary growth constraint includes a material having a tensile strength of at least 10,000 psi (greater than 70 MPa). For example, the primary growth constraint system 151 and / or the secondary growth constraint system 152 may include any of a wide range of metals, alloys, ceramics, glass, plastics, or combinations thereof (i.e., composites). In one exemplary embodiment, the primary growth constraint system 151 and / or secondary growth constraint system 152 include metals such as stainless steel (e.g., SS316, 440C, or 440C hard), aluminum (e.g., aluminum 7075-T6, hard H18), titanium (e.g., 6Al-4V), beryllium, beryllium copper (hard), copper (O2-free, hard), and nickel. However, generally, when the primary growth constraint system 151 and / or secondary growth constraint system 152 include metals, it is generally preferable that the metals are incorporated to limit corrosion and to limit the generation of electrical short circuits between the electrode structure 110 and the counter electrode structure 112. In another exemplary embodiment, the primary growth constraint system 151 and / or secondary growth constraint system 152 include ceramics such as alumina (e.g., sintered or Coorstek AD96), zirconia (e.g., Coorstek YZTP), and yttria-stabilized zirconia (e.g., ENRG E-Strate®). In another exemplary embodiment, the primary growth constraint system 151 includes glass such as Schott D263 tempered glass.In another exemplary embodiment, the primary growth constraint system 151 and / or secondary growth constraint system 152 include plastics such as polyether ether ketone (PEEK) (e.g., Aptiv 1102), carbon-containing PEEK (e.g., Victrex 90HMF40 or Xycomp 1000-04), carbon-containing polyphenylene sulfide (PPS) (e.g., Tepex Dynalite 207), polyether ether ketone (PEEK) with 30% glass (e.g., Victrex 90HMF40 or Xycomp 1000-04), and polyimide (e.g., Kapton®). In another exemplary embodiment, the primary growth constraint system 151 and / or the secondary growth constraint system 152 include composite materials such as E-glass standard cloth / epoxy, 0°, E-glass UD / epoxy, 0°, Kevlar standard cloth / epoxy, 0°, Kevlar UD / epoxy, 0°, carbon standard cloth / epoxy, 0°, carbon UD / epoxy, 0°, and Toyobo Zylon® HM fiber / epoxy. In another exemplary embodiment, the primary growth constraint system 151 and / or the secondary growth constraint system 152 include fibers such as Kevlar 49 aramid fiber, S-glass fiber, carbon fiber, Vectran UM LCP fiber, Dyneema, and Zylon. In one embodiment, at least one of the primary growth constraint system 151 and the secondary growth constraint system 152 includes a sheet of material having a thickness in the range of about 10 to about 100 micrometers. In another embodiment, at least one of the primary growth constraint system 151 and the secondary growth constraint system 152 includes a sheet of material having a thickness in the range of about 30 to about 75 micrometers.

[0121] The constituent units of electrode structure group 110 and counter electrode structure group 112 may include electroactive materials capable of absorbing and releasing carrier ions such as lithium ions, sodium ions, potassium ions, calcium ions, magnesium ions, or aluminum ions. In some embodiments, the constituent units of electrode structure group 110 include an anode-activated electroactive material (sometimes called a negative electrode), and the constituent units of counter electrode structure group 112 include a cathode-activated electroactive material (sometimes called a positive electrode). In other embodiments, the constituent units of electrode structure group 110 include a cathode-activated electroactive material, and the constituent units of counter electrode structure group 112 include an anode-activated electroactive material. In each of the embodiments and examples listed in this paragraph, the negative electrode active material may be an electrode active material formed from a particle material, such as by forming a particle aggregate electrode, forming a slurry of particle material and casting it into a layered shape, or a monolithic electrode.

[0122] According to one embodiment, the electrode active material used in the electrode structure 110 corresponding to the anode of the electrode assembly 106 includes a material that expands when carrier ions are inserted into the electrode active material during charging of the secondary battery 102 and / or the electrode assembly 106. For example, the electrode active material may include an anode active material that accepts carrier ions during charging of the secondary battery, such as by intercalation or alloying with carrier ions, in an amount sufficient to generate an increase in the volume of the electrode active material. For example, in one embodiment, the electrode active material may include a material having the ability to accept 2 moles or more of carrier ions per mole of electrode active material when the secondary battery 102 is charged from a discharged state to a charged state. As a further example, the electrode active material may include a material having the ability to accept 1.5 moles or more of carrier ions per mole of electrode active material, such as 2.0 moles or more of carrier ions per mole of electrode active material, and even 2.5 moles or more of carrier ions per mole of electrode active material, such as 3.5 moles or more of carrier ions per mole of electrode active material. The carrier ions accepted by the electrode active material may be at least one of lithium, potassium, sodium, calcium, and magnesium. Examples of electrode active materials that expand to provide such a volume change include one or more of silicon (e.g., SiO), aluminum, tin, zinc, silver, antimony, bismuth, gold, platinum, germanium, palladium, and their alloys and compounds. For example, in one embodiment, the electrode active material may include silicon-containing materials in particulate form, such as one or more of particulate silicon, particulate silicon oxide, and mixtures thereof. In another embodiment, the electrode active material consists of silicon or silicon oxide. In yet another embodiment, the electrode active material may include materials that exhibit a smaller or even negligible volume change. For example, in one embodiment, the electrode active material may include carbon-containing materials such as graphite. In yet another embodiment, the electrode structure may include a layer of lithium metal, such as an electrode structure with an electrode current collector, on which the layer of lithium metal is deposited during the charging process as a result of the transfer of carrier ions from the counter electrode structure to the electrode structure.

[0123] Furthermore, according to certain embodiments, exemplary anode-active electroactive materials include any of the range of metals, metalloids, alloys, oxides, and compounds that can form alloys with graphite and carbon materials such as soft or hard carbon, or with lithium. Specific examples of metals or metalloids that can constitute an anode material include graphite, tin, lead, magnesium, aluminum, boron, gallium, silicon, Si / C composites, Si / graphite blends, 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 may be aluminum, tin, or silicon, or their oxides, nitrides, fluorides, or other alloys thereof. In another exemplary embodiment, the anode-active material may include silicon, silicon oxide, or alloys thereof.

[0124] In another embodiment, the anode active material may include lithium metal, lithium alloy, carbon, petroleum coke, activated carbon, graphite, silicon compounds, tin compounds, and alloys thereof. In one embodiment, the anode active material may be carbon such as non-graphitizable carbon, graphite-based carbon, Li x Fe2O3 (0 ≤ x ≤ 1), Li x WO2(0≦x≦1), Sn x Me 1-x Me' y O z(Me: Mn, Fe, Pb, Ge; Me’: Al, B, P, Si, elements found in Groups 1, 2, and 3 of the periodic table, halogens, 0 < x ≦ 1, 1 ≦ y ≦ 3, 1 ≦ z ≦ 8), such as metal composite oxides, lithium metal, lithium alloys, silicon-based alloys, tin-based alloys, SnO, SnO2, PbO, PbO2, Pb2O3, Pb3O4, Sb2O3, Sb2O4, Sb2O5, GeO, GeO2, Bi2O3, Bi2O4, Bi2O5, etc., such as metal oxides, conductive polymers such as polyacetylene, Li-Co-Ni-based materials, etc. In one embodiment, the anode active material can include crystalline graphite such as natural graphite, synthetic graphite, etc., and amorphous carbon such as soft carbon, hard carbon, etc. Other examples of carbon materials suitable for the anode active material can include graphite, kish graphite, pyrolytic carbon, mesophase pitch-based carbon fibers, mesocarbon microbeads, mesophase pitch, graphitized carbon fibers, and high-temperature sintered carbon such as coke derived from petroleum or coal tar pitch. In one embodiment, the negative electrode active material can include tin oxide, titanium nitrate, and silicon. In another embodiment, the negative electrode can include a lithium metal such as a lithium metal film, or a lithium alloy such as an alloy of lithium, and one or more types of metals selected from the group consisting of Na, K, Rb, Cs, Fr, Be, Mg, Ca, Sr, Ba, Ra, Al, and Sn. In yet another embodiment, the anode active material is a metal compound capable of alloying and / or intercalating with lithium, such as Si, Al, C, Pt, Sn, Pb, Ir, Ni, Cu, Ti, Na, K, Rb, Cs, Fr, Be, Ca, Sr, Sb, Ba, Ra, Ge, Zn, Bi, In, Mg, Ga, Cd, Si alloy, Sn alloy, Al alloy, etc., SiO v(0 < v < 2), metal oxides capable of doping and undoping lithium ions such as SnO₂, vanadium oxide, or lithium vanadium oxide, and composite materials containing metal compounds and carbon materials such as Si-C composite materials or Sn-C composite materials can be included. For example, in one embodiment, metals such as lithium, indium, tin, aluminum, or silicon, or their alloys, transition metal oxides such as Li₄ / ₃Ti₅ / ₃O₄ or SnO, and artificial graphite, graphite carbon fiber, resin-fired carbon, pyrolytic vapor-grown carbon, cork, mesocarbon microbeads ("MCMB"), furfuryl alcohol resin-fired carbon, polyacene, pitch-based carbon fiber, vapor-grown carbon fiber, or natural graphite, etc., can be carbonaceous materials. In another embodiment, the negative electrode active material can include a composition suitable for carrier ions such as sodium or magnesium. For example, in one embodiment, the negative electrode active material is a layered carbonaceous material and a chemical formula Na x Sn y-z M z composition disposed between the layers of the layered carbonaceous material, where M is Ti, K, Ge, P, or a combination thereof, 0 < x ≦ 15, 1 ≦ y ≦ 5, and 0 ≦ z ≦ 1. In one embodiment, when the secondary battery including the electrode structure having the anode active material is charged from the discharged state to the charged state, the anode active material has a capacity of carrier ions that is 2 moles or more of carrier ions per mole of the anode active material.

[0125] In one embodiment, the anode active material is 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; (c) Si, Ge, Sn, Pb (d) Sb, Bi, Zn, Al, Ti, Fe, Ni, Co, V, or Cd oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellides, as well as mixtures, composites, or lithium-containing composites thereof; (e) salts and hydroxides of Sn; (f) lithium titanate, lithium manganate, lithium aluminate, lithium-containing titanium oxide, lithium transition metal oxides, ZnCo2O4; (g) particles of graphite and carbon; (h) lithium metals; and (e) combinations thereof. In one embodiment, the anode active material is selected from the group consisting of alloys and intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, or Cd with other elements. In one embodiment, the anode active material is selected from the group consisting of oxides, carbides, nitrides, sulfides, phosphides, selenides, and tellurides of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Fe, Ni, Co, V, and Cd. In one embodiment, the anode active material is selected from the group consisting of silicon and silicon oxides and carbides. In one embodiment, the anode active material is selected from the group consisting of graphite and carbon.

[0126] In one embodiment, the negative electrode active material may further include conductive materials and / or conductive additives such as carbon-based materials, carbon black, graphite, graphene, activated carbon, carbon fibers, carbon black such as acetylene black, Ketjen black, channel black, furnace black, lamp black, thermal black, etc., conductive fibers such as carbon fibers, metal fibers, etc., conductive tubes such as carbon nanotubes, metal powders such as carbon fluoride powder, aluminum powder, nickel powder, etc., conductive whiskers such as zinc oxide, titanium potassium oxide, etc., conductive metal oxides such as titanium oxide, or conductive materials such as polyphenylene derivatives. In addition, metal fibers such as metal mesh, metal powders such as copper, silver, nickel, and aluminum, or organic conductive materials such as polyphenylene derivatives may also be used. In another embodiment, a binder such as one or more of the following may be provided, which can be used alone or in mixtures: polyethylene, polyethylene oxide, polypropylene, polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), styrene-butadiene rubber, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer, vinylidene fluoride-hexafluoropropylene copolymer, vinylidene fluoride-chlorotrifluoroethylene copolymer, ethylene-tetrafluoroethylene copolymer, polychlorotrifluoroethylene, vinylidene fluoride-pentafluoropropylene copolymer, propylene-tetrafluoroethylene copolymer, ethylene-chlorotrifluoroethylene copolymer, vinylidene fluoride-hexafluoropropylene-tetrafluoroethylene copolymer, vinylidene fluoride-perfluoromethyl vinyl ether tetrafluoroethylene copolymer, ethylene-acrylic acid copolymer, etc.

[0127] Examples of cathode active materials include any of the broad range of cathode active materials. For example, in lithium-ion batteries, the cathode active material may include cathode materials selected from transition metal oxides, transition metal sulfides, transition metal nitrides, lithium transition metal oxides, lithium transition metal sulfides, and lithium transition metal nitrides. 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. Furthermore, compounds for the cathode active material layer may include lithium-containing compounds further comprising metal oxides or metal phosphates, such as compounds comprising lithium, cobalt, and oxygen (e.g., LiCoO2), compounds comprising lithium, manganese, and oxygen (e.g., LiMn2O4), and compounds comprising lithium iron and phosphate (e.g., LiFePO). In one embodiment, the cathode active material comprises at least one of lithium manganese oxide, lithium cobalt oxide, lithium nickel oxide, lithium iron phosphate, or a composite oxide formed from a combination of the aforementioned oxides. In another embodiment, the cathode active material comprises one or more of lithium cobalt oxide (LiCoO2), lithium nickel oxide (LiNiO2), etc., or a substitution compound having one or more transition metals, Li 1+x Mn 2-xLithium manganese oxides such as O4 (where x is 0 to 0.33 in the formula), LiMnO3, LiMn2O3, LiMnO2, etc., lithium copper oxide (Li2CuO2), vanadium oxides such as LiV3O8, LiFe3O4, V2O5, Cu2V2O7, LiNi 1-x M x LiMn, a Ni-site type lithium nickel oxide represented by the chemical formula O2 (wherein M = Co, Mn, Al, Cu, Fe, Mg, B, or Ga, and x = 0.01~0.3). 2-x M x It may contain one or more of the following: lithium manganese composite oxide represented by the chemical formula O2 (wherein M = Co, Ni, Fe, Cr, Zn, or Ta, and x = 0.01 to 0.1) or Li2Mn3MO8 (wherein M = Fe, Co, Ni, Cu, or Zn), LiMn2O4 in which part of Li is substituted with alkaline earth metal ions, disulfide compounds, Fe2(MoO4)3, etc. In one embodiment, the cathode active material is a lithium manganese composite oxide represented by the chemical formula Li 1+x Fe 1-x M' x (PO 4-b )X b It may include lithium metal phosphates having an olivine crystal structure, where M' is at least one selected from Al, Mg, Ni, Co, Mn, Ti, Ga, Cu, V, Nb, Zr, Ce, In, Zn, and Y, and X is at least one selected from F, S, and N, where -0.5≦a≦+0.5, 0≦x≦0.5, and 0≦b≦0.1, and LiFePO4, Li(Fe,Mn)PO4, Li(Fe,Co)PO4, Li(Fe,Ni)PO4, etc. are at least one such. In one embodiment, the cathode active material is LiCoO2, LiNiO2, LiMnO2, LiMn2O4, LiNi 1-y Co y O2, LiCo 1-y Mn y O2, LiLiLi 1-y Mn y O2 (0 ≤ y ≤ 1), Li (Ni a Co b Mn c )O4(0 <a<2,0<b<2,0<c<2、かつa+b+c=2)、LiMn 2-zNi z O4, LiMn 2-z Co z O4 (0 < z < 2), LiCoPO4, and LiFePO4, or a mixture of two or more of them, and includes at least one of them.

[0128] In another embodiment, the cathode active material can include elemental sulfur (S8), sulfur-based compounds, or a mixture of them. Sulfur-based compounds specifically include Li2S n (n ≥ 1), organic sulfur compounds, carbon-sulfur polymers ((C2S x ) n : x = 2.5 to 50, n ≥ 2), etc. In another embodiment, the cathode active material can include oxides of lithium and zirconium.

[0129] In another embodiment, the cathode active material can include at least one composite oxide of lithium and a metal such as cobalt, manganese, nickel, or a combination of them. Examples include Li a A 1-b M b D2 (where 0.90 ≤ a ≤ 1 and 0 ≤ b ≤ 0.5), Li a E 1-b M b O 2-c D c (where 0.90 ≤ a ≤ 1, 0 ≤ b ≤ 0.5, and 0 ≤ c ≤ 0.05), LiE 2-b M b O 4-c D c (where 0 ≤ b ≤ 0.5 and 0 ≤ c ≤ 0.05), Li a Ni 1-b-c Co b M c D a (where 0.90 ≤ a ≤ 1, 0 ≤ b ≤ 0.5, 0 ≤ c ≤ 0.05, and 0 < a ≤ 2), Li a Ni 1-b-c Co b M c O 2-a X a (where 0.90 ≤ a ≤ 1, 0 ≤ b ≤ 0.5, 0 ≤ c ≤ 0.05, and 0 < a < 2), Li a Ni1-b-c Co b M c O 2-a X2(wherein 0.90≦a≦1, 0≦b≦0.5, 0≦c≦0.05, and 0 <a<2)、Li a Ni 1-b-c Mn b M c O 2-a X a (In the formula, 0.90≦a≦1, 0≦b≦0.5, 0≦c≦0.05, and 0 <a<2)、Li a Ni 1-b-c Mn b M c O 2-a X2(wherein 0.90≦a≦1, 0≦b≦0.5, 0≦c≦0.05, and 0 <a<2)、Li a Ni b E c G d O2 (wherein 0.90≦a≦1, 0≦b≦0.9, 0≦c≦0.5, and 0.001≦d≦0.1), Li a Ni b Co c Mn d GeO2 (wherein 0.90≦a≦1, 0≦b≦0.9, 0≦c≦0.5, 0≦d≦0.5, and 0.001≦e≦0.1), Li a NiG b O2 (wherein the formula, 0.90 ≤ a ≤ 1 and 0.001 ≤ b ≤ 0.1), Li a CoG b O2 (wherein the formula, 0.90 ≤ a ≤ 1 and 0.001 ≤ b ≤ 0.1), Li a MnG b O2 (wherein the formula, 0.90 ≤ a ≤ 1 and 0.001 ≤ b ≤ 0.1), Li a Mn2G b O4 (wherein the formula, 0.90 ≤ a ≤ 1 and 0.001 ≤ b ≤ 0.1), QO2, QS2, LiQS2, V2O5, LiV2O5, LiX'O2, LiNiVO4, Li (3-f) J2(PO4)3(0≦f≦2), Li (3-f)Fe2(PO4)3(0≦f≦2), and LiFePO4. In the above chemical formula, A is Ni, Co, Mn, or a combination thereof, M is Al, Ni, Co, Mn, Cr, Fe, Mg, Sr, V, a rare earth element, or a combination thereof, D is O, F, S, P, or a combination thereof, E is Co, Mn, or a combination thereof, X is F, S, P, or a combination thereof, G is Al, Cr, Mn, Fe, Mg, La, Ce, Sr, V, or a combination thereof, Q is Ti, Mo, Mn, or a combination thereof, X’ is Cr, V, Fe, Sc, Y, or a combination thereof, and J is V, Cr, Mn, Co, Ni, Cu, or a combination thereof. For example, LiCoO2, LiMn x O 2x (x = 1 or 2), LiNi 1-x Mn x O 2x (0 < x < 1), LiNi 1-x-y Co x Mn y O2(0≦x≦z≦0.5), or FePO4 can be used. In one embodiment, the cathode active material includes at least one of lithium cobalt oxide, lithium nickel oxide, lithium nickel cobalt oxide, lithium nickel cobalt aluminum oxide, lithium nickel cobalt manganese oxide, lithium manganese oxide, or lithium iron phosphate, nickel sulfide, copper sulfide, sulfur, iron oxide, or vanadium oxide and other lithium compounds.

[0130] In one embodiment, the cathode active material is an oxide such as NaFeO2, NaMnO2, NaNiO2, or NaCoO2 with the chemical formula NaM 1 a O2, or at least one of oxides represented by the chemical formula NaMn 1-a M 1 a O2, and can include a sodium-containing material, where M 1 is at least one transition metal element, and 0 < a < 1. Representative positive active materials include Na[Ni 1 / 2 Mn1 / 2 ]O2, Na 2 / 3 [Fe 1 / 2 Mn 1 / 2 ]O2, etc., Na 0.44 Mn 1-a M 1 a Oxides represented by O2, Na 0.7 Mn 1-a M 1 a O 2.05 Oxides represented by (wherein M in the formula) 1 (where is at least one transition metal element and 0 ≤ a < 1), Na6Fe2Si 12 O 30 or Na2Fe5Si 12 Na as O b M 2 c Si 12 O 30 Oxides represented by (wherein M in the formula) 2 (where is at least one transition metal element, and 2≦b≦6 and 2≦c≦5), Na2Fe2Si6O 18 or Na2MnFeSi6O 18 Na such as d M 3 e Si6O 18 Oxides represented by (wherein M in the formula) 3 It is a transition metal element (where 3 ≤ d ≤ 6 and 1 ≤ e ≤ 2), such as Na2FeSiO6. f M 4 g Oxides represented by Si2O6 (wherein M, 4 (where is at least one element selected from transition metal elements, magnesium (Mg), and aluminum (Al), with 1 ≤ f ≤ 2 and 1 ≤ g ≤ 2), phosphates such as NaFePO4, Na3Fe2(PO4)3, Na3V2(PO4)3, Na4Co3(PO4)2P2O7, borates such as NaFeBO4 or Na3Fe2(BO4)3, and Na3FeF6 or Na2MnF6. h M 5 Fluoride represented by F6 (where M in the formula) 5The positive active material is at least one transition metal element (where 2 ≤ h ≤ 3), and examples include fluorophosphates such as Na3V2(PO4)2F3 and Na3V2(PO4)2FO2. The positive active material is not limited to those described above, and any suitable positive active material used in the art can be used. In one embodiment, the positive active material is preferably NaMnO2, Na[Ni 1 / 2 Mn 1 / 2 ]O2 and Na 2 / 3 [Fe 1 / 2 Mns 1 / 2 Examples include layered oxide cathode materials such as O2, phosphate cathodes such as Na3V2(PO4)3 and Na4Co3(PO4)2P2O7, or fluorophosphate cathodes such as Na3V2(PO4)2F3 and Na3V2(PO4)2FO2. In one embodiment, S (or lithium-ionized Li2S), LiF, Fe, Cu, Ni, FeF2, FeO d F 3.2d The cathode active material is selected from the group consisting of FeF3, CoF3, CoF2, CuF2, and NiF2, where 0 ≤ d ≤ 0.5. In one embodiment, the cathode active material includes lithium iron phosphate (LiFePO4). In one embodiment, the cathode active material is selected from the group consisting of intercalation chemical cathode materials and conversion chemical cathode materials.

[0131] In one embodiment, the electrode current collector may include a negative electrode current collector and may include a suitable conductive material such as a metallic material. For example, in one embodiment, the negative electrode current collector may include at least one of copper, nickel, aluminum, stainless steel, titanium, palladium, calcined carbon, charred carbon, indium, iron, magnesium, cobalt, germanium, or a surface treatment material for copper or stainless steel (having lithium, carbon, nickel, titanium, silver, aluminum-cadmium alloy, and / or other alloys thereof). As another example, in one embodiment, the negative electrode current collector may include at least one of copper, stainless steel, aluminum, nickel, titanium, calcined carbon, or a surface treatment material for copper or stainless steel (having carbon, nickel, titanium, silver, aluminum-cadmium alloy, and / or other alloys thereof). In one embodiment, the negative electrode current collector may include at least one of copper and stainless steel.

[0132] In one embodiment, the counter electrode current collector may include a positive electrode current collector and may include a suitable conductive material such as a metallic material. In one embodiment, the positive electrode current collector includes at least one of stainless steel, aluminum, nickel, titanium, sintered carbon, aluminum, or a surface-treated material of stainless steel (having carbon, nickel, titanium, silver, and / or alloys thereof). In one embodiment, the positive electrode current collector includes aluminum.

[0133] In another embodiment, the cathode active material may further comprise one or more conductive additives and / or binders, which may be, for example, any of the conductive additives and / or binders described herein for the anode active material.

[0134] According to certain embodiments, the electrical isolation separator layer 130 can electrically isolate each component unit of the electrode structure 110 from each component unit of the counter electrode structure 112 group. The electrical isolation separator layer is designed to prevent electrical short circuits while also allowing the transport of ion charge carriers necessary to close the circuit during the passage of current in the electrochemical cell. In one embodiment, the electrical isolation separator layer is microporous and permeable to electrolytes, such as non-aqueous liquid electrolytes or gel electrolytes. Alternatively, the electrical isolation separator layer may include a solid electrolyte, i.e., a solid ion conductor, which can function as both a separator and an electrolyte in the battery.

[0135] In certain embodiments, the electrical insulating separator layer 130 would typically include a microporous separator material that can permeate a non-aqueous electrolyte. For example, in one embodiment, the microporous separator material includes pores having a diameter in the range of at least 50 Å, more typically about 2,500 Å, and a polyefficiency in the range of about 25% to about 75%, more typically about 35% to 55%. Additionally, the microporous separator material may permeate a non-aqueous electrolyte to allow the conduction of carrier ions between adjacent constituent units of the electrode group and the counter electrode group. In certain embodiments, for example, disregarding the multiefficiency of microporous separator materials, at least 70 volume percent of the electrical insulating separator material between the constituent units of the electrode structure group 110 and the nearest constituent units of the counter electrode structure group 112 (i.e., "adjacent pairs") for ion exchange during a charge or discharge cycle is microporous separator material; in other words, the microporous separator material constitutes at least 70 volume percent of the electrical insulating material between the constituent units of the electrode structure group 110 and the nearest constituent units of the counter electrode structure group 112.

[0136] In one embodiment, the microporous separator material comprises particulate material and a binder and has a porosity (void ratio) of at least about 20 volume%. The pores of the microporous separator material will have a diameter of at least 50 Å and will typically fall within the range of about 250 to 2,500 Å. The microporous separator material will typically have a porosity of less than about 75%. In one embodiment, the microporous separator material has a porosity (void ratio) of at least about 25 volume%. In one embodiment, the microporous separator material will have a porosity of about 35 to 55%.

[0137] Binders for microporous separator materials can be selected from a wide range of inorganic or polymeric materials. For example, in one embodiment, the binder may be an organic polymeric material such as a fluoropolymer derived from monomers containing vinylidene fluoride, hexafluoropropylene, tetrafluoropropene, etc. 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-diene-propenter polymer, polystyrene, polymethyl methacrylate, polyethylene glycol, polyvinyl acetate, polyvinyl butyral, polyacetal, and polyethylene glycol diacrylate. In yet 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, polyacrylonitrile, polyvinylidene fluoride polyacrylonitrile, and polyethylene oxide. In another embodiment, the binder is selected from the group consisting of acrylates, styrenes, epoxys, and silicones. Other suitable binders may be selected from polyvinylidene fluoride-co-hexafluoropropylene, polyvinylidene fluoride-co-trichloroethylene, polymethyl methacrylate, polyacrylonitrile, polyvinylpyrrolidone, polyvinyl acetate, polyethylene-co-vinyl acetate, polyethylene oxide, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, cyanoethyl pullulan, cyanoethyl polyvinyl alcohol, cyanoethylcellulose, cyanoethyl sucrose, pullulan, carboxymethylcellulose, acrylonitrile-styrene-butadiene copolymer, polyimide, or mixtures thereof.In another embodiment, the binder can be selected from any one of polyvinylidene fluoride - hexafluoropropylene, polyvinylidene fluoride - trichloroethylene, polymethyl methacrylate, polyacrylonitrile, polyvinylpyrrolidone, polyvinyl acetate, ethylene vinyl acetate copolymer, polyethylene oxide, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, cyanoethylpullulan, cyanoethyl polyvinyl alcohol, cyanoethyl cellulose, pullulan, carboxymethyl cellulose, acrylonitrile styrene butadiene copolymer, polyimide, polyethylene terephthalate, polybutylene terephthalate, polyester, polyacetal, polyamide, polyether ether ketone, polyether sulfone, polyphenylene oxide, polyphenylene sulfide, polyethylene naphthalene, and / or combinations thereof. In another embodiment, the binder is a copolymer or blend of two or more of the aforementioned polymers.

[0138] The particulate material composed of the microporous separator material can also be selected from a wide range of materials. Generally, such materials have relatively low electronic conductivity and ionic conductivity at the operating temperature and do not corrode under the operating voltage of the battery electrode or current collector in contact with the microporous separator material. For example, in one embodiment, the particulate material has a conductivity for carrier ions (e.g., lithium) of less than 1×10 -4 S / cm. As a further example, in one embodiment, the particulate material has a conductivity for carrier ions of less than 1×10 -5 S / cm. As a further example, in one embodiment, the particulate material has a conductivity for carrier ions of less than 1×10 -6It has a conductivity to carrier ions of less than S / cm. 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. Exemplary particulate materials include particulate polyethylene, polypropylene, TiO2-polymer composites, silica aerogel, fumed silica, silica gel, silica hydrogel, silica xerogel, 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. Other suitable particles include BaTiO3, Pb(Zr,Ti)O3(PZT), and Pb 1-x La x Zr 1-y Ti y O3(PLZT), PB(Mg3Nb) 2 / 3 This may include O3-PbTiO3 (PMN-PT), hafnia (HfO2), SrTiO3, SnO2, CeO2, MgO, NiO, CaO, ZnO, ZrO2, Y2O3, Al2O3, TiO2, SiC, or mixtures thereof. In one embodiment, the particulate material will have an average particle size of about 20 nm to 2 micrometers, more typically 200 nm to 1.5 micrometers. In one embodiment, the particulate material will have an average particle size of about 500 nm to 1 micrometer.

[0139] According to one embodiment of the assembled energy storage device, the microporous separator material 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. Another example is that the electrolyte may contain sodium ions dissolved in it, such as one or more of the following: NaClO4, NaPF6, NaBF4, NaCF3SO3, NaN(CF3SO2)2, NaN(C2F5SO2)2, and NaC(CF3SO2)3. Salts of magnesium and / or potassium can be provided in a similar manner. For example, magnesium salts such as magnesium chloride (MgCl2), magnesium bromide (MgBr2), or magnesium iodide (MgI2) may be provided, and / or magnesium perchlorate (Mg(ClO4)2), magnesium nitrate (Mg(NO3)2), magnesium sulfate (MgSO4), magnesium tetrafluoroborate (Mg(BF4)2), magnesium tetraphenylborate (Mg(B(C6H5)4)2), magnesium hexafluorophosphate (Mg(PF6)2), magnesium hexafluoroarsenate (Mg(AsF6)2), magnesium perfluoroalkylsulfonate ((Mg(R f1 SO3)2) and R f1 ( is a perfluoroalkyl group), perfluoroalkylsulfonylimed magnesium (Mg((R f2 SO2)2N)2, and R f2which is a perfluoroalkyl group), and magnesium salts which can be at least one selected from the group consisting of hexaalkyldisilazide ((Mg(HRDS)2, where R is an alkyl group)) are the same. Exemplary organic solvents for dissolving the lithium salts include cyclic esters, chain esters, cyclic ethers, and chain ethers. Specific examples of cyclic esters include propylene carbonate, ethylene carbonate, butylene carbonate, γ-butyrolactone, vinylene carbonate, 2-methyl-γ-butyrolactone, acetyl-γ-butyrolactone, and γ-valerolactone. 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, alkyl propionate, dialkyl malonate, and alkyl acetate. Specific examples of cyclic ethers include tetrahydrofuran, alkyl tetrahydrofuran, dialkyl tetrahydrofuran, alkoxy tetrahydrofuran, dialkoxy tetrahydrofuran, 1,3-dioxolane, alkyl-1,3-dioxolane, and 1,4-dioxolane. Specific examples of chain 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. In one embodiment, the electrode assembly includes a non-aqueous electrolyte containing a mixture of a lithium salt and an organic solvent.

[0140] In another embodiment, the electrical insulating separator 130 includes a solid electrolyte, for example, as in a solid-state battery. Generally speaking, a solid electrolyte can facilitate the transport of carrier ions without requiring the addition of a liquid electrolyte or gel electrolyte. According to a particular embodiment, when a solid electrolyte is provided, it may be possible for the solid electrolyte itself to provide an insulator between electrodes and allow the passage of carrier ions through the insulator, and may not require the addition of a liquid electrolyte that permeates the structure.

[0141] In one embodiment, the secondary battery 102 may contain an electrolyte that is any of the following: an organic liquid electrolyte, an inorganic liquid electrolyte, an aqueous electrolyte, a non-aqueous electrolyte, a solid polymer electrolyte, a solid ceramic electrolyte, a solid glass electrolyte, a garnet electrolyte, a gel polymer electrolyte, an inorganic solid electrolyte, or a molten inorganic electrolyte. Furthermore, with or without a liquid electrolyte, other arrangements and / or configurations of the electrical insulating separator 130 may be provided. In one embodiment, the solid electrolyte may include a ceramic or glass material that can conduct carrier ions while providing electrical insulation. Examples of ion-conducting materials include garnet materials, sulfide glass, lithium ion-conducting glass ceramics, or phosphate ceramic materials. In one embodiment, the solid polymer electrolyte may include any polymer formed from polyethylene oxide (PEO)-based, polyvinyl acetate (PVA)-based, polyethyleneimine (PEI)-based, polyvinylidene fluoride (PVDF)-based, polyacrylonitrile (PAN)-based, LiPON (lithium phosphate nitride), and polymethyl methacrylate (PMMA)-based polymers or copolymers thereof. In another embodiment, sulfide-based solid electrolytes may be provided, such as sulfide-based solid electrolytes comprising at least one of lithium and / or phosphorus, such as Li2S and P2S5, and at least one of other sulfides such as SiS2, GeS2, Li3PS4, Li4P2S7, Li4SiS4, Li2S-P2S5, and 50Li4SiO4, 50Li3BO3, and / or B2S3. Yet another embodiment of the solid electrolyte is Li3N, LiI, Li5NI2, Li3N-LiI-LiOH, LiSiO4, LiSiO4-LiI-LiOH, Li2SiS3, Li4SiO4, Li4SiO4-LiI-LiOH, and Li3PO4-Li2S-SiS2, Li2S-P2S5, Li2S-P2S5-L4SiO4, Li2S-Ga2S3-GeS2, Li2S-Sb2S3-GeS2, Li 3.25 -Ge 0.25 -P 0.75 S4, (La,Li)TiO3(LLTO), Li6La2CaTa2O 12 Li6La2ANb2O 12(A=Ca,Sr), Li2Nd3TeSbO 12 Li3BO 2.5 N 0.5 , Li9SiAlO8, Li 1+x Al x Ge 2-x (PO4)3(LAGP), Li 1+x Al x Ti 2-x (PO4)3(LATP), Li 1+x Ti 2-x Al x Si y (PO4) 3-y LiAl x Zr 2-x (PO4)3, LiTi x Zr 2-x Examples of lithium (Li) nitrides, halides, and sulfides such as (PO4)3 may be used as solid electrolytes, and other embodiments of solid electrolytes may include garnet materials, such as those described in U.S. Patent No. 10,361,455, which are incorporated herein in whole. In one embodiment, the garnet solid electrolyte is a nesosilicate having the general chemical formula X3Y2(SiO4)3, where X may be a divalent cation such as Ca, Mg, Fe, or Mn, or Y may be a trivalent cation such as Al, Fe, or Cr.

[0142] In one embodiment, the electrical insulating separator includes a solid electrolyte selected from the group consisting of sulfide-based electrolytes. In another embodiment, the electrical insulating separator includes lithium tin sulfide (LSn), lithium phosphate sulfide (β-Li3PS4), and lithium phosphate sulfide chloride iodide (Li6PS5Cl 0.9 I 0.1 In another embodiment, the electrical insulating separator comprises a solid electrolyte selected from the group consisting of ) . 0.34 La 0.56 TiO3), Al-doped lithium zirconate lanthanum (Li6.24La3Zr2Al0.24O11.98), Ta-doped lithium zirconate (Li 6.4La3Zr 1.4 Ta 0.6 O 12 ), and lithium aluminum titanium phosphate (Li 1.4 Al 0.4 Ti 1.6 The present invention includes a solid electrolyte selected from the group consisting of (PO4)3). In one embodiment, the electrical insulating separator includes a polymer electrolyte selected from the group consisting of PEO-based polymer electrolytes, polymer ceramic composite electrolytes (solid), polymer ceramic composite electrolytes, and polymer ceramic composite electrolytes.

[0143] Embodiment The following listed embodiments 1 to 336 describe embodiments of the present disclosure.

[0144] Enumerated Embodiment 1: A method for manufacturing a structure comprising an electrode assembly and first and second end plates, wherein the electrode assembly includes an electrical insulating material, The electrode assembly comprises a group of unit cells stacked continuously in the stacking direction, and first and second longitudinal end faces on opposite sides separated along the stacking direction, the first and second end plates being separated in the stacking direction and overlapping the first and second longitudinal end faces, (i) each unit cell comprises an electrode structure, a counter electrode structure, and an electrical insulating separator between the electrode structure and the counter electrode structure, (ii) the electrode structure, counter electrode structure, and electrical insulating separator within each unit cell have a first and second vertical end face on opposite sides separated vertically, and (iii) the vertical direction is perpendicular to the stacking direction, The method includes providing a porous electrical insulating material to an electrode assembly using a stencil.

[0145] Enumerated embodiment 2. A structure comprising an electrode assembly and first and second end plates, wherein the electrode assembly includes an electrical insulating material, It comprises a group of unit cells stacked continuously in the stacking direction, first and second longitudinal end faces on opposite sides separated along the stacking direction, and first and second end plates separated in the stacking direction and overlapping the first and second longitudinal end faces, (i) Each unit cell comprises an electrode structure, a counter electrode structure, and an electrical insulating separator between the electrode structure and the counter electrode structure, (ii) the electrode structure, counter electrode structure, and electrical insulating separator within each unit cell have first and second end faces on opposite sides separated in the vertical direction, and (iii) the vertical direction is perpendicular to the stacking direction.

[0146] Enumerated Embodiment 3: The first and second end plates each have a vertical thickness t of the cross-sectional area in a plane perpendicular to the stacking direction. EP The first vertical thickness t of the first cross-sectional area of ​​each of the first and second end plates in the inner region of each of the first and second end plates adjacent to the stacked continuous unit cell EP1 This refers to the second vertical thickness t of the second cross-sectional area in the outer regions of the first and second end plates, which are located outside the inner regions in the stacking direction. EP2 A method or structure according to any one of the previously enumerated embodiments, which is larger than the method or structure described in any one of the previously enumerated embodiments.

[0147] Enumerated Embodiment 4: Each of the first and second end plates has a maximum vertical thickness t in a cross-sectional area in a plane perpendicular to the stacking direction having a maximum vertical thickness for each end plate. EPMAX The first and second end plates have a maximum vertical thickness t EPMAX The method or structure according to any one of the previously enumerated embodiments, comprising first and second vertical end face regions that coincide with, wherein the first and second vertical end face regions are located on first and second vertical side surfaces opposite to the first and second end plates.

[0148] Enumerated Embodiment 5: The method or structure according to any one of the previously enumerated embodiments, wherein each of the first and second end plates has first and second vertical end face regions that coincide with the respective first and second maximum vertical ranges on the first and second vertical sides opposite the first and second end plates.

[0149] Enumerated Embodiment 6: The method according to any one of the previously enumerated embodiments, comprising (a) positioning a stencil, which comprises a stencil frame defining a stencil opening on first and second end plates, such that the stencil frame covers at least a portion of the periphery of an electrode assembly, wherein the first vertical end faces of the electrode structures and counter electrode structures of the constituent units of the unit cell group are exposed through the stencil opening.

[0150] Enumerated Embodiment 7: (a) Positioning a stencil comprising a stencil frame defining a stencil opening on first and second end plates, wherein the stencil is positioned such that the upper surface of the stencil frame is the maximum vertical thickness t of each of the first and second end plates in the vertical direction. EPMAX The method according to any one of the previously enumerated embodiments, positioned on the first and second end plates so as not to exceed the first vertical end face regions of the first and second end plates, which coincide with the first vertical end face regions of the first and second end plates.

[0151] Enumerated Embodiment 8: (a) The method according to any one of the previously enumerated embodiments, comprising positioning a stencil having a stencil frame defining a stencil opening on first and second end plates, wherein the stencil is positioned on the first and second end plates such that the upper surface of the stencil frame does not exceed a first vertical end face region of the first and second end plates, which coincides with the first maximum vertical range of each of the first and second end plates that lies on the same vertical side surface of the electrode assembly as the upper surface of the stencil frame.

[0152] Enumerated Embodiment 9: (b) The method according to any one of the previously enumerated embodiments, comprising applying a porous electrical insulating material through a stencil opening to cover the first vertical end face of an electrode structure or counter electrode structure of a constituent unit of a group of unit cells.

[0153] Enumerated Embodiment 10: (b) The method according to any one of the prior enumerated embodiments, comprising applying a porous electrical insulating material through a stencil opening to cover a first vertical end face of the counter electrode structure of a constituent unit of a group of unit cells.

[0154] Enumerated Embodiment 11: The method according to any one of the prior enumerated embodiments, wherein each electrode structure of a constituent unit of a unit cell group comprises a layer of electrode active material, and each counter electrode structure of a constituent unit of a unit cell group comprises a layer of counter electrode active material, and (b) a porous electrical insulating material is applied through a stencil opening to cover a first vertical end face of the layer of counter electrode active material of the constituent unit of the unit cell group.

[0155] Enumerated Embodiment 12: (c) The method according to any one of the previously enumerated embodiments, comprising positioning the stencil on the first and second end plates such that the second vertical end faces of the electrode structures and counter electrode structures of the constituent units of the unit cell group are exposed through the stencil opening.

[0156] The method according to any one of the previously enumerated embodiments, wherein the stencil is positioned on the first and second end plates such that the upper surface of the stencil frame does not exceed the first vertical end face region of the first and second end plates, which coincides with the second maximum vertical range of each of the first and second end plates that lies on the same vertical side surface of the electrode assembly as the upper surface of the stencil frame.

[0157] In the enumerated embodiment 14:(c), the upper surface of the stencil frame is the maximum vertical thickness t of the first and second end plates, respectively. EPMAX The method according to any one of the previously enumerated embodiments, wherein the stencil is positioned on the first and second end plates so as not to exceed the second vertical end face regions of the first and second end plates that coincide with the stencil.

[0158] Enumerated Embodiment 15: (d) The method according to any one of the prior enumerated embodiments, comprising applying a porous electrical insulating material through a stencil opening to cover a second vertical end face of an electrode structure or counter electrode structure of a constituent unit of a group of unit cells.

[0159] Enumerated Embodiment 16: (d) A method according to any one of the preceding enumerated embodiments, comprising applying a porous electrical insulating material through a stencil opening to cover a second vertical end face of the counter electrode structure of the constituent unit of the unit cell group.

[0160] Enumerated Embodiment 17: Each electrode structure of the constituent unit of the unit cell group includes a layer of electrode active material, each counter electrode structure of the constituent unit of the unit cell group includes a layer of counter electrode active material, and (d) comprises applying a porous electrical insulating material through a stencil opening to cover a second vertical end face of the layer of counter electrode active material of the constituent unit of the unit cell group, a method according to any one of the preceding enumerated embodiments.

[0161] Enumerated Embodiment 18: A method according to any one of the preceding enumerated embodiments, comprising rotating the electrode assembly about an axis perpendicular to the vertical direction after applying the porous electrical insulating material to the electrode assembly.

[0162] Enumerated Embodiment 19: The electrode assembly is rotated following the application of the porous electrical insulating material to the first vertical end face of the electrode structure or the counter electrode structure, and the method further comprises applying the porous electrical insulating material to the second vertical end face of the electrode structure or the counter electrode structure after rotation, a method according to any one of the preceding enumerated embodiments.

[0163] Enumerated Embodiment 20: The maximum vertical thickness of the electrode structure and the counter electrode structure in a cross-sectional area perpendicular to the stacking direction does not exceed the respective maximum vertical thickness t EPMAX of each of the first and second end plates in the vertical direction, a method or structure according to any one of the preceding enumerated embodiments.

[0164] Enumerated Embodiment 21: The maximum vertical thickness of the counter electrode structure in a cross-sectional area perpendicular to the stacking direction does not exceed the respective maximum vertical thickness t EPMAX of each of the first and second end plates in the vertical direction, a method or structure according to any one of the preceding enumerated embodiments.

[0165] Enumerated Embodiment 22: The maximum vertical thickness of the counter electrode active material layer of the counter electrode structure in a cross-sectional area perpendicular to the stacking direction is equal to the maximum vertical thickness t of each of the first and second end plates in the vertical direction. EPMAX A method or structure according to any one of the previously enumerated embodiments, not exceeding [a certain value].

[0166] Enumerated Embodiment 23: The method or structure according to any one of the previously enumerated embodiments, wherein the first vertical end face of the electrode structure and the counter electrode structure does not exceed the first vertical end face region of the first and second end plates, which coincides with the first maximum vertical range of the first and second end plates on the same vertical side surface of the electrode assembly as the first vertical end face.

[0167] Enumerated Embodiment 24: The method or structure according to any one of the previously enumerated embodiments, wherein the first vertical end face of the opposing electrode structure does not exceed the first vertical end face region of the first and second end plates, which coincides with the first maximum vertical range of the first and second end plates on the same vertical side surface of the electrode assembly as the first vertical end face.

[0168] Enumerated Embodiment 25: The method or structure according to any one of the previously enumerated embodiments, wherein the first vertical end face of the layer of the counter electrode active material of the counter electrode structure does not exceed the first vertical end face region of the first and second end plates, which coincides with the first maximum vertical range of the first and second end plates on the same vertical side surface of the electrode assembly.

[0169] Enumerated Embodiment 26: The method or structure according to any one of the previously enumerated embodiments, wherein the second vertical end face of the electrode structure and the counter electrode structure does not exceed the second vertical end face region of the first and second end plates, which coincides with the second maximum vertical range of the first and second end plates on the same vertical side surface of the electrode assembly.

[0170] Enumerated Embodiment 27: The method or structure according to any one of the previously enumerated embodiments, wherein the second vertical end face of the opposing electrode structure does not exceed the second vertical end face region of the first and second end plates, which coincides with the second maximum vertical range of the first and second end plates on the same vertical side surface of the electrode assembly as the second vertical end face.

[0171] Enumerated Embodiment 28: The method or structure according to any one of the previously enumerated embodiments, wherein the second vertical end face of the layer of the counter electrode active material of the counter electrode structure does not exceed the second vertical end face region of the first and second end plates, which coincides with the second maximum vertical range of the first and second end plates on the same vertical side surface of the electrode assembly.

[0172] Enumerated Embodiment 29: The method or structure according to any one of the previously enumerated embodiments, wherein the first vertical end face of the electrode structure and the counter electrode structure is recessed relative to the first vertical end face region of the first and second end plates, such that the first vertical end face coincides with the first maximum vertical range of the first and second end plates on the same vertical side surface of the electrode assembly.

[0173] Enumerated Embodiment 30: The method or structure according to any one of the previously enumerated embodiments, wherein the first vertical end face of the opposing electrode structure is recessed relative to the first vertical end face region of the first and second end plates, such that the first vertical end face coincides with the first maximum vertical range of the first and second end plates on the same vertical side surface of the electrode assembly.

[0174] Enumerated Embodiment 31: The method or structure according to any one of the previously enumerated embodiments, wherein each electrode structure of a constituent unit of a unit cell group comprises a layer of electrode active material, and each counter electrode structure of a constituent unit of a unit cell group comprises a layer of counter electrode active material, and the first vertical end face of the layer of counter electrode active material of the counter electrode structure is recessed relative to the first vertical end face region of the first and second end plates, which coincide with the first maximum vertical range of the first and second end plates on the same vertical side surface of the electrode assembly.

[0175] Enumerated Embodiment 32: Each electrode structure of the constituent unit of the unit cell group comprises a layer of electrode active material, and each counter electrode structure of the constituent unit of the unit cell group comprises a layer of counter electrode active material, and the maximum vertical thickness of the counter electrode active material layer of the counter electrode structure in a plane perpendicular to the stacking direction is the maximum vertical thickness t of the first and second end plates in the vertical direction. EPMAX A method or structure according to any one of the previously enumerated embodiments, which does not exceed the first vertical end face region of the first and second end plates, which is consistent with the above.

[0176] Enumerated Embodiment 33: The method or structure according to any one of the previously enumerated embodiments, wherein the second vertical end face of the electrode structure and the counter electrode structure is recessed relative to the second vertical end face region of the first and second end plates, such that the second vertical end face coincides with the second maximum vertical range of the first and second end plates on the same vertical side surface of the electrode assembly.

[0177] Enumerated Embodiment 34: The method or structure according to any one of the previously enumerated embodiments, wherein the second vertical end face of the opposing electrode structure is recessed relative to the second vertical end face region of the first and second end plates, such that the second vertical end face coincides with the second maximum vertical range of the first and second end plates on the same vertical side surface of the electrode assembly.

[0178] Enumerated Embodiment 35: The method or structure according to any one of the previously enumerated embodiments, wherein each electrode structure of a constituent unit of a unit cell group comprises a layer of electrode active material, and each counter electrode structure of a constituent unit of a unit cell group comprises a layer of counter electrode active material, and the second vertical end face of the layer of counter electrode active material of the counter electrode structure is recessed with respect to the second vertical end face region of the first and second end plates, which coincides with the second maximum vertical range of the first and second end plates on the same vertical side surface of the electrode assembly.

[0179] The method according to any one of the previously enumerated embodiments, wherein the stencil is positioned such that the upper surface of the stencil frame is above the first vertical end face of the electrode structure or counter electrode structure in the electrode assembly in the vertical direction.

[0180] The method according to any one of the previously enumerated embodiments, wherein the stencil is positioned such that the upper surface of the stencil frame is above the first vertical end face of the counter electrode structure in the electrode assembly in the vertical direction, in the enumerated embodiment 37:(a).

[0181] Enumerated Embodiment 38: The method according to any one of the previously enumerated embodiments, wherein each electrode structure of a unit cell group comprises a layer of electrode active material, and each counter electrode structure of a unit cell group comprises a layer of counter electrode active material, and in (a), the upper surface of the stencil frame is positioned in the vertical direction above the first vertical end face of the layer of counter electrode active material of the counter electrode structure in the electrode assembly.

[0182] The method according to any one of the previously enumerated embodiments, wherein the stencil is positioned such that the upper surface of the stencil frame is above the second vertical end face of the electrode structure or counter electrode structure in the electrode assembly in the vertical direction, in the enumerated embodiment 39:(c).

[0183] The method according to any one of the previously enumerated embodiments, wherein the stencil is positioned such that the upper surface of the stencil frame is above the second vertical end face of the counter electrode structure in the electrode assembly in the vertical direction, in the enumerated embodiment 40:(c).

[0184] Enumerated Embodiment 41: The method according to any one of the previously enumerated embodiments, wherein each electrode structure of the unit cell group comprises a layer of electrode active material, and each counter electrode structure of the unit cell group comprises a layer of counter electrode active material, and in (c), the upper surface of the stencil frame is positioned in the vertical direction above the second vertical end face of the layer of counter electrode active material of the counter electrode structure in the electrode assembly.

[0185] The method according to any one of the previously enumerated embodiments, wherein the stencil is positioned such that the upper surface of the stencil frame does not exceed, or is below, a first vertical end face of the electrode structure or counter electrode structure in the electrode assembly in the vertical direction.

[0186] The method according to any one of the previously enumerated embodiments, wherein the stencil is positioned such that the upper surface of the stencil frame does not exceed, or is below, the first vertical end face of the counter electrode structure in the electrode assembly in the vertical direction.

[0187] Enumerated Embodiment 44: The method according to any one of the previously enumerated embodiments, wherein each electrode structure of the unit cell group comprises a layer of electrode active material, and each counter electrode structure of the unit cell group comprises a layer of counter electrode active material, and in (a), the upper surface of the stencil frame is positioned in the vertical direction not to exceed or below a first vertical end face of the layer of counter electrode active material of the counter electrode structure in the electrode assembly.

[0188] The method according to any one of the previously enumerated embodiments, wherein the stencil is positioned such that the upper surface of the stencil frame does not exceed, or is below, a second vertical end face of the electrode structure or counter electrode structure in the electrode assembly in the vertical direction.

[0189] The method according to any one of the previously enumerated embodiments, wherein the stencil is positioned such that the upper surface of the stencil frame does not exceed, or is below, the second vertical end face of the counter electrode structure in the electrode assembly in the vertical direction.

[0190] Enumerated Embodiment 47: The method according to any one of the previously enumerated embodiments, wherein in either (a) or (c), the stencil is positioned around the first and second end plates in the stacking direction.

[0191] Enumerated Embodiment 48: The method according to any one of the previously enumerated embodiments, wherein each electrode structure of the unit cell group comprises a layer of electrode active material, and each counter electrode structure of the unit cell group comprises a layer of counter electrode active material, and in (c), the upper surface of the stencil frame is positioned in the vertical direction not to exceed or below the second vertical end face of the layer of counter electrode active material of the counter electrode structure in the electrode assembly.

[0192] In the enumerated embodiment 49:(a), the stencil frame is received on the surface of the outer regions of the first and second end plates, and the outer region has a first vertical thickness t in the second cross-sectional area perpendicular to the stacking direction in the inner region adjacent to the stacked continuous unit cell in the second cross-sectional area perpendicular to the stacking direction in the inner region. EP1 A second vertical thickness t that is smaller than EP2 A method according to any one of the previously enumerated embodiments, having the following characteristics.

[0193] In the enumerated embodiment 50:(c), the stencil frame is received on the surface of the outer regions of the first and second end plates, and the outer region has a first vertical thickness t in the second cross-sectional area perpendicular to the stacking direction in the inner region adjacent to the stacked continuous unit cell in the second cross-sectional area perpendicular to the stacking direction in the inner region. EP1 A second vertical thickness t that is smaller than EP2 A method according to any one of the previously enumerated embodiments, having the following characteristics.

[0194] The method according to any one of the previously enumerated embodiments, wherein the stencil frame is received on the surface area of ​​the outer region of the first and second end plates, which does not exceed or falls below the first surface area of ​​the first and second end plates, which coincides with the first maximum vertical range of each of the first and second end plates in the vertical direction.

[0195] The method according to any one of the previously enumerated embodiments, wherein the stencil frame is received on the surface area of ​​the outer region of the first and second end plates, which does not exceed or falls below the second surface area of ​​the first and second end plates, which coincides with the second maximum vertical range of the respective first and second end plates in the vertical direction.

[0196] Enumerated Embodiment 53: The method or structure according to any one of the previously enumerated embodiments, wherein each of the first and second end plates has first and second vertical end faces on first and second vertical sides opposite to each of the first and second end plates, and at least one of the first and second vertical end faces includes an inner region in an inner region adjacent to a stacked continuous unit cell and an outer region in an outer region outside the inner region in the stacking direction, the outer region being offset vertically inward from the inner region.

[0197] Enumerated Embodiment 54: The method or structure according to any one of the previously enumerated embodiments, wherein each of the first and second end plate vertical end faces includes an inner region that is vertically separated on the opposite side in an inner region adjacent to a stacked continuous unit cell, and an outer region that is vertically separated on the opposite side in an outer region outside the inner region in the stacking direction, wherein the outer region opposite each of the first and second end plate vertical end faces is offset vertically inward from the inner region opposite.

[0198] Enumerated Embodiment 55: The method according to any one of the previously enumerated embodiments, wherein the stencil frame comprises first and second opposite ledges, and the stencil is positioned on the electrode assembly such that, in either (a) or (c), the first and second opposite ledges of the stencil frame are received by outer surface regions offset inward from the first and second end plates, which are on the same vertical side of the stencil frame and the electrode assembly.

[0199] Enumerated Embodiment 56: The stencil frame comprises first and second opposite ledges, and in either (a) or (c), the upper frame surface of the frame region opposite the first and second is the upper frame surface of the first and second end plates in the vertical direction, with respect to the respective maximum vertical thickness t EPMAX The method according to any one of the previously enumerated embodiments, wherein the first and second end plates are positioned such that they do not extend beyond or exceed the first surface area of ​​the first and second end plates, or are recessed relative to the first surface area.

[0200] Enumerated Embodiment 57: The method according to any one of the prior enumerated embodiments, wherein the stencil frame comprises first and second opposite ledges, and in (a), the upper frame surface of the first and second opposite frame regions is positioned such that the upper frame surface does not extend beyond a first surface region of the first and second end plates, or is recessed relative to this first surface region, such that the upper frame surface coincides with a first maximum vertical range of the first and second end plates that lies on the same vertical side surface of the electrode assembly as the upper surface of the first and second opposite frame regions.

[0201] Enumerated Embodiment 58: The method according to any one of the prior enumerated embodiments, wherein the stencil frame comprises first and second opposite ledges, and in (c), the upper frame surface of the first and second opposite frame regions is positioned such that the upper frame surface does not extend beyond or is recessed to a second surface region of the first and second end plates, such that the upper frame surface coincides with a second maximum vertical range of the first and second end plates that lies on the same vertical side surface of the electrode assembly as the upper surface of the first and second opposite frame regions.

[0202] Enumerated Embodiment 59: The method or structure according to any one of the previously enumerated embodiments, wherein the electrode assembly comprises a vertical axis (Y) in the stacking direction and a vertical axis (Z) in the vertical direction, and the first and second end plates each have opposite vertical end faces having a cross-sectional profile in the YZ plane, wherein each is chamfered, inclined, stepped, or any combination thereof.

[0203] Enumerated Embodiment 60: The method or structure according to any one of the previously enumerated embodiments, wherein the cross-sectional profiles of the first and second end plates in the YZ plane decrease monotonically from the inner region to the outer region of the respective first and second end plates.

[0204] Enumerated Embodiment 61: The method or structure according to any one of the previously enumerated embodiments, wherein the cross-sectional profiles of the first and second end plates in the YZ plane are progressively reduced from the inner region to the outer region of each of the first and second end plates.

[0205] Enumerated Embodiment 62: The method or structure according to any one of the previously enumerated embodiments, wherein the outer regions of each of the first and second end plates include stepped features adapted to receive a stencil frame.

[0206] Enumerated Embodiment 63: A method according to any one of the previously enumerated embodiments, comprising rotating the electrode assembly about a longitudinal axis in the stacking direction, or a transverse axis perpendicular to the stacking direction and the vertical direction, thereby vertically reversing the positions of the first and second vertical end faces of the electrode structure and the counter electrode structure.

[0207] The method according to any one of the prior enumerated embodiments, wherein the enumerated embodiment 64:(b) includes using a blade to apply a slurry of porous electrical insulating material through a stencil opening to cover a first vertical end face of an electrode structure or counter electrode structure of a constituent unit of a group of unit cells.

[0208] The method according to any one of the prior enumerated embodiments, wherein the enumerated embodiment 65:(b) includes using a blade to apply a slurry of porous electrical insulating material through a stencil opening to cover the first vertical end face of the opposing electrode structure of a constituent unit of a group of unit cells.

[0209] Enumerated Embodiment 66: The method according to any one of the prior enumerated embodiments, wherein each electrode structure of a constituent unit of a unit cell group comprises a layer of electrode active material, and each counter electrode structure of a constituent unit of a unit cell group comprises a layer of counter electrode active material, and (b) using a blade to apply a slurry of porous electrical insulating material through a stencil opening to cover a first vertical end face of the layer of counter electrode active material of the counter electrode structure of a constituent unit of a unit cell group.

[0210] The method according to any one of the prior enumerated embodiments, wherein the enumerated embodiment 67:(d) includes using a blade to apply a slurry of porous electrical insulating material through a stencil opening to cover a second vertical end face of an electrode structure or counter electrode structure of a constituent unit of a group of unit cells.

[0211] The method according to any one of the prior enumerated embodiments, wherein the enumerated embodiment 68:(d) includes using a blade to apply a slurry of porous electrical insulating material through a stencil opening to cover the second vertical end face of the opposing electrode structure of a constituent unit of a group of unit cells.

[0212] Enumerated Embodiment 69: The method according to any one of the prior enumerated embodiments, wherein each electrode structure of a constituent unit of a unit cell group comprises a layer of electrode active material, and each counter electrode structure of a constituent unit of a unit cell group comprises a layer of counter electrode active material, and (d) using a blade to apply a slurry of porous electrical insulating material through a stencil opening to cover a second vertical end face of the layer of counter electrode active material of the counter electrode structure of a constituent unit of a unit cell group.

[0213] The method according to any one of the prior enumerated embodiments, wherein the enumerated embodiment 70:(b) includes running a blade along the first vertical end faces of the first and second end plates in a transverse direction perpendicular to the vertical and stacking directions to apply a porous electrical insulating material to the first vertical end faces of the electrode structure or counter electrode structure through a stencil opening.

[0214] Enumerated Embodiment 71: The blade has a maximum vertical thickness t in the vertical direction. EPMAX The method according to any one of the previously enumerated embodiments, wherein the first surface region of the first and second end plates runs across the first vertical end face, which is consistent with the first vertical end face.

[0215] Enumerated Embodiment 72: The method according to any one of the previously enumerated embodiments, wherein the blade travels across a first vertical end face in a first surface area of ​​the first and second end plates, which coincides with the first maximum extent of each of the first and second end plates in the vertical direction.

[0216] The method according to any one of the previously enumerated embodiments, wherein the enumerated embodiment 73:(b) includes running a blade across the first vertical end faces of the first and second end plates in a transverse direction perpendicular to the stacking direction and the vertical direction.

[0217] The method according to any one of the previously enumerated embodiments, wherein the length of the blade extends across the electrode assembly in the stacking direction from the first end plate to the second end plate, in the enumerated embodiment 74:(b).

[0218] The method according to any one of the prior enumerated embodiments, wherein the enumerated embodiment 75:(b) includes applying a porous electrical insulating material to either the surface of a blade or an electrode assembly and running the blade laterally along the first vertical end faces of the first and second end plates.

[0219] The method according to any one of the prior enumerated embodiments, wherein the enumerated embodiment 76:(d) includes running a blade along the second vertical end faces of the first and second end plates in a transverse direction perpendicular to the vertical and stacking directions to apply a porous electrical insulating material through a stencil opening to the second vertical end face of the electrode structure or counter electrode structure.

[0220] Enumerated Embodiment 77: The blade has a maximum vertical thickness t of the first and second end plates in the vertical direction. EPMAX The method according to any one of the previously enumerated embodiments, wherein the second surface region of the first and second end plates runs across the second vertical end face, which is consistent with the second vertical end face.

[0221] Enumerated Embodiment 78: The method according to any one of the previously enumerated embodiments, wherein the blade travels across the second vertical end faces of the first and second end plates in a second surface area that coincides with the second maximum extent of the first and second end plates in the vertical direction.

[0222] Enumerated Embodiment 79: The method according to any one of the previously enumerated embodiments, wherein the blade travels across the second vertical end faces of the first and second end plates in a transverse direction perpendicular to the stacking direction and the vertical direction.

[0223] The method according to any one of the previously enumerated embodiments, wherein the length of the blade extends across the electrode assembly in the stacking direction from the first end plate to the second end plate, in the enumerated embodiment 80:(d).

[0224] The method according to any one of the prior enumerated embodiments, wherein the enumerated embodiment 81:(d) includes running a blade along the second vertical end faces of the first and second end plates in a transverse direction perpendicular to the vertical and stacking directions to apply a porous electrical insulating material to the second vertical end faces of the electrode structure or counter electrode structure through a stencil opening.

[0225] The method according to any one of the prior enumerated embodiments, wherein the enumerated embodiment 82:(d) includes applying a porous electrical insulating material to either the surface of a blade or an electrode assembly and running the blade laterally along the second vertical end faces of the first and second end plates.

[0226] The method according to any one of the previously enumerated embodiments, wherein the enumerated embodiment 83:(a) includes positioning the stencil such that at least a portion of the first vertical end faces of the first and second end plates adjacent to the stacked continuous unit cells is exposed through the stencil opening.

[0227] The method according to any one of the prior enumerated embodiments, wherein the enumerated embodiment 84:(c) includes positioning the stencil such that at least a portion of the second vertical end faces of the first and second end plates adjacent to the stacked continuous unit cells is exposed through the stencil opening.

[0228] Enumerated embodiment 85:(a) is the maximum vertical thickness t of the first and second end plates in the vertical direction. EPMAX The method according to any one of the prior enumerated embodiments, comprising positioning the stencil such that first surface areas of the first and second end plates, which coincide with the stencil, are exposed through the stencil opening.

[0229] The method according to any one of the prior enumerated embodiments, wherein the enumerated embodiment 86:(a) includes positioning the stencil such that a first surface area on the first vertical side surface of the first and second end plates, which coincides with the first maximum vertical range of the first and second end plates, is exposed through the stencil opening.

[0230] Enumerated embodiment 87:(c) is the maximum vertical thickness t of the first and second end plates in the vertical direction. EPMAX The method according to any one of the prior enumerated embodiments, comprising positioning the stencil such that a second surface area on the second vertical side surface of the first and second end plates, which coincides with the stencil, is exposed through the stencil opening.

[0231] The method according to any one of the prior enumerated embodiments, wherein the enumerated embodiment 88:(c) includes positioning the stencil such that a second surface area on the second vertical side surface of the first and second end plates, which coincides with the second maximum vertical range of the first and second end plates, is exposed through the stencil opening.

[0232] Enumerated Embodiment 89: The method according to any one of the prior enumerated embodiments, wherein the stencil is positioned such that the stencil frame covers at least partially the periphery of the electrode assembly in a transverse direction perpendicular to both the stacking direction and the vertical direction.

[0233] Enumerated Embodiment 90: The method according to any one of the previously enumerated embodiments, wherein each unit cell comprises an electrode current collector end section and a counter electrode current collector end section extending from their respective electrode structure and counter electrode structure in opposite lateral directions perpendicular to both the stacking direction and the vertical direction.

[0234] Enumerated Embodiment 91: The method according to any one of the previously enumerated embodiments, wherein an end section of either the electrode current collector or the counter electrode current collector is recessed perpendicularly to the first and second vertical end faces of the electrode structure and the counter electrode structure.

[0235] The method according to any one of the prior enumerated embodiments, wherein in either (a) or (c), the stencil is positioned such that the stencil frame covers at least partially any end section of either the electrode current collector or the counter electrode current collector surrounding the electrode assembly in a transverse direction perpendicular to the stacking direction and the vertical direction.

[0236] Enumerated Embodiment 93: The method according to any one of the previously enumerated embodiments, wherein the stencil is positioned such that the ends of the electrode current collector and the counter electrode current collector are recessed relative to the stencil frame in either (a) or (c).

[0237] The method according to any one of the previously enumerated embodiments, wherein in either (a) or (c), the stencil is positioned such that the lateral ledge on the opposite side of the stencil frame is positioned over the ends of the electrode current collector and the counter electrode current collector.

[0238] Enumerated Embodiment 95: The first and second vertical end faces of the ends of the electrode current collector and the counter electrode current collector correspond to (i) the first and second vertical end faces of the electrode structure, (ii) the first and second surface regions of the first and second end plates which coincide with the first and second maximum vertical ranges of the first and second end plates, and (iii) the maximum vertical thickness t of the first and second end plates in the vertical direction. EPMAX The method or structure according to any one of the previously enumerated embodiments, wherein the first and second surface areas of the first and second end plates are in line with and recessed by at least 0.010 mm relative to either of them.

[0239] Enumerated Embodiment 96: The first and second vertical end faces of the ends of the electrode current collector and the counter electrode current collector are (i) the first and second vertical end faces of the electrode structure, (ii) the first surface regions of the first and second end plates which coincide with the first and second maximum vertical ranges of the first and second end plates, and (iii) the maximum vertical thickness t of the first and second end plates in the vertical direction. EPMAXThe method or structure according to any one of the previously enumerated embodiments, wherein the first surface areas of the first and second end plates are in line with and recessed by at least 0.025 mm relative to either of them.

[0240] Enumerated Embodiment 97: The first and second vertical end faces of the ends of the electrode current collector and the counter electrode current collector correspond to (i) the first and second vertical end faces of the electrode structure, (ii) the first surface regions of the first and second end plates which coincide with the first and second maximum vertical ranges of the first and second end plates, and (iii) the respective maximum vertical thickness t of the first and second end plates in the vertical direction. EPMAX The method or structure according to any one of the previously enumerated embodiments, wherein the first surface areas of the first and second end plates are in line with and recessed by at least 0.050 mm relative to either of them.

[0241] Enumerated Embodiment 98: The method or structure according to any one of the previously enumerated embodiments, wherein the first and second vertical end faces of the ends of the electrode current collector and the counter electrode current collector are recessed in the vertical distance between the first and second vertical end faces of the ends of the electrode current collector and the counter electrode current collector and the first and second vertical end faces of the electrode structure or the counter electrode structure, so as to accommodate a stencil frame.

[0242] Enumerated Embodiment 99: The method according to any one of the previously enumerated embodiments, further comprising arranging an electrode assembly between a set of bumpers on opposite sides in the stacking direction and applying pressure to the first and second end plates in the stacking direction via the bumpers.

[0243] Enumerated Embodiment 100: The method according to any one of the previously enumerated embodiments, wherein an electrode assembly is positioned between bumpers such that a first surface area of ​​the first and second end plates, which coincides with a first maximum vertical range of the first and second end plates, extends vertically past the first and second vertical end faces of the bumper.

[0244] Enumerated Embodiment 101: The electrode assembly has a maximum vertical thickness t of the first and second end plates in the vertical direction.EPMAX The method according to any one of the previously enumerated embodiments, wherein the first surface areas of the first and second end plates, which coincide with the first end plates, are positioned between the bumpers such that they extend vertically through the first and second vertical end faces of the bumpers.

[0245] Enumerated Embodiment 102: The method according to any one of the previously enumerated embodiments, further comprising mounting at least a portion of the stencil frame onto a set of bumpers on the opposite side.

[0246] Enumerated Embodiment 103: The method according to any one of the previously enumerated embodiments, wherein the first and second surface areas of the first and second end plates, which coincide with the first and second maximum vertical ranges of the first and second end plates, extend at least 0.010 mm past the first and second vertical end faces of the bumper set.

[0247] Enumerated Embodiment 104: Maximum vertical thickness t of the first and second end plates in the vertical direction EPMAX The method according to any one of the previously enumerated embodiments, wherein the first and second surface areas of the first and second end plates, which coincide with the first and second end plates, extend at least 0.010 mm past the first and second vertical end faces of the bumper set.

[0248] Enumerated Embodiment 105: The method according to any one of the previously enumerated embodiments, wherein the first and second surface areas of the first and second end plates, which coincide with the first and second maximum vertical ranges of the first and second end plates, extend at least 0.025 mm past the first and second vertical end faces of the set of bumpers.

[0249] Enumerated Embodiment 106: Maximum vertical thickness t of the first and second end plates in the vertical direction EPMAX The method according to any one of the previously enumerated embodiments, wherein the first and second surface areas of the first and second end plates, which coincide with the first and second end plates, extend by at least 0.025 mm past the first and second vertical end faces of the bumper set.

[0250] Enumerated Embodiment 107: The method according to any one of the previously enumerated embodiments, wherein the first and second surface areas of the first and second end plates, which coincide with the first and second maximum vertical ranges of the first and second end plates, extend at least 0.050 mm past the first and second vertical end faces of the set of bumpers.

[0251] Enumerated Embodiment 108: Maximum vertical thickness t of the first and second end plates in the vertical direction EPMAX The method according to any one of the previously enumerated embodiments, wherein the first and second surface areas of the first and second end plates, which coincide with the first and second end plates, extend at least 0.050 mm past the first and second vertical end faces of the bumper set.

[0252] Enumerated Embodiment 109: Cross-sectional thickness t of each of the first and second end plates EP The method or structure according to any one of the previously enumerated embodiments, wherein the stacking direction decreases from the inner regions of each first and second end plate adjacent to the stacked continuous unit cells to the second regions outside each first and second end plate that are outside the first region in the stacking direction.

[0253] Enumerated Embodiment 110: A secondary battery having the structure described in any one of the previously enumerated embodiments.

[0254] Enumerated Embodiment 111: A secondary battery manufactured according to the method described in any one of the previously enumerated embodiments.

[0255] Enumerated Embodiment 112: A method for transferring carrier ions from an auxiliary electrode including a carrier ion source to a structure or secondary battery comprising an electrode assembly as described in any one of the previously enumerated embodiments,

[0256] A porous electrical insulating material covers the first or second vertical end face of the electrode structure or counter electrode structure of a constituent unit of a unit cell group, and the porous electrical insulating material has a porosity in the range of 20% to 60%.

[0257] A method comprising transferring carrier ions from an auxiliary electrode to a constituent unit of a group of unit cells via a porous electrical insulating material.

[0258] Enumerated Embodiment 113: A secondary battery having the structure described in any one of the previously enumerated embodiments, wherein the electrode assembly is

[0259] A structure or secondary battery comprising a porous electrical insulating material covering the first or second vertical end face of the electrode structure or counter electrode structure of a constituent unit of a unit cell group, wherein the porous electrical insulating material has a porosity in the range of 20% to 60%.

[0260] Enumerated Embodiment 114: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein a porous electrical insulating material covers both the first and second vertical end faces of the electrode structure or counter electrode structure of a constituent unit of a unit cell group.

[0261] Enumerated Embodiment 115: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein a porous electrical insulating material covers the first and second vertical end faces of both the electrode structure or the counter electrode structure of the constituent units of the unit cell group.

[0262] Enumerated Embodiment 116: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein a porous electrical insulating material covers both the first and second vertical end faces of both the electrode structure or the counter electrode structure of a constituent unit of a group of unit cells.

[0263] Enumerated Embodiment 117: A method according to any one of the prior enumerated embodiments, for transporting carrier ions to achieve and / or restore a discharge voltage Vces eod at a predetermined counter electrode structure end and a discharge voltage Ves,eod at a predetermined electrode structure end.

[0264] Enumerated Embodiment 118: The method according to any one of the previously enumerated embodiments, wherein carrier ions are transported to replenish carrier ions lost in the formation of SEI.

[0265] Enumerated Embodiment 119: The method according to any one of the previously enumerated embodiments, wherein carrier ions are transported during an initial or subsequent charging cycle performed by an electrode assembly to compensate for carrier ion loss.

[0266] Enumerated Embodiment 120: A method according to any one of the prior enumerated embodiments, wherein the method comprises (i) transferring carrier ions from a counter electrode structure to an electrode structure in a unit cell group during an initial or subsequent charging cycle to at least partially charge an electrode assembly; and (ii) transferring carrier ions from an auxiliary electrode to a counter electrode structure and / or an electrode structure through a porous electrical insulating material to provide the electrode assembly with a predetermined discharge voltage Vces,eod at a predetermined end of the counter electrode structure and a predetermined discharge voltage Ves,eod at a predetermined end of the electrode structure.

[0267] Enumerated Embodiment 121: The method according to any one of the prior enumerated embodiments, wherein the process further comprises, after (iii)(ii), transferring carrier ions from the counter electrode structures of the constituent units of the unit cell group to the electrode structures to charge the electrode assembly.

[0268] Enumerated Embodiment 122: A method according to any one of the prior enumerated embodiments, wherein (ii) is performed simultaneously with (i).

[0269] The method according to any one of the previously enumerated embodiments, wherein in the enumerated embodiment 123:(ii), a bias voltage is applied between an auxiliary electrode and the electrode structure and / or counter electrode structure of a constituent unit of a unit cell group to provide a flow of carrier ions through a porous electrical insulating material member.

[0270] Enumerated Embodiment 124: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the constituent units of a unit cell group have first and second edges including first and second vertical end faces on opposite sides, the first vertical end faces of an electrode structure and a counter electrode structure within the same unit cell group constituent unit are offset perpendicularly from each other to form a first recess, the second vertical end faces of an electrode structure and a counter electrode structure within the same unit cell group constituent unit are offset perpendicularly from each other to form a second recess, the first and second end faces of a counter electrode structure are offset perpendicularly inward with respect to the first and second vertical end faces of the respective electrode structures within the same unit cell group constituent unit, and the porous electrical insulating material is located within at least one of the first and second recesses.

[0271] Enumerated Embodiment 125: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein a porous electrical insulating material substantially fills the first and second recesses of the constituent units of a group of unit cells.

[0272] Enumerated Embodiment 126: A secondary battery, structure, or method according to any one of the previously enumerated embodiments, wherein, for a constituent unit of a unit cell group, at least a portion of the porous electrical insulating material covering the first or second vertical end face of the electrode structure and / or counter electrode structure is adjacent to an electrical insulating separator.

[0273] Enumerated Embodiment 127: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein a porous electrical insulating material is disposed inward relative to the first and second vertical end faces of the electrode structure in the constituent unit of the unit cell group and substantially fills the regions of the first and second recesses that abut against the side surfaces of the electrical insulating separator facing the opposing electrode structure.

[0274] Enumerated Embodiment 128: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the electrode structure of a constituent unit of a unit cell group comprises an electrode active material layer and an electrode current collector layer, the counter electrode structure of a constituent unit of a unit cell group comprises a counter electrode active material layer and a counter electrode current collector layer, and a porous electrical insulating material covers the first and second vertical end faces of the counter electrode active material layer of the constituent unit of a unit cell group.

[0275] Enumerated Embodiment 129: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material has a porosity of at least 25%.

[0276] Enumerated Embodiment 130: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material has a porosity of at least 30%.

[0277] Enumerated Embodiment 131: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material has a porosity of at least 35%.

[0278] Enumerated Embodiment 132: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material has a porosity of at least 40%.

[0279] Enumerated Embodiment 133: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material has a porosity of at least 45%.

[0280] Enumerated Embodiment 134: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material has a porosity of at least 50%.

[0281] Enumerated Embodiment 135: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material has a porosity of at least 55%.

[0282] Enumerated Embodiment 136: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material has a porosity of 55% or less.

[0283] Enumerated Embodiment 137: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material has a porosity of 50% or less.

[0284] Enumerated Embodiment 138: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material has a porosity of 45% or less.

[0285] Enumerated Embodiment 139: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material has a porosity of 40% or less.

[0286] Enumerated Embodiment 140: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material has a porosity of 35% or less.

[0287] Enumerated Embodiment 141: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the electrical insulating separator is microporous, and the ratio of the porosity of the porous electrical insulating material to the porosity of the electrical insulating separator is in the range of 1:0.75 to 1:1.5.

[0288] Enumerated Embodiment 142: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material comprises a particulate material dispersed in a binder material.

[0289] Enumerated Embodiment 143: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises a stable metal oxide and / or ceramic.

[0290] Enumerated Embodiment 144: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises one or more of alumina, boron nitride, titania, silica, zirconia, magnesium oxide, and calcium oxide.

[0291] Enumerated Embodiment 145: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises alumina.

[0292] Enumerated Embodiment 146: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises particles having a d50 particle size (median particle size) of at least 0.35 microns.

[0293] Enumerated Embodiment 147: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises particles having a d50 particle size (median particle size) of at least 0.45 microns.

[0294] Enumerated Embodiment 148: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises particles having a d50 particle size (median particle size) of at least 0.5 microns.

[0295] Enumerated Embodiment 149: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises particles having a d50 particle size (median particle size) of at least 0.75 microns.

[0296] Enumerated Embodiment 150: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particle material comprises particles having a d50 particle size (median particle size) of 40 microns or less.

[0297] Enumerated Embodiment 151: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particle material comprises particles having a d50 particle size (median particle size) of 35 microns or less.

[0298] Enumerated Embodiment 152: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particle material comprises particles having a d50 particle size (median particle size) of 25 microns or less.

[0299] Enumerated Embodiment 153: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particle material comprises particles having a d50 particle size (median particle size) of 20 microns or less.

[0300] Enumerated Embodiment 154: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 80% by weight of the particles have a particle size of at least 0.35 microns.

[0301] Enumerated Embodiment 155: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 85% by weight of the particles have a particle size of at least 0.35 microns.

[0302] Enumerated Embodiment 156: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 90% by weight of the particles have a particle size of at least 0.35 microns.

[0303] Enumerated Embodiment 157: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 95% by weight of the particles have a particle size of at least 0.35 microns.

[0304] Enumerated Embodiment 158: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 80% by weight of the particles have a particle size of at least 0.45 microns.

[0305] Enumerated Embodiment 159: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 85% by weight of the particles have a particle size of at least 0.45 microns.

[0306] Enumerated Embodiment 160: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 90% by weight of the particles have a particle size of at least 0.45 microns.

[0307] Enumerated Embodiment 161: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 95% by weight of the particles have a particle size of at least 0.45 microns.

[0308] Enumerated Embodiment 162: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 80% by weight of the particles have a particle size of at least 0.5 microns.

[0309] Enumerated Embodiment 163: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 85% by weight of the particles have a particle size of at least 0.5 microns.

[0310] Enumerated Embodiment 164: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 90% by weight of the particles have a particle size of at least 0.5 microns.

[0311] Enumerated Embodiment 165: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 95% by weight of the particles have a particle size of at least 0.5 microns.

[0312] Enumerated Embodiment 166: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 80% by weight of the particles have a particle size of at least 0.75 microns.

[0313] Enumerated Embodiment 167: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 85% by weight of the particles have a particle size of at least 0.75 microns.

[0314] Enumerated Embodiment 168: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 90% by weight of the particles have a particle size of at least 0.75 microns.

[0315] Enumerated Embodiment 169: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 95% by weight of the particles have a particle size of at least 0.75 microns.

[0316] Enumerated Embodiment 170: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 80% by weight of the particles have a particle size of 40 microns or less.

[0317] Enumerated Embodiment 171: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 85% by weight of the particles have a particle size of 40 microns or less.

[0318] Enumerated Embodiment 172: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 90% by weight of the particles have a particle size of 40 microns or less.

[0319] Enumerated Embodiment 173: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 95% by weight of the particles have a particle size of 40 microns or less.

[0320] Enumerated Embodiment 174: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 80% by weight of the particles have a particle size of 35 microns or less.

[0321] Enumerated Embodiment 175: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 85% by weight of the particles have a particle size of 35 microns or less.

[0322] Enumerated Embodiment 176: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 90% by weight of the particles have a particle size of 35 microns or less.

[0323] Enumerated Embodiment 177: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 95% by weight of the particles have a particle size of 35 microns or less.

[0324] Enumerated Embodiment 178: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 80% by weight of the particles have a particle size of 25 microns or less.

[0325] Enumerated Embodiment 179: A method, structure, or secondary battery according to any one of the previously enumerated embodiments 2, wherein at least 85% by weight of the particles have a particle size of 25 microns or less.

[0326] Enumerated Embodiment 180: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 90% by weight of the particles have a particle size of 25 microns or less.

[0327] Enumerated Embodiment 181: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 95% by weight of the particles have a particle size of 25 microns or less.

[0328] Enumerated Embodiment 182: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 80% by weight of the particles have a particle size of 20 microns or less.

[0329] Enumerated Embodiment 183: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 85% by weight of the particles have a particle size of 25 microns or less.

[0330] Enumerated Embodiment 184: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 90% by weight of the particles have a particle size of 25 microns or less.

[0331] Enumerated Embodiment 185: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least 95% by weight of the particles have a particle size of 25 microns or less.

[0332] Enumerated Embodiment 186: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises at least 70% by weight of a porous electrical insulating material.

[0333] Enumerated Embodiment 187: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises at least 75% by weight of a porous electrical insulating material.

[0334] Enumerated Embodiment 188: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises at least 80% by weight of a porous electrical insulating material.

[0335] Enumerated Embodiment 189: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises at least 85% by weight of a porous electrical insulating material.

[0336] Enumerated Embodiment 190: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises 99.5% by weight or less of porous electrical insulating material.

[0337] Enumerated Embodiment 191: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises 97% by weight or less of a porous electrical insulating material.

[0338] Enumerated Embodiment 192: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises 95% by weight or less of a porous electrical insulating material.

[0339] Enumerated Embodiment 193: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the particulate material comprises 90% by weight or less of porous electrical insulating material.

[0340] Enumerated Embodiment 194: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the binder material comprises a polymer material selected from the group consisting of polyvinylidene fluoride (PVDF), polyethylene, polypropylene, ethylene acrylic acid (EAA), ethylene methacrylic acid (EMAA), and copolymers thereof.

[0341] Enumerated Embodiment 195: The electrode assembly comprises a lateral plane having a transverse axis, a longitudinal axis, and a vertical axis, which are mutually perpendicular to each other and correspond to the x, y, and z axes of a virtual three-dimensional Cartesian coordinate system, respectively, with a first longitudinal end face and a second longitudinal end face that are longitudinally separated from each other; and a lateral plane that surrounds the longitudinal axis AEA of the electrode assembly and connects the first and second longitudinal end faces, the lateral plane having first and second regions on opposite sides of the longitudinal axis and separated in a first direction perpendicular to the longitudinal axis, the electrode assembly having a maximum width WEA measured in the longitudinal direction, a maximum length LEA measured in the transverse direction and bounded by the lateral plane, and a maximum height HEA measured in the transverse direction and bounded by the lateral plane, and further,

[0342] Each electrode structure of a constituent unit of a unit cell group includes a length LE measured laterally between the first and second opposite lateral end faces of the electrode structure, a height HE measured vertically between the first and second opposite vertical end faces of the electrode structure, and a width WE measured longitudinally between the first and second opposite surfaces of the electrode structure; each counter electrode structure of a constituent unit of a unit cell group includes a length LCE measured laterally between the first and second opposite lateral end faces of the counter electrode structure, a height HCE measured vertically between the first and second opposite vertical end faces of the counter electrode structure, and a width WCE measured longitudinally between the first and second opposite surfaces of the counter electrode structure.

[0343] A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein, regarding the electrode structure of the constituent units of the unit cell group, the ratio of LE to WE and HE is at least 5:1 each, and the ratio of HE to WE is in the range of about 2:1 to about 100:1, and regarding the counter electrode structure of the constituent units of the unit cell group, the ratio of LCE to WCE and HCE is at least 5:1 each, and the ratio of HCE to WCE is in the range of about 2:1 to about 100:1.

[0344] Enumerated Embodiment 196: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material extends for at least 50% of the length LCE of the counter electrode structure of the components of the unit cell group.

[0345] Enumerated Embodiment 197: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material extends for at least 60% of the length LCE of the counter electrode structure of the components of the unit cell group.

[0346] Enumerated Embodiment 198: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material extends for at least 75% of the length LCE of the counter electrode structure of the components of the unit cell group.

[0347] Enumerated Embodiment 199: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material extends for at least 85% of the length LCE of the counter electrode structure of the components of the unit cell group.

[0348] Enumerated Embodiment 200: The method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the porous electrical insulating material extends for at least 90% of the length LCE of the counter electrode structure of the components of the unit cell group.

[0349] Enumerated Embodiment 201: Each electrode structure of a constituent unit of a unit cell group comprises a layer of electrode active material, and each counter electrode structure of a constituent unit of a unit cell group comprises a layer of counter electrode active material, and with respect to adjacent electrode active material layers and counter electrode active material layers in the constituent unit of a unit cell,

[0350] The first vertical end face of the opposing electrode active material layer is provided with a first recess disposed inward relative to the first vertical end face of the electrode active material layer and the separator,

[0351] The second vertical end face of the opposing electrode active material layer is provided with a second recess disposed inward relative to the second vertical end face of the electrode active material layer and the separator.

[0352] A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein a porous electrical insulating material is disposed adjacent to an electrical insulating separator and in a first recess of the first vertical end face of the counter electrode active material layer, and the porous electrical insulating material is disposed adjacent to an electrical insulating separator and in a second recess of the second vertical end face of the counter electrode active material layer.

[0353] Enumerated Embodiment 202: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein the secondary battery comprises a set of electrode constraints.

[0354] Enumerated Embodiment 203: A secondary battery, structure, or method according to any one of the previously enumerated embodiments, wherein the set of electrode constraints comprises a primary growth constraint system comprising first and second primary growth constraints and at least one primary connecting member, the first and second primary growth constraints being separated from each other in the stacking direction, the at least one primary connecting member connecting the first and second primary growth constraints, the primary growth constraint system suppressing the growth of the electrode assembly in the stacking direction, and the first and second primary growth constraints corresponding to the respective first and second end plates.

[0355] Enumerated Embodiment 204: A secondary growth constraint system comprising a set of electrode constraints, comprising first and second secondary growth constraints separated vertically and connected by at least one secondary connecting member, wherein the secondary growth constraint system at least partially suppresses the vertical growth of the electrode assembly during the cycling of the electrode assembly.

[0356] Enumerated Embodiment 205: A method, structure, or secondary battery according to any one of the previously enumerated embodiments, wherein at least one primary connecting member and at least one secondary connecting member are subjected to tension.

[0357] Enumerated Embodiment 206: A method, structure, or secondary battery according to any one of the ...

Claims

1. A device for conducting electricity, The device described above, The device comprises a unit cell including an electrode separated from a counter electrode, wherein the electrode and the counter electrode are stacked along a first axis. The device described above, The end plates are stacked along the first axis and are operably coupled to the unit cells such that the first surface of the end plates faces the unit cells, The end plate has a plurality of sides, each of which is offset inward (i) toward the inner section of the end plate and (ii) toward away from the unit cell along the first axis, and the plurality of sides of the end plate are separated from each other along a second axis perpendicular to the first axis. The device described above, The device comprises a constraint system configured to at least partially restrict the growth of the unit cell by counteracting the expansion of the unit cell during operation, wherein the constraint system is coupled to the unit cell and the end plate, and the constraint system is in contact with a second surface of the end plate facing the first surface. device.

2. The aforementioned stack of unit cells comprises a unit cell and other unit cells similar to the unit cell. The device comprises a stack of the unit cells, Multiple unit cells in the stack of the aforementioned unit cells are stacked along the first axis, The stack of the aforementioned unit cells has opposing ends, The first surface of the end plate faces the stack of the unit cells, The aforementioned stack of unit cells includes at least two unit cells. The device according to claim 1.

3. The constraint system is configured to at least partially restrict the growth of the stack of unit cells by counteracting the expansion of the stack of unit cells during the operation of the device. The constraint system is coupled with the stack of unit cells and the end plates. The device according to claim 2.

4. The constraint system includes a plurality of openings, The device according to claim 1.

5. The opening of the aforementioned opening has a major axis that is arranged in the direction normal to the first axis, The opening of the aforementioned opening includes a plurality of openings. The device according to claim 4.

6. The plurality of openings are arranged at equal intervals along a part of the constraint system. The device according to claim 4.

7. The constraint system includes a set of opposing constraints, including the constraint. The device according to claim 1.

8. Among the set of opposing constraint members, the opposing constraint members are spaced apart from each other. The device according to claim 7.

9. The end plate is the first end plate, The device comprises a second end plate stacked along a first axis and operably coupled to a unit cell such that the first surface of the second end plate faces the unit cell, The second end plate has a plurality of sides, each of which is offset inward (i) toward the inner section of the second end plate, and (ii) (a) away from the unit cell and (b) along the first axis, and the plurality of sides of the second end plate are separated from each other along a second axis perpendicular to the first axis. The first end plate faces the second end plate. The device according to claim 1.

10. The device further comprises an electrically insulating porous material, The constraint system includes at least one opening through which the porous material is visible. The porous material is configured such that carrier ions enter the unit cell through at least one opening and pass through a portion of the porous material. The device according to claim 1.

11. The porous material includes ceramics. The device according to claim 10.

12. The constraint system includes elemental metals, metal alloys, ceramics, glass, plastics, combinations thereof, or composites thereof. The device according to claim 1.

13. The constraint system comprises at least one opening having an oval-shaped lateral cross-section. The device according to claim 1.

14. The aforementioned constraint system (a) During the initial formation process, (b) When replenishing the carrier ions in the unit cell during a cycle between a charging state and a discharging state, or (c) In the combination of the initial formation process described in (a) and the carrier ion replenishment described in (b), It is configured to allow the movement of carrier ions to the aforementioned unit cell, The device according to claim 1.

15. The constraint system is configured to allow the movement of carrier ions to the unit cell during the initial formation process. The device according to claim 14.

16. The electrode includes a current collector having a tab extension configured to connect to an electrode busbar. The device includes the electrode busbar, The device according to claim 1.

17. The constraint system is configured to at least partially restrict the growth of the unit cell by applying a pressure that exceeds the pressure generated by the electrode or the counter electrode during the operation of the device. The device according to claim 1.

18. The device according to claim 17, wherein the constraint system is configured to restrict the growth of the unit cell along the second axis.

19. The operation of the aforementioned device is as follows: (a) Repeatedly charging the unit cell, (b) Repeatedly discharging the unit cell, or (c) Repeatedly performing the combination of charging the unit cell described in (a) and discharging the unit cell described in (b), including The device according to claim 17.

20. The electrode is made of silicon, silicon-carbon composite, silicon oxide, porous silicon, silicon alloy, Materials containing particulate silicon, or any combination thereof, The device according to claim 19.

21. The device is configured for repeated cycles between a charging state and a discharging state, The cycle includes at least two cycles. The device according to claim 1.

22. The constraint system is wrapped around at least a portion of the end plate and provides a curved profile including curvature. The device according to claim 1.

23. The curvature is defined around the side surface of the end plate. The device according to claim 22.

24. The electrode and / or the counter electrode have a length, width and height, The aforementioned height, length, and width are aligned with the axes of the Cartesian coordinate system. The ratio of the maximum length to the maximum height is at least 2:

1. The ratio of the maximum width to the maximum height is at least 2:

1. The ratio of the height to the width is at least 0.4:

1. The device according to claim 1.

25. The device comprises the unit cell, the end plate, and a housing surrounding the constraint system. The housing is configured for liquid sealing, sealing of the unit cell, hermetically sealing, or any combination thereof. The device according to claim 1.

26. The end face of the unit cell is subjected to a compressive load of at least 100 pounds / square inch (psi), The end face is aligned with an axis perpendicular to the first axis. The device according to claim 1.

27. A method of conducting electricity, (a) A step of manufacturing the device according to any one of claims 1 to 26, (b) A step of carrying out the initial formation step of the device, (c) A step of using the device, or (d) Any combination of the manufacturing process described in (a), the carrying out process described in (b), and the using process described in (c), Methods that include...

28. A device for energy storage, The device includes a control unit electrically coupled to a unit cell of the device according to any one of claims 1 to 26, The control unit is configured to control the movement of carrier ions to the unit cell. device.

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